5720 B G MAN 0007 - Rev0

Original Instructions
MAINTENANCE MANUAL
PR200
C1847
Revision 0
992663-5720-B-G-MAN-0007
K3001-001-0037
PR200 MAINTENANCE MANUAL
1. Introduction
Copyright © Sandvik Mining and Construction Materials Handling Chapter 1 | 1 (16)

pr200_C1847-MM01_en-v1_Rev0.doc
MAINTENANCE MANUAL PR200
2 (16) | Chapter 1 Copyright © Sandvik Mining and Construction Materials Handling

TABLE OF CONTENTS
1 DOCUMENT HISTORY AND REVIEW INFORMATION .................................................................................................... 4

1.1 Document history ...................................................................................................................................................4
1.2 Review information.................................................................................................................................................4
2 PRODUCT DOCUMENTATION .................................................................................................................................. 5

2.1 Target group ...........................................................................................................................................................5
2.2 Supplementary instructions ..................................................................................................................................5
2.3 Location of the manuals on the product ..............................................................................................................5
2.4 How to identify the correct manual for the product.............................................................................................6
2.5 Objective of the product documentation ..............................................................................................................6
2.6 Replacement copies for the Maintenance Manual ...............................................................................................6
2.7 Warranty and liability .............................................................................................................................................7
2.8 Copyright notice .....................................................................................................................................................7
3 IDENTIFICATION OF THE PRODUCT .......................................................................................................................... 8

3.1 Identification plate of the product .........................................................................................................................8
3.2 Location of the Identification plate on the product .............................................................................................8
3.3 Name and address of the manufacturer ...............................................................................................................9
4 DEFINITIONS ....................................................................................................................................................... 10
5 TERMINOLOGY AND ABBREVIATIONS .................................................................................................................... 11
Copyright © Sandvik Mining and Construction Materials Handling Chapter 1 | 3(16)

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 Description Modified by
0 10-2015 First issue Michael Stock
1.2 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

2 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:
 the chapter on ENVIRONMENT, HEALTH AND SAFETY

 the safety instructions contained in various other chapters
2.2 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’s-
and Maintenance Manual must be located on the machine.

2.4 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:

 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.

3 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

3.3 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

4 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”).

5 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”).

TABLE OF FIGURES
Figure 1: Identification plate for PR200 - C1847 ....................................................................................................... 8

Figure 2: Location of the Identification plate ............................................................................................................ 8

TABLE OF TABLES
Table 1: Document history.......................................................................................................................................... 4

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

Company Information
Machine: PR200
Order: C1847
Output language: EN
Original language: EN
Revision: 0 - 10.2015
Created by: Michael Stock
Checked by: Markus Adamer
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.

www.mining.sandvik.com
2. Environment, Health and Safety


TABLE OF CONTENTS

2 SAFETY LABELS, MESSAGES, SIGNALS .................................................................................................................. 6

2.1 General safety regulations .....................................................................................................................................6
2.2 Signal words ...........................................................................................................................................................6
2.3 Layout of safety signs ............................................................................................................................................7
2.4 Mandatory action symbols ....................................................................................................................................7
2.5 Prohibited action symbols .....................................................................................................................................8
2.6 General hazard symbol ..........................................................................................................................................9
2.7 Hazard symbols ......................................................................................................................................................9
2.8 Labels on the machine .........................................................................................................................................12
2.9 Visual and audible signals ...................................................................................................................................14
3 GUIDELINES AND USER OBLIGATIONS................................................................................................................... 15

3.1 Safety guidelines ..................................................................................................................................................15
3.2 User obligations ...................................................................................................................................................15
3.3 Managing work related hazards ..........................................................................................................................16
3.4 Scheduled safety inspections and preventive maintenance ............................................................................17
3.5 Personal safety guidelines ..................................................................................................................................17
3.6 Personal Protective Equipment ...........................................................................................................................18
4 M ACHINE SAFETY ............................................................................................................................................... 21

4.1 Intended use of the machine ...............................................................................................................................21
4.2 Modifications ........................................................................................................................................................21
4.3 Hazard zones ........................................................................................................................................................22
4.4 Confined space .....................................................................................................................................................23
4.5 Access to the machine .........................................................................................................................................23
5 SAFEGUARDING AND COMPLEMENTARY PROTECTIVE MEASURES........................................................................... 24

5.1 Safeguards ............................................................................................................................................................24
5.2 Protective devices ................................................................................................................................................24
5.3 Emergency stop buttons......................................................................................................................................25
5.4 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 Fire prevention ......................................................................................................................................................30
8.2 In case of fire accident .........................................................................................................................................31
8.3 Fire extinguishers (optional) ...............................................................................................................................31
8.4 Using a fire extinguisher (optional).....................................................................................................................31
8.5 After a fire accident ..............................................................................................................................................32
9 PROTECTION AGAINST HAZARDS ......................................................................................................................... 33

9.1 Noise hazard .........................................................................................................................................................33
9.2 Dust hazard ...........................................................................................................................................................33
9.3 High pressure hazard ...........................................................................................................................................34
9.4 Electric energy hazard .........................................................................................................................................34

10 EMERGENCY PROCEDURES ................................................................................................................................. 35

10.1 Emergency stop ................................................................................................................................................... 35
10.2 Emergency exit ..................................................................................................................................................... 35
10.3 Falling objects hazard.......................................................................................................................................... 35
10.4 Electric accidents ................................................................................................................................................. 35
10.5 After an accident or emergency situation .......................................................................................................... 36
11 SAFETY CONSIDERATIONS FOR MAINTENANCE ...................................................................................................... 37

11.1 Daily inspections and tasks for operators ......................................................................................................... 37
11.2 Definite technical skills and operator’s training ................................................................................................ 37
12 ENVIRONMENT .................................................................................................................................................... 38
12.1 Decommissioning ................................................................................................................................................ 38
12.2 Dismantling ........................................................................................................................................................... 38
12.2.1 Dismantling for transportation ........................................................................................................................ 38
12.2.2 Dismantling for disposal ................................................................................................................................. 38
12.3 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 Potential product related hazards identified by the user .................................................................................. 41
12.5 Incident reporting ................................................................................................................................................. 41
13 ORDERING SPARE PARTS .................................................................................................................................... 42


0 10-2015 First issue Lan Wang
named.

11-2015 Marco Andrade Mechanical lead engineer
11-2015 Walter Goncalves Electrical lead engineer

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 sub-
suppliers. 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:
 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.
2.2 Signal words
In the documentation for this machine the following symbols are used for very important
information or instructions.
DANGER indicates a hazard with a high level of risk

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

WARNING 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.

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 Wear approved safety

gloves footwear
Wear approved safety harness Wear approved protective Wear approved high visibility
clothing clothing

Read manual Keep safe distance Apply indicator for pinhole leak
test
Switch off and lock-out Disconnect equipment from Signal horn

equipment power source
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 Do not smoke

hands
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

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 Sideways tipping hazard

hazard
Figure 4: Mechanical hazard symbols (ISO)
Electrical hazard Electrical shock / Electrocution Battery hazard

hazard
Strong magnetic field hazard

Figure 5: Electrical hazard symbols (ISO)

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)

2.8 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

3 5
2 4
6
10
12
8
13
11
1 CA00016233, CA00016238 2 CA00016272

3 CA00016234 4 CA00016244
5 CA00016272 6 CA00016233
7 CA00016198, CA00016228, 8 CA00016272
CA00016230, CA00016175,
CA00016233, CA00016218,
CA00016272, CA00016246,
CA00016241
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:

 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.

3 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.

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!

 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.

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.

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.

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.

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

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

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 2
1 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).

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
 Must be present
 Must be properly secured
 Not damaged or bent
 Labeling must be present and legible
5.2 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

 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.

6 EMERGENCY EXIT
In an emergency situation use the safest escape way on both sides of the machine.
1 2
1 Emergency exit 2 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).

7 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 re-
established.
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.

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:
 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
1 2 3 4 3 4
1 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
To engage the locking spindles in the storm tie-down tower use the handweels on both sides of
the tower.
1 2 3 3 3
1 Bucket wheel boom 2 Storm tower

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

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:

 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.
8.2 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.

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)”.

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.

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.

10 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
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:

 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.

11 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

12 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.
 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.

12.3.3 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.

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.

13 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".

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

TABLE OF TABLES
Table 1: Document history ......................................................................................................................................... 5

Table 2: Review information....................................................................................................................................... 5

Company Information
Machine: PR200
Order: C1847
Output language: EN
Revision: 0 - 10-2015
Created by: Lan Wang
+43 3842 2077 – 0 +43 3842 2077 – 201

3. Troubleshooting for maintenance


TABLE OF CONTENTS

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


named.


2 TROUBLESHOOTING TABLE
Table 3: Troubleshooting
No. Problem Malfunction Action
1 Causes of mistracking.  Faults with the belt or its  Check belt splice.
splices.  Check belt surfaces.
2 Causes of mistracking.  Faults with material  Center material stream on
loading. receiving belt.
 Provide homogenous
material stream.
3 Causes of mistracking.  Wander due to faults  Check belt splice.
with splices or the belt.
4 Causes of mistracking.  Wander due to  Align and/or adjust
component problems. conveyor components.
5 Conveyor running to one  One or more idlers not  Adjust idlers.
side at a given point on rectangular to the
longitudinal axis of the
structure. belt.
 Sticking idlers.  Clean idlers and belt,
install belt cleaning.
 Conveyor frame or  Level the structure.
structure not level or
crooked.
 Guiding not sufficient.  Tilt idlers and/or install belt
guiding.
6 Particular section of the  Belt splicing not straight.  Re-splice the belt.
belt runs to one side at  Bowed belt  A new belt should
all points. straighten out after
operated under full load
tension, use self-aligning
idlers on the return strand
ahead of the tail pulley if
necessary.
 Loading being placed on  Adjust chute and loading
the belt off-center. conditions to place load in
the center of the belt.
 Guiding not sufficient.  Tilt idlers and/or install bet
guiding.
7 Conveyor belt runs to  One or more idlers not  Adjust idlers.
one side at all points. rectangular to the
belt.
 Sticking idlers.  Clean idlers and belt,
install belt cleaning.
 Sticking or blocking  Maintain the guider idler
guide idler set. set movable or replace it.
 Rubber cushions discs  Exchange rubber cushion
worn out or loose. discs.

No. Problem Malfunction Action

 Conveyor frame or  Level the structure.
structure not level or
crooked.
 Side loading.  Loading in direction of belt
travel, in center of
conveyor.
8 Conveyor belt runs to  Missing steering devices  Install steering devices,
one side for a longer on return stand. e.g. troughed roof idlers in
angle of 10-15° on the
distance. return stand.
 Material trapped  Install v-scrapers, install
between belt and tail decking or guards.
pulley.
 Not parallel installed  Check the position of the
scraper on return strand. scraper, change worn
scraper blades.
 Rubber sealing of the  Install sealings
chute is not correct perpendicular to the belt
installed or not surface, change worn
symmetric. sealings.
 Loading being placed on  Adjust chute and loading
the belt off-center. conditions to place load in
center of the belt.
 Material builds up at the  Remove accumulation;
pulley. install scrapers, install
decking or guards,
improve loading.
9 Belt running to one side  Belt too stiff to train.  Reduce the troughing
at or close to the pulley. angel; tilt troughing idlers
forward but not more than
2°.
 Belt to flexible in cross  Use belt with higher rating
direction. or thicker carcass.
 One or more idlers not  Correction of idlers.
rectangular to the
belt.
 Sticking idlers.  Lubricate or exchange
idlers, improve
maintenance.

TABLE OF FIGURES
No table of figures entries found.

TABLE OF TABLES
Table 1: Document history ......................................................................................................................................... 4

Table 2: Review information....................................................................................................................................... 4
Table 3: Troubleshooting ........................................................................................................................................... 5

Company Information
Machine: PR200
Order: C1847
Output language: EN
Revision: 0 - 10.2015
+43 3842 2077 – 0 +43 3842 2077 – 201

4. Maintenance instructions


TABLE OF CONTENTS

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

2.1 Safety instructions .................................................................................................................................................6
2.1.1 General safety instructions ...............................................................................................................................6
2.1.2 Qualification of personnel assigned .................................................................................................................6
2.1.3 Tools ................................................................................................................................................................6
2.1.4 Power supply....................................................................................................................................................7
2.1.5 Lighting.............................................................................................................................................................7
2.1.6 Original Spare parts .........................................................................................................................................7
3 CLEANING ............................................................................................................................................................ 8
3.1 Safety during cleaning and maintenance .............................................................................................................8
3.2 Cleaning intervals ...................................................................................................................................................8
3.3 Cleaning methods...................................................................................................................................................8
4 SAFETY INSPECTIONS ......................................................................................................................................... 10

4.1 Safety inspection protocol ...................................................................................................................................10
4.2 Structural Integrity................................................................................................................................................12
4.2.1 Frequency of inspection .................................................................................................................................12
4.2.2 Structural Components...................................................................................................................................12
4.2.3 Portal ..............................................................................................................................................................14
4.2.4 Slew deck structural inspection ......................................................................................................................16
4.2.5 Rocker & Counterweight boom structural inspection ......................................................................................18
4.2.6 Bucket wheel boom structural inspection .......................................................................................................19
4.2.7 Bucket wheel structural inspection .................................................................................................................22
4.2.8 Long travel arrangement structural inspection ...............................................................................................24
4.3 Mechanical inspection .........................................................................................................................................26
4.3.1 Frequency of inspection .................................................................................................................................26
4.3.2 Long travel drive arrangement .......................................................................................................................26
4.3.3 Rocker & Counterweight boom ......................................................................................................................39
4.3.4 Bucket wheel boom ........................................................................................................................................44
4.3.5 Bucket wheel boom conveyor system ............................................................................................................48
4.3.6 Bucket wheel ..................................................................................................................................................51
5 PERIODIC MAINTENANCE ..................................................................................................................................... 54

5.1 Maintenance of surface treatment.......................................................................................................................54
5.2 Description of maintenance symbols .................................................................................................................54
5.3 Maintenance of safety switch ..............................................................................................................................55
5.4 Maintenance of pull cord emergency switch .....................................................................................................55
5.5 Maintenance of start pre-warning device ...........................................................................................................55
5.6 Setting up a maintenance schedule ....................................................................................................................55
5.7 Maintenance schedule - Daily ..............................................................................................................................57
5.8 Maintenance schedule - Weekly ..........................................................................................................................59
5.9 Maintenance schedule – Monthly ........................................................................................................................62
5.10 Maintenance schedule - Every 3 month..............................................................................................................66
5.11 Maintenance schedule - Every 6 month..............................................................................................................68
5.12 Maintenance schedule – Every year ...................................................................................................................71
5.13 Maintenance schedule - Every 2 years ...............................................................................................................75
6 FASTENERS ........................................................................................................................................................ 78
6.1 Coefficients of friction and lubrication ...............................................................................................................80

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

7.1 General information ............................................................................................................................................. 81
7.1.1 Safety during lubrication ................................................................................................................................ 81
7.2 Methods for taking oil samples ........................................................................................................................... 81
7.3 Oil lubrication schedule ....................................................................................................................................... 82
7.4 Grease lubrication schedule ............................................................................................................................... 82


named.


2 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.

2.1.4 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.

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.

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.

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

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:

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 SC
 Visual V
 Non-Destructive Testing NDT
 Dimension Check D
 Motion Check MC
 Observation 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 Figure 2: Corroded and heavily pitted

longitudinal beam

Figure 3: Web plate of boom girder deformed Figure 4: Damaged edge of cross beam

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 OK Not OK Remarks
1 Any encrustation, such as V

accumulation of spillage or material
that sticks to the structure that hasn’t
been cleaned off in the preparation
wash down.
2 Areas with insufficient paint protection. V, (NDT)
3 Loss of cross sectional area due to V, (NDT)
wear or corrosion.
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.

Figure 5: Portal general arrangement

4.2.4 Slew deck structural inspection

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.
1 Any encrustation, such as accumulation V

of spillage or material that sticks to the
structure that hasn’t been cleaned off in
the preparation wash down.
3 Loss of cross sectional area due to V, (NDT)
wear or corrosion.
of any defects on the figures below and give a brief description.

Figure 6: Slew deck general arrangement

4.2.5 Rocker & Counterweight boom structural inspection

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:

3 Loss of cross sectional area due to wear V, (NDT)
or corrosion.
of any defects on the figure below and give a brief description.
Figure 7: Rocker & Counterweight boom
4.2.6 Bucket wheel boom structural inspection

992663-5720-B-M-DWG-0045-1 Bucket wheel boom steel structure general arrangement 1/2
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


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:

or corrosion.

Figure 8: Bucket wheel boom steel structure

4.2.7 Bucket wheel structural inspection

992663-5720-B-M-DWG-0040-1 Bucket wheel general arrangement 1/3
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:

or corrosion.

Figure 9: Bucket wheel general arrangement

4.2.8 Long travel arrangement structural inspection

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

or corrosion.


Figure 10: Equalizer bogie

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:
 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
4.3.2 Long travel drive arrangement

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


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
1, 2 3, 4 5, 6 7, 8 9,10 11,12 13,14 15,16 17,18
19,20 21,22 23,24 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: - 5 mm

 Max. permissible reduction for measurement A & B: - 3 mm
 All measurements taken from point C have to be in the range o: ± 3 mm
 Nominal dimension for measurement C: 25 mm
 Nominal dimension for measurement A & B: 25 mm

Figure 12: Wheel flange diagram
Bogie No. Position Measurement Position Measurement
A A
Machine wheel
B B
1
C C
A A
Machine wheel
B B
2
C C
A A
Machine wheel
B B
3
C C
A A
Machine wheel
B B
4
C C
A A
Machine wheel
B B
5
C C
A A
Machine wheel
B B
6
C C
A A
Machine wheel
B B
7
C C
Machine wheel A A
8 B B

C C
A A
Machine wheel
B B
9
C C
A A
Machine wheel
B B
10
C C
A A
Machine wheel
B B
11
C C
A A
Machine wheel
B B
12
C C
A A
Machine wheel
B B
13
C C
A A
Machine wheel
B B
14
C C
A A
Machine wheel
B B
15
C C
A A
Machine wheel
B B
16
C C
A A
Machine wheel
B B
17
C C
A A
Machine wheel
B B
18
C C

A A
Machine wheel
B B
19
C C
A A
Machine wheel
B B
20
C C
A A
Machine wheel
B B
21
C C
A A
Machine wheel
B B
22
C C
A A
Machine wheel
B B
23
C C
A A
Machine wheel
B B
24
C C
A A
Machine wheel
B B
25
C C
A A
Machine wheel
B B
26
C C
A A
Machine wheel
B B
27
C C
A A
Machine wheel
B B
28
C C
Machine wheel A A


29 B B
C C
A A
Machine wheel
B B
30
C C
A A
Machine wheel
B B
31
C C
A A
Machine wheel
B B
32
C C
A A
Machine wheel
B B
33
C C
A A
Machine wheel
B B
34
C C
A A
Machine wheel
B B
35
C C
A A
Machine wheel
B B
36
C C

4.3.2.2 2-wheel bogie single driven left
6,7 5
3
2
8
4
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 OK Not OK QTY Remarks

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

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

2 Wheel axle V, O 6
3 Drive shaft V, O 3
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

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:

2 Wheel axle V, O 4
4 Bogie pin V, O 2
5 Encoder V, O 2

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

1 Bogie pin V, O 12
2 Mounting bolts V, O all
4.3.2.6 Six wheel bogie
Figure 17: Six wheel bogie

Inspect all six six wheel bogies according to the following table:

1 Bogie pin V, O 6
4.3.2.7 Twelve wheel bogie
Figure 18: Six wheel bogie
Inspect both twelve wheel bogies according to the following table:

1 Bogie pin V, O 4

4.3.2.8 Slewing system

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
3
4
Figure 19: Slewing system
For mechanical inspection of the slew drive unit use the OEM-Manual of the manufacturer.

Inspect the slewing assembly according following table:
1 Slew drive unit V, O 3

2 Slew bearing V, O 1
3 Slew drive pinion V 1
4 Slew bearing V 72/72
mounting bolts/studs
5 Slew drive mounting V all
bolts

4.3.3 Rocker & Counterweight boom

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)
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)

4.3.3.1 Pivot suspension rod (point-E)
5
1 6
3 7
Figure 21: Pivot suspension rod (point-E)
Inspect the pivot suspension rod (point-E) assembly according to the following table:

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
6 Pivot pin V, O 1
7 Cover V, O 2

4.3.3.2 Pivot connection rod (point-G)
2
1 10
3
9
11
12
4 13
6 5 15
7 14
Figure 22: Pivot connection rod (point-G)
Inspect the pivot connection rod (point-G) assembly according to the following table:

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
7 Cover 1 V, O 2
Pivot flaoting side
9 Pivot pin V, O 2
11 Cover 1 V, O 2
14 V-seal V-250A V, O 4


15 Cover 2 V, O 2
4.3.3.3 Pivot rocker (point-D)
3 11
1 2 12 13
4
10
7 5 16 15
8 6
14
Figure 23: Pivot rocker (point-D)
Inspect the pivot rocker (point-D) assembly according to the following table:

Pivot fixed side
1 Cover 1 V, O 1
4 Cover 2 V, O 1
5 Pivot pin V, O 1
Pivot flaoting side
10 Pivot pin V, O 1
11 Cover 2 V, O 1


13 Cover 1 V, O 1
15 V-seal V-300A V, O 1
16 V-seal V-340A V, O 1
4.3.3.4 Pivot counterweight boom (point-F)
6
1 2
3 5
Figure 24: Pivot counterweight boom (point-F)
Inspect the pivot counterweight boom (point-F) assembly according to the following table:

Pivot fixed side
1 Pivot pin 1 V, O 1
3 Cover V, O 2
4 Mounting bolts V, O 1
Pivot floating side
5 Cover V, O 1


4.3.4 Bucket wheel boom

1847PR1-70-030 Pivot bucket wheel boom (point A)
1847PR1-70-045 Pivot mast (point C)
1847PR1-70-080 Pivot mast (point B)
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)

4.3.4.1 Pivot bucket wheel boom (point-A)
3 11
2 12
10
1 4
5 5 14
8 7 6 13
Figure 26: Pivot bucket wheel boom (point-A)
Inspect the pivot bucket wheel boom (point-A) assembly according to the following table:

Pivot fixed side
1 Cover 1 V, O 1
4 Cover 2 V, O 1
5 Pivot pin V, O 1
Pivot flaoting side
10 V-seal V-304A 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


4.3.4.2 Pivot mast (point-C)
2
6
1
Figure 27: Pivot mast (point-C)
Inspect the pivot mast (point-C) assembly according to the following table:

Pivot fixed side
3 Cover V, O 2
Pivot floating side
5 Cover V, O 2

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


4.3.5 Bucket wheel boom conveyor system

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

2 9
7 8
1 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.
Inspect the discharge boom conveyor system according to the following table:

1 Center chute V, O 1
2 Drive/Take-up V 1
pulley
3 Take-up station V, O 1
4 Take-up V, O all
equipment
5 Primary scraper V 1
6 Secondary scraper V 1
7 Idlers/Garlands V 50
8 Conveyor belt V 1
9 Bucket wheel V, O 1
chute
10 Tail pulley V 1
11 Snub pulley V 3
11 Conveyor V, O 2
drive/brake incl.


torque arm
12 Plough scraper V 1
13 Mounting brackets V all
of the components
14 Mounting supports V all
of the components
15 Mounting pins and V all
bolts

4.3.6 Bucket wheel

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
Figure 30: Bucket wheel arrangement 1/2

1
2 6
Figure 31: Bucket wheel arrangement 2/2
Figure 32: Buckets

Inspect the bucket wheel according to the following table:

1 Bucket wheel V 1
2 Bucket wheel drive V, O 1
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

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 Description Symbol Description
Adjust Drain
Change/Replace Lubricate
Check Measure
Clean Service

5.3 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.
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
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.

5.7 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
Maintenance Procedure  Notes 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 

components
Motor – Bucket wheel boom conveyor drive unit PR200-OEM
Visual check of the Surface. 

components
Gearbox – Bucket wheel boom conveyor drive unit
Check oil temperature 

components
Conveyor belt PR200-OEM
Check for unsual noise and vibration 
Check misalignment of belt 
Pulleys PR200-OEM
Check for damage 

Operation – Daily
Check for freely rotation 
Clear any material around the pulleys 
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

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:

5.8 Maintenance schedule - Weekly
Operation – Weekly
Motor – Long travel 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 

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

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

Conveyor belt PR200-OEM
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

Check gratings and handrails security of 
the grating.
Check gratings and handrails for damage 
and deformation.
Remove material built-up (on gratings). 
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:

5.9 Maintenance schedule – Monthly
Operation – Monthly
Cleaning the surface. 

Check housing temperature 
Check oil level 
Check the oil level sensor 
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

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
components
Gearbox – Slew drive unit
Check housing temperature 
Check oil level 
Check the oil level sensor 
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 
Check general state of the brake (after 
Check thruster reserve stroke (after 
Check brake spring tension (torque) (after 

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 
Slew bearing PR200-OEM
Re-lubrication of bearing 
Check the bolts 
Motor –Discharge boom conveyor drive unit PR200-OEM

ducts.
Gearbox – Discharge boom conveyor drive unit
Check oil level 
Check gearbox for leakage 

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. 
Check screw joints at the aggregate, 
lubrication points and pipelines for
tightness
Check hose pipes and hose fittings for 

tightness
Walkways and Platforms – Structural Equipment
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:

5.10 Maintenance schedule - Every 3 month
Operation – Every 3 month

Gearbox – Long travel drive unit PR200-OEM
Check the coupling 

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
Clean the exterior of the vent plug 

Clean coarse filter 
Clean the air filter 
Coupling – Slew drive unit

Check for alignment 
Check the connection bolts 
Check the backlash 
Check the flexible spider/ elements 

Check the backlash 

Operation – Every 3 month

Check meshing gearing with pinion of 
slew drive unit
Check the gearing for unusual wear 
Gearbox – Discharge boom conveyor drive unit 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
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:

5.11 Maintenance schedule - Every 6 month
Operation – 6 month
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)
Check the oil quality 
Clean the gearbox ventilation or replace if 

necessary
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 

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)
Check the sealing system 

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
Check all settings and reset if necessary 
(1000 cycles).
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 and replace the rubber buffers (for 

gear units with torque arm)
Distribution Boards – Electrical Equipment
Inspection inside DB’s ensure all surfaces 

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:

5.12 Maintenance schedule – Every year
Operation – Every year

Gearbox – Long travel drive unit PR200-OEM
Check the friction clutch and adjust if 
necessary
Carry out a complete inspection of the 
geared motor
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)
Grease the bearing in the agitator flange 
Check the air gap 
Clean the fan wheel of the motor 

(depending on outside influences)
Test the water content of the oil (after 
approx. 400 hours)
Check hose lines 


Check friction linings of torque-limiting 
backstop
Check the raceway system 

Test the water content of the oil (after 
approx. 400 hours)
Check hose lines 
Check shrink disk 
Check friction linings of torque-limiting 

backstop
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.
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
Check slip rings and graphite brushes for 
wear and exchange if needed (Every
Check all screws and other connections 
(Every 4,500 to 5,000 operating hours)
Cable reel – Guide facility


Check for wear of contact guide roller 
Cable reel – Guide facility/ direction change over roles
Check for wear of idler (Every 4,500 to 
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 
Cable reel – Bearings of the real
Re-grease if required (Every 4,500 to 
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


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:

5.13 Maintenance schedule - Every 2 years
Operation – Every 2 years

Gearbox – Long travel drive unit 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 


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 
Cable reel – Drive motor
Re-grease the bearings (Every 8,000 to 
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


Replace CPU battery. 
When completed:
Date: Operation:
Approved:

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 Tightening torque
Strenght FM Tab in kN vor μG MA in Nm für μK = μG
Size
Grade
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
8.8 4.6 4.5 4.4 4.3 4.2 3.9 3.7 2.3 2.6 3.0 3.3 3.6 4.1 4.5
M4 10.9 6.8 6.7 6.5 6.3 6.1 5.7 5.4 3.3 3.9 4.6 4.8 5.3 6.0 6.6
12.9 8.0 7.8 7.6 7.4 7.1 6.7 6.3 3.9 4.5 5.1 5.6 6.2 7.0 7.8
8.8 7.6 7.4 7.2 7.0 6.8 6.4 6.0 4.4 5.2 5.9 6.5 7.1 8.1 9.0
M5 10.9 11.1 10.8 10.6 10.3 10.0 9.4 8.8 6.5 7.6 8.6 9.5 10.4 11.9 13.2
12.9 13.0 12.7 12.4 12.0 11.7 11.0 10.3 7.6 8.9 10.0 11.2 12.2 14.0 15.5
8.8 10.7 10.4 10.2 9.9 9.6 9.0 8.4 7.7 9.0 10.1 11.3 12.3 14.1 15.6
M6 10.9 15.7 15.3 14.9 14.5 14.1 13.2 12.4 11.3 13.2 14.9 16.5 18.0 20.7 22.9
12.9 18.4 17.9 17.5 17.0 16.5 15.5 14.5 13.2 15.4 17.4 19.3 21.1 24.2 26.8
8.8 15.5 15.1 14.8 14.4 14.0 13.1 12.3 12.6 14.8 16.8 18.7 20.5 23.6 26.2
M7 10.9 22.7 22.5 21.7 21.1 20.5 19.3 18.1 18.5 21.7 24.7 27.5 30.1 34.7 38.5
12.9 26.6 26.0 25.4 24.7 24.0 22.6 21.2 21.6 25.4 28.9 32.2 35.2 40.6 45.1
8.8 19.5 19.1 18.6 18.1 17.6 16.5 15.5 18.5 21.6 24.6 27.3 29.8 34.3 38.0
M8 10.9 28.7 28.0 27.3 26.6 25.8 24.3 22.7 27.2 31.8 36.1 40.1 43.8 50.3 55.8
12.9 33.6 32.8 32.0 31.1 30.2 28.4 26.6 31.8 37.2 42.2 46.9 51.2 58.9 65.3
8.8 31.0 30.3 29.6 28.8 27.9 26.3 24.7 36 43 48 54 59 68 75

M10 10.9 45.6 44.5 43.4 42.2 41.0 38.6 36.2 53 63 71 79 87 100 110
12.9 53.3 52.1 50.8 49.4 48.0 45.2 42.4 62 73 83 93 101 116 129
8.8 45.2 44.1 43.0 41.9 40.7 38.3 35.9 63 73 84 93 102 117 130
M12 10.9 66.3 64.8 63.2 61.5 59.8 56.3 52.8 92 108 123 137 149 172 191
12.9 77.6 75.9 74.0 72.0 70.0 65.8 61.8 108 126 144 160 175 201 223
8.8 62.0 60.6 59.1 57.5 55.9 52.6 49.3 100 117 133 148 162 187 207
M14 10.9 91.0 88.9 86.7 84.4 82.1 77.2 72.5 146 172 195 218 238 274 304
12.9 106.5 104.1 101.5 98.8 96.0 90.4 84.8 171 201 229 255 279 321 356


Strenght FM Tab in kN vor μG MA in Nm für μK = μG
Size
Grade
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
8.8 84.7 82.9 80.9 78.8 76.6 72.2 67.8 153 180 206 230 252 291 325
M16 10.9 124.4 121.7 118.8 115.7 112.6 106.1 99.6 224 264 302 338 370 428 477
12.9 145.5 142.4 139.0 135.4 131.7 124.1 116.6 262 309 354 395 433 501 558
8.8 107 104 102 99 96 91 85 220 259 295 329 360 415 462
M18 10.9 152 149 145 141 137 129 121 314 369 421 469 513 592 657
12.9 178 174 170 165 160 151 142 367 432 492 549 601 692 769
8.8 136 134 130 127 123 116 109 308 363 415 464 509 588 655
M20 10.9 194 190 186 181 176 166 156 438 517 592 661 725 838 933
12.9 227 223 217 212 206 194 182 513 605 692 773 848 980 1092
8.8 170 166 162 158 154 145 137 417 495 567 634 697 808 901
M22 10.9 242 237 231 225 219 207 194 595 704 807 904 993 1151 1284
12.9 283 277 271 264 257 242 228 696 824 945 1057 1162 1347 1502
8.8 196 192 188 183 178 168 157 529 625 714 798 875 1011 1126
M24 10.9 280 274 267 260 253 239 224 754 890 1017 1136 1246 1440 1604
12.9 327 320 313 305 296 279 262 882 1041 1190 1329 1458 1685 1877
8.8 257 252 246 240 234 220 207 772 915 1050 1176 1292 1498 1672
M27 10.9 367 359 351 342 333 314 295 1100 1304 1496 1674 1840 2134 2381
12.9 429 420 410 400 389 367 345 1287 1526 1750 1959 2153 2497 2787
8.8 313 307 300 292 284 268 252 1053 1246 1428 1597 1754 2931 2265
M30 10.9 446 437 427 416 405 382 359 1500 1775 2033 2274 2498 2893 3226
12.9 522 511 499 487 474 447 420 1755 2077 2380 2662 2923 3386 3775
8.8 389 381 373 363 354 334 314 1415 1679 1928 2161 2377 2759 3081
M33 10.9 554 543 531 517 504 475 447 2015 2392 2747 3078 3385 3930 4388
12.9 649 635 621 605 589 556 523 2358 2799 3214 3601 3961 4598 5135
8.8 458 448 438 427 415 392 368 1825 2164 2482 2778 3054 3541 3951
M36 10.9 652 638 623 608 591 558 524 2600 3082 3535 3957 4349 5043 5627
12.9 763 747 729 711 692 653 614 3042 3607 4136 4631 5089 5902 6585
8.8 548 537 525 512 498 470 443 2348 2791 3208 3597 3958 4598 5137
M39 10.9 781 765 748 729 710 670 630 3345 3975 4569 5123 5637 6549 7317
12.9 914 895 875 853 831 784 738 3914 4652 5346 5994 6596 7664 8562

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).

7 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.
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.
 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
For detailed information refer to the external Document “Oil and Grease
Lubrication Schedules (pr200_C1847-LS_en-v1.pdf)”.
7.4 Grease lubrication schedule
It is important to use the OEM-Manual for correct lubrication

procedures.


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

TABLE OF TABLES

Table 3: Drawing reference ....................................................................................................................................... 14
Table 10: Drawing reference ..................................................................................................................................... 37
Table 15: Maintenance symbols ............................................................................................................................... 54
Table 16: Assembly preload and tightening torque ............................................................................................... 78
Table 17: Recommended lubrication and friction coefficients .............................................................................. 80

Company Information
Machine: PR200
Order: C1847
Output language: EN
Revision: 0 - 10.2015
+43 3842 2077 – 0 +43 3842 2077 – 201

5. Repair/Replacement Instructions


TABLE OF CONTENTS

2 SLEW ASSEMBLY .................................................................................................................................................. 5

2.1 Slew bearing ...........................................................................................................................................................5
2.1.1 Personnel .........................................................................................................................................................5
2.1.2 Equipment ........................................................................................................................................................5
2.1.3 Masses of equipment .......................................................................................................................................6
2.1.4 Time schedule ..................................................................................................................................................6
2.1.5 Additional safety instructions ............................................................................................................................6
2.1.6 Preparation for replacement .............................................................................................................................6
2.1.7 Repair/ Replacement location ..........................................................................................................................7
2.1.8 Repair/ Replacement procedure ......................................................................................................................8
3 APPENDIX .......................................................................................................................................................... 14
3.1 Standard torque table...........................................................................................................................................14
Table of Figures ...............................................................................................................................................................16


0 30.10.2015 First issue Daniel Hammer
named.


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:
 6 x Mechanical tradesperson
 2 x Electrical tradesperson
 1 x Rigger
 1 x Crane operator
 1 x EWP
2.1.2 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

992663-5720-B-M-DWG-0039 Slewing assembly general arrangement
1847PR1-50-010 Portal assembly
1847PR1-60-010 Slew deck with pylon assembly

2.1.3 Masses of equipment
Table 4: Masses of equipment

Slew bearing approx.5,952 kg
2.1.4 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.

2.1.7 Repair/ Replacement location
Figure 1: Slew bearing – Repair/ Replacement location on machine
1 Slew bearing
Figure 2: Slew bearing – Repair/ Replacement location detailed view

2.1.8 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.

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.

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.

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.

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.
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.
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.
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.
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.

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.

Strength FM Tab in kN vor μG MA in Nm für μK = μG
Size
Grade
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
8.8 4.6 4.5 4.4 4.3 4.2 3.9 3.7 2.3 2.6 3.0 3.3 3.6 4.1 4.5
M4 10.9 6.8 6.7 6.5 6.3 6.1 5.7 5.4 3.3 3.9 4.6 4.8 5.3 6.0 6.6
12.9 8.0 7.8 7.6 7.4 7.1 6.7 6.3 3.9 4.5 5.1 5.6 6.2 7.0 7.8
8.8 7.6 7.4 7.2 7.0 6.8 6.4 6.0 4.4 5.2 5.9 6.5 7.1 8.1 9.0
M5 10.9 11.1 10.8 10.6 10.3 10.0 9.4 8.8 6.5 7.6 8.6 9.5 10.4 11.9 13.2
12.9 13.0 12.7 12.4 12.0 11.7 11.0 10.3 7.6 8.9 10.0 11.2 12.2 14.0 15.5
8.8 10.7 10.4 10.2 9.9 9.6 9.0 8.4 7.7 9.0 10.1 11.3 12.3 14.1 15.6
M6 10.9 15.7 15.3 14.9 14.5 14.1 13.2 12.4 11.3 13.2 14.9 16.5 18.0 20.7 22.9
12.9 18.4 17.9 17.5 17.0 16.5 15.5 14.5 13.2 15.4 17.4 19.3 21.1 24.2 26.8
8.8 15.5 15.1 14.8 14.4 14.0 13.1 12.3 12.6 14.8 16.8 18.7 20.5 23.6 26.2
M7 10.9 22.7 22.5 21.7 21.1 20.5 19.3 18.1 18.5 21.7 24.7 27.5 30.1 34.7 38.5
12.9 26.6 26.0 25.4 24.7 24.0 22.6 21.2 21.6 25.4 28.9 32.2 35.2 40.6 45.1
8.8 19.5 19.1 18.6 18.1 17.6 16.5 15.5 18.5 21.6 24.6 27.3 29.8 34.3 38.0
M8 10.9 28.7 28.0 27.3 26.6 25.8 24.3 22.7 27.2 31.8 36.1 40.1 43.8 50.3 55.8
12.9 33.6 32.8 32.0 31.1 30.2 28.4 26.6 31.8 37.2 42.2 46.9 51.2 58.9 65.3
8.8 31.0 30.3 29.6 28.8 27.9 26.3 24.7 36 43 48 54 59 68 75

M10 10.9 45.6 44.5 43.4 42.2 41.0 38.6 36.2 53 63 71 79 87 100 110
12.9 53.3 52.1 50.8 49.4 48.0 45.2 42.4 62 73 83 93 101 116 129
8.8 45.2 44.1 43.0 41.9 40.7 38.3 35.9 63 73 84 93 102 117 130
M12 10.9 66.3 64.8 63.2 61.5 59.8 56.3 52.8 92 108 123 137 149 172 191
12.9 77.6 75.9 74.0 72.0 70.0 65.8 61.8 108 126 144 160 175 201 223
8.8 62.0 60.6 59.1 57.5 55.9 52.6 49.3 100 117 133 148 162 187 207
M14 10.9 91.0 88.9 86.7 84.4 82.1 77.2 72.5 146 172 195 218 238 274 304
12.9 106.5 104.1 101.5 98.8 96.0 90.4 84.8 171 201 229 255 279 321 356


Strength FM Tab in kN vor μG MA in Nm für μK = μG
Size
Grade
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
8.8 84.7 82.9 80.9 78.8 76.6 72.2 67.8 153 180 206 230 252 291 325
M16 10.9 124.4 121.7 118.8 115.7 112.6 106.1 99.6 224 264 302 338 370 428 477
12.9 145.5 142.4 139.0 135.4 131.7 124.1 116.6 262 309 354 395 433 501 558
8.8 107 104 102 99 96 91 85 220 259 295 329 360 415 462
M18 10.9 152 149 145 141 137 129 121 314 369 421 469 513 592 657
12.9 178 174 170 165 160 151 142 367 432 492 549 601 692 769
8.8 136 134 130 127 123 116 109 308 363 415 464 509 588 655
M20 10.9 194 190 186 181 176 166 156 438 517 592 661 725 838 933
12.9 227 223 217 212 206 194 182 513 605 692 773 848 980 1092
8.8 170 166 162 158 154 145 137 417 495 567 634 697 808 901
M22 10.9 242 237 231 225 219 207 194 595 704 807 904 993 1151 1284
12.9 283 277 271 264 257 242 228 696 824 945 1057 1162 1347 1502
8.8 196 192 188 183 178 168 157 529 625 714 798 875 1011 1126
M24 10.9 280 274 267 260 253 239 224 754 890 1017 1136 1246 1440 1604
12.9 327 320 313 305 296 279 262 882 1041 1190 1329 1458 1685 1877
8.8 257 252 246 240 234 220 207 772 915 1050 1176 1292 1498 1672
M27 10.9 367 359 351 342 333 314 295 1100 1304 1496 1674 1840 2134 2381
12.9 429 420 410 400 389 367 345 1287 1526 1750 1959 2153 2497 2787
8.8 313 307 300 292 284 268 252 1053 1246 1428 1597 1754 2931 2265
M30 10.9 446 437 427 416 405 382 359 1500 1775 2033 2274 2498 2893 3226
12.9 522 511 499 487 474 447 420 1755 2077 2380 2662 2923 3386 3775
8.8 389 381 373 363 354 334 314 1415 1679 1928 2161 2377 2759 3081
M33 10.9 554 543 531 517 504 475 447 2015 2392 2747 3078 3385 3930 4388
12.9 649 635 621 605 589 556 523 2358 2799 3214 3601 3961 4598 5135
8.8 458 448 438 427 415 392 368 1825 2164 2482 2778 3054 3541 3951
M36 10.9 652 638 623 608 591 558 524 2600 3082 3535 3957 4349 5043 5627
12.9 763 747 729 711 692 653 614 3042 3607 4136 4631 5089 5902 6585
8.8 548 537 525 512 498 470 443 2348 2791 3208 3597 3958 4598 5137
M39 10.9 781 765 748 729 710 670 630 3345 3975 4569 5123 5637 6549 7317
12.9 914 895 875 853 831 784 738 3914 4652 5346 5994 6596 7664 8562
Table 5: Assembly preload and tightening torque

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

TABLE OF TABLES

Table 3: Drawing reference ......................................................................................................................................... 5
Table 4: Masses of equipment .................................................................................................................................... 6
Table 5: Assembly preload and tightening torque ................................................................................................. 15

Company Information
Machine: PR200
Order: C1847
Output language: SR
Revision: 0 - 30.10.2015
Created by: Daniel Hammer
+43 3842 2077 – 0 +43 3842 2077 – 201
info.mining@sandvik.com Lokal Internet Site: www.mining.sandvik.com

6. Accompanying documents


TABLE OF CONTENTS

2 REFERENCE TO OEM-M ANUAL ............................................................................................................................. 5
3 OIL AND GREASE LUBRICATION SCHEDULES ........................................................................................................... 7


named.


2 REFERENCE TO OEM-MANUAL
Table 3: Reference to OEM-Manual
Code Title Manufacturer/Supplier

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

Code Title Manufacturer/Supplier
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

3 OIL AND GREASE LUBRICATION SCHEDULES

TABLE OF FIGURES

TABLE OF TABLES

Table 3: Reference to OEM-Manual ............................................................................................................................ 5

Company Information
Machine: PR200
Order: C1847
Output language: EN
Revision: 0 - 10.2015
+43 3842 2077 – 0 +43 3842 2077 – 201
info.mining@sandvik.com Lokal Internet Site: www.mining.sandvik.com

7. Feedback

pr200_C1847-MM07.0_en-v1_Rev0.doc

TABLE OF CONTENTS

2 DOCUMENTATION CUSTOMER SATISFACTION SURVEY............................................................................................ 5


named.


2 DOCUMENTATION CUSTOMER SATISFACTION SURVEY
For detailed information refer to the external Document “Documentation –

Customer Satisfaction Survey ‘(pr200_C1847-MM07.1_en_v1.pdf)”.

TABLE OF FIGURES

TABLE OF TABLES


Company Information
Machine: PR200
Order: C1847
Output language: EN
Revision: 0 - 10.2015
+43 3842 2077 – 0 +43 3842 2077 – 201


5720 B G MAN 0007 - Rev0

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Original Instructions

Copyright © Sandvik Mining and Construction Materials Handling Chapter 1 | 1 (16)

2 (16) | Chapter 1 Copyright © Sandvik Mining and Construction Materials Handling

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

2 PRODUCT DOCUMENTATION .................................................................................................................................. 5

3 IDENTIFICATION OF THE PRODUCT .......................................................................................................................... 8

5 TERMINOLOGY AND ABBREVIATIONS .................................................................................................................... 11

Copyright © Sandvik Mining and Construction Materials Handling Chapter 1 | 3(16)

1 DOCUMENT HISTORY AND REVIEW INFORMATION

1.1 Document history

Table 1: Document history

1.2 Review information

Table 2: Review information

4 (16) | Chapter 1 Copyright © Sandvik Mining and Construction Materials Handling

2.1 Target group

 Operation ( starting and stopping)

In particular, the following must be considered:

 the chapter on ENVIRONMENT, HEALTH AND SAFETY

2.2 Supplementary instructions

Instructions on any special operational conditions concerning work organization, sequence of

2.3 Location of the manuals on the product

Copyright © Sandvik Mining and Construction Materials Handling Chapter 1 | 5 (16)

2.4 How to identify the correct manual for the product

2.5 Objective of the product documentation

Table 3: Content of the Maintenance Manual

2.6 Replacement copies for the Maintenance Manual

6 (16) | Chapter 1 Copyright © Sandvik Mining and Construction Materials Handling

 Machine type and Sandvik Reference Number or contract number

2.7 Warranty and liability

2.8 Copyright notice

All Rights Reserved.

Copyright © Sandvik Mining and Construction Materials Handling Chapter 1 | 7 (16)

3 IDENTIFICATION OF THE PRODUCT

3.1 Identification plate of the product

Figure 1: Identification plate for PR200 - C1847

3.2 Location of the Identification plate on the product

Figure 2: Location of the Identification plate

8 (16) | Chapter 1 Copyright © Sandvik Mining and Construction Materials Handling

3.3 Name and address of the manufacturer

Sandvik Mining and Construction Materials Handling GmbH & Co KG

Copyright © Sandvik Mining and Construction Materials Handling Chapter 1 | 9 (16)

The definitions are described in the Operator’s Manual.

For detailed information refer to “Operator’s Manual / Chapter Introduction

10 (16) | Chapter 1 Copyright © Sandvik Mining and Construction Materials Handling

5 TERMINOLOGY AND ABBREVIATIONS

For detailed information refer to “Operator’s Manual / Chapter Introduction

Copyright © Sandvik Mining and Construction Materials Handling Chapter 1 | 11 (16)

Figure 1: Identification plate for PR200 - C1847 ....................................................................................................... 8

12 (16) | Chapter 1 Copyright © Sandvik Mining and Construction Materials Handling

Table 1: Document history.......................................................................................................................................... 4

Copyright © Sandvik Mining and Construction Materials Handling Chapter 1 | 13 (16)

Copyright © Sandvik Mining and Construction Materials Handling Chapter 1 | 15(16)

2. Environment, Health and Safety

Copyright © Sandvik Mining and Construction Materials Handling Chapter 2 | 1 (46)

2 (46) | Chapter 2 Copyright © Sandvik Mining and Construction Materials Handling

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

2 SAFETY LABELS, MESSAGES, SIGNALS .................................................................................................................. 6

3 GUIDELINES AND USER OBLIGATIONS................................................................................................................... 15

4 M ACHINE SAFETY ............................................................................................................................................... 21

5 SAFEGUARDING AND COMPLEMENTARY PROTECTIVE MEASURES........................................................................... 24

6 EMERGENCY EXIT ............................................................................................................................................... 26

7 LOCKING AND ENERGY DISSIPATION .................................................................................................................... 27

8 FIRE RISK CONTROL MEASURES........................................................................................................................... 30