Professional Documents
Culture Documents
TABLE OF CONTENTS
Table of Contents ............................................................................................................................................. 3
Preamble............................................................................................................................................................ 9
Copyright © ......................................................................................................................................................... 9
Definitions ........................................................................................................................................................... 9
Intellectual Property .......................................................................................................................................... 10
Further Information ........................................................................................................................................... 10
Revision Status ................................................................................................................................................. 11
Access to Electronic Manuals .......................................................................................................................... 11
Translations ...................................................................................................................................................... 11
1. Safety................................................................................................................................................ 13
1.1 Operational Limitations ..................................................................................................................... 13
1.2 Training ............................................................................................................................................. 13
1.3 Compliance Requirements ................................................................................................................ 14
1.4 Disclaimer ......................................................................................................................................... 14
1.5 Warnings, Cautions and Notes ......................................................................................................... 15
1.5.1 Warnings ........................................................................................................................................... 15
1.5.2 Cautions ............................................................................................................................................ 16
1.5.3 Notes ................................................................................................................................................. 16
1.6 Personal Protective Equipment ......................................................................................................... 16
1.7 Falling Object Protection ................................................................................................................... 17
2. Specifications .................................................................................................................................. 19
2.1 Identification ...................................................................................................................................... 19
2.2 Machine Vendor Data Drawings ....................................................................................................... 19
2.3 Machine Details ................................................................................................................................. 20
2.4 Options Supplied ............................................................................................................................... 21
2.5 Sound Levels Assessment ................................................................................................................ 22
3. Description ...................................................................................................................................... 25
3.1 Machine Safety Features .................................................................................................................. 26
3.1.1 Emergency Stops .............................................................................................................................. 26
3.1.2 Operator's Seat Belt .......................................................................................................................... 26
3.1.3 Brakes ............................................................................................................................................... 26
3.1.4 Tiedown Equipment .......................................................................................................................... 26
3.1.5 Imminent Motion Warning ................................................................................................................. 26
3.1.6 Boom Overload Sensors ................................................................................................................... 26
3.1.7 Console on turntable Enabler Button ................................................................................................ 27
3.1.8 Base Enable Button .......................................................................................................................... 27
3.1.9 Baseframe Console Lockout Plate .................................................................................................... 27
3.1.10 Visual and Audible Alarm .................................................................................................................. 27
3.1.11 Hydraulic Oil - Over Pressure Protection .......................................................................................... 27
3.1.12 Hydraulic Oil - Low Level Protection ................................................................................................. 27
3.1.13 Hydraulic Oil - High Temperature Protection .................................................................................... 27
3.1.14 Counterbalance Valves ..................................................................................................................... 28
3.1.15 Hydraulic Hose Coverings................................................................................................................. 28
Preamble
Copyright ©
The contents of this manual are the copyright of Russell Mineral Equipment Pty Ltd, and may not be
reproduced, adapted, communicated or stored, in whole or in part by any means without written permission
from Russell Mineral Equipment Pty Ltd
Except as otherwise agreed in the Contract Terms and Conditions, while every care has been taken to
ensure the accuracy of information contained in this manual, no liability (however caused, including the
negligence of Russell Mineral Equipment Pty Ltd) will be accepted for any errors or omissions. Due to
ongoing product development, Russell Mineral Equipment Pty Ltd reserves the right to change without
notice, any product details including specification, appearance and performance.
Excerpts from publications by component manufacturers are reproduced in this manual with the consent of
those suppliers. Graphical illustrations used in this manual may be representative of the general type of
machine rather than this specific machine. Refer to the engineering drawings in Chapter 7 and Chapter 8
for authoritative data relevant to this machine.
Notwithstanding anything in this document, nothing in this document imposes any obligations on Russell
Mineral Equipment Pty Ltd except as expressly contemplated by the Contract Terms and Conditions, if any.
Definitions
In this document:
Russell Mineral Equipment and RME means Russell Mineral Equipment Pty Ltd ACN 010 708 406.
RUSSELL 7 Mill Relining Machine; RUSSELL 7; and Mill Relining Machine means the mill relining machine
serial number 12R4751-MRM384 supplied by Russell Mineral Equipment to Southern Peru Copper
Corporation for the Toquepala mine site.
Contract Terms and Conditions means Russell Mineral Equipment’s standard terms and conditions, except
where otherwise agreed.
Russell Mineral Equipment owns all intellectual property (including copyright and patents) in the RUSSELL 7
Mill Relining Machine and any materials or documents supplied with the RUSSELL 7 Mill Relining Machine
including this manual. Nothing in this document grants users of the RUSSELL 7 Mill Relining Machine any
intellectual property rights (including copyright and patent rights) of Russell Mineral Equipment. The
RUSSELL 7 Mill Relining Machine must only be used in the manner agreed with Russell Mineral Equipment.
Further Information
RME’s ASSET SUPPORT PLATFORM offers global support for RME’s customers and their items of RME
Mill Relining System equipment. Please contact support@rmeGlobal.com http://www.rmeGlobal.com.
Revision Status
The printed version of this manual was issued on Monday, 15 May 2017. It is not controlled, updated or
revised by Russell Mineral Equipment Pty Ltd.
The USB business card version of the manual is a copy of the printed version and is also not controlled,
updated or revised.
Controlled and revised manuals for this RUSSELL 7 Mill Relining Machine may be accessed by using the
Russell Mineral Equipment website.
This manual is provided in Portable Document Format (.pdf) which may be downloaded and printed or used
electronically.
Access to electronic manuals is gained via the Client Login Portal of the Russell Mineral Equipment Pty Ltd
website: http://www.rmeGlobal.com. An account for each individual accessing the manuals for each mine
site is required.
If you do not have a Client Account, click on the "Request Account" button in the Client Login Portal, and
complete the details on the form. Your request will be verified by Russell Mineral Equipment Pty Ltd and full
access to your manuals will be provided as soon as possible.
If you do have a Client Account with the Client Login Portal your manuals will be available as per contractual
agreements as agreed in writing with Russell Mineral Equipment Pty Ltd
Translations
Whilst Russell Mineral Equipment Pty Ltd has exercised its best efforts to provide an accurate translation of
the text of the document, Russell Mineral Equipment Pty Ltd does not warrant the accuracy or reliability of
the information translated and will not be liable for any losses caused by reliance on such translated
information. If any questions or issues arise out of the accuracy of the translated information in the non-
English translated document, please refer to the English version of the document, which is the document that
officially applies to the contract.
1. Safety
Mill relining operations are dangerous, this safety summary supplies information and warnings to personnel
with regard to some of the hazards and risks of using RUSSELL 7 Mill Relining Machine during reline
operations.
All personnel must be trained and understand the use of RUSSELL 7 Mill Relining Machine before use.
Information about the safety features of the RUSSELL 7 Mill Relining Machine are specified in this manual.
This RUSSELL 7 Mill Relining Machine is to be used solely for the purpose of BALL Mill Liner
Placement.
This RUSSELL 7 Mill Relining Machine is a powerful hydraulic manipulator with seven axes of mill relining
motion and another two functions for machine transport. It must be connected to a 480 V 60 Hz 3 phase
site electric power supply and must never be allowed to pull tight, or drive over, its electrical trailing lead.
It has a three-section boom that may be raised or lowered, extended or retracted and slewed in a 360°
continuous motion to the right or left. The boom has attached at its outer end a grapple and grapple tool,
which interfaces with new liners. The grapple allows precise placement in relation to the shell of the mill, so
that liner attachment bolts can be fitted and tightened. The grapple tool also has a conventional hook for
slinging of new or worn liners.
This RUSSELL 7 Mill Relining Machine may only be used in a mill matching the provided specifications. Its
baseframe height and range of motions are only suitable for entry into this type of BALL mill.
Under no circumstances is the machine or its components to be used for the dislodgement of worn liners, or
for forcing new liners into position. The RUSSELL 7 Mill Relining Machine is not to be used as a towing or
carrying vehicle. Any or all of these actions may damage the machine and will void any warranty.
1.2 Training
RUSSELL 7 Mill Relining Machine must only be operated by trained personnel. Russell Mineral Equipment
supplies familiarisation training on site, during commissioning of the equipment.
Russell Mineral Equipment supplies personnel training in the use of RUSSELL 7 Mill Relining Machine.
Personnel are approved or certified to operate RUSSELL 7 Mill Relining Machine safely and efficiently when
training is completed successfully. Contact RME for information.
It is a Russell Mineral Equipment requirement that the site owner carry out its own risk assessment for all
mill relining operations.
It is a Russell Mineral Equipment requirement that the site owner carry out its own risk assessment for all
maintenance requirements on Russell Mineral Equipment machinery or equipment.
Strict compliance with this manual, all local and national laws, regulations and practices regarding the safe
operation and maintenance of this machine is necessary to assure the personal safety of those working on,
or around, this machine. Failure to operate the RUSSELL 7 Mill Relining Machine in accordance with this
manual could result in severe injury or death.
1.4 Disclaimer
Russell Mineral Equipment, throughout this manual, gives warnings, cautions, notes and instructions
concerning the use of the RUSSELL 7 Mill Relining Machine and safety precautions that are designed to
enable operators to obtain optimum service from the machine in safety.
Russell Mineral Equipment provides familiarisation training modules for operation and use of the RUSSELL 7
Mill Relining Machine and with respect to safety issues.
Strict compliance with this manual, all local and national laws, regulations, mandatory industry codes,
applicable Australian standards as published by Standards Australia Limited from time to time and practices
regarding the safe operation and maintenance of this machine is necessary to assure the personal safety of
those working on, or around, this machine. Failure to operate the RUSSELL 7 Mill Relining Machine in
accordance with this manual could result in severe injury or death.
Unless otherwise agreed in the Contract Terms and Conditions, Russell Mineral Equipment for itself, its
directors, officers, employees and agents expressly disclaims any liability whatsoever, whether it be for
personal injury, death, property damage, economic loss or any other loss by any person or entity related to
use and operation of the RUSSELL 7 Mill Relining Machine (however caused, including by the negligence of
Russell Mineral Equipment).
WARNINGS, CAUTIONS and NOTES are given throughout this manual in the following form:
WARNING. These procedures must be followed to avoid the possibility of injury to personnel.
CAUTION. These procedures should be followed to avoid damage to the machine components.
NOTE. These notes call attention to procedures which make a task easier or more efficient.
Where Warnings, Cautions or Notes occur immediately adjacent to each other, their borders may be merged.
1.5.1 WARNINGS
When using any machine functions, the RUSSELL 7 Mill Relining Machine operator must be alert and
constantly vigilant as to the whereabouts of other personnel in the mill. Ensure that they are not in such a
location as to be in danger of injury from movements within the machine itself or from crushing between the
machine and the mill shell.
Assistant personnel in the mill during relining operations must be alert and constantly vigilant as to the
movements of the RUSSELL 7 Mill Relining Machine. Ensure that you do not place yourself in a position
where you can be injured by machine movements or by being caught between the machine and the mill
shell.
Crush Hazard. Incorrect lug spacing may cause a liner to fall from the grapple tool.
Only the correctly manufactured and tested grapple tool and liners are to be used. If any changes are
made to the specifications of the mill liners, contact Russell Mineral Equipment to assess the liner and
grapple tool engagement integrity.
Be careful when you do work with pressurized hydraulic fluid. It can cause injury. Release the pressure in
the system before you remove hoses or other hydraulic components. Do not use a hand or any other body
part to check for leaks in a pressurized line. Get medical aid immediately if hydraulic fluid causes an injury.
The swivel hook must hang freely and not contact the grapple or any other part of the machine when in use.
All Service requirements and Non-Destructive Examination inspections are listed in the Service Section of
this manual. These inspections must be carried out to ensure the structural integrity of machine
components is maintained for the safety of personnel. If the RUSSELL 7 Mill Relining Machine does not
have a current NDE inspection certificate, it must not be used.
1.5.2 CAUTIONS
It is a Russell Mineral Equipment requirement that the site owner only uses the machine for lifting and
placement of liners during mill relining operations.
1.5.3 NOTES
Move function and control levers slowly and progressively. Vigorous movements of the levers will result in
jerky movements. Gradual easing of the controls will ensure smooth accelerating motion.
Personnel must wear protective equipment while using the equipment. Minimum PPE;
3. Hard hat.
5. Gloves.
During the mill relining process, it is necessary for a RUSSELL 7 Mill Relining Machine operator and other
crew to be inside the confined space of the mill. If basic safety precautions are not established and followed
diligently, this can be a dangerous process.
The following warnings about risks/hazards, associated consequences and safeguarding precautions are
compiled from Russell Mineral Equipment’s risk assessment of dangers from falling objects inside the mill.
Although these warnings alert personnel to possible hazards, specific site conditions and staff procedures
will also need to be addressed by local site management.
The risk from falling objects is greatest during and after incremental rotation (inching) of the mill to expose
further portions of the shell for the removal and replacement of mill liners.
All workers must leave the mill during incremental rotation (inching).
Grinding balls, rocks or other debris can become stuck on the mill wall or into compacted slurry and
between liners, and can be raised above the mill relining crew when the mill is incrementally rotated.
If nuts are removed from liner attachment bolts and a liner does not release from the mill shell, then this
liner could move slightly when the mill is incrementally rotated causing grinding balls, rocks or other debris
to fall and the liner itself could also fall.
Cracked or fractured liners can be raised above the relining crew during incremental rotation. Part of the
liner could move, release debris, or fall. New liners may have as yet undetected cracks.
Precaution: The owner shall ensure that thorough cleaning and inspection of the overhead portion of the mill
is done after each incremental rotation, and before the relining crew enters the mill.
Precaution: The owner shall conduct an internal and external inspection of the mill to ensure loose liners
have fallen from the mill shell. This will be carried out each time any liner bolts are removed from the mill
and prior to any crew entering the mill.
Precaution: The owner shall conduct an inspection of the mill liners prior to the relining crew entering the
mill and after each incremental rotation.
2. Specifications
This section refers to Vendor Data Drawings (Page 265) and the Electrical and Hydraulic Schematic
Drawings (Page 269) for the machine specifications.
2.1 Identification
Information Identifier
Model MRM RT 4 x 2
Dimensions of the Machine TQAMRM384-VDD-01 (Page 293) and TQAMRM384-VDD-03 (Page 295)
Machine Operating Reaction Loads TQAMRM384-VDD-03 (Page 295) and TQAMRM384-VDD-04 (Page 296)
12R5098 Joysticks
12R4754 Tiedowns
NOTE. The hydraulic mount cabinet has the option to have the joysticks electrical components installed to
allow the operator to have dual seating.
Sound levels that the machine produced were measured in the workshop after the machine was completed.
The sound values that are produced at the site may be different. Environmental conditions that may have
an effect on sound values include:
Method of Measuring
Sound values were measured in the sequence shown in the table while the equipment was operating
correctly. All values were measured at a distance of one metre from the machine.
Model 322
Sampling indicates that sound levels generated by the RUSSELL 7 Mill Relining Machine vary but excludes
levels which may cause damage to the hearing of the majority of the population. While the sample results
show there is no requirement for any workplace noise controls to be set in place, the test environment does
not accurately reflect the normal work environment.
Personnel must wear hearing protection and use any other measures deemed necessary by the site
whilst the machine is carrying out its normal operations.
3. Description
This section tells you about the primary parts of the RUSSELL 7 Mill Relining Machine. You must
understand this information before you go to the next section, which gives the instructions to operate the
machine.
Emergency Stops, referred to as E-Stops throughout this manual, are placed near all control positions and
close to where personnel are working.
When an E-Stop is engaged, it shuts down the machine's power pack, and stops all machine motion. Any
time you see an emergency or dangerous situation, engage an E-Stop. Refer to Emergency Stops (Page
69).
A seat belt is provided for the safety of the operator and should be used whenever the operator is seated at
the Operator's Console (Page 41).
3.1.3 BRAKES
Brakes are incorporated in the gearboxes of all the drive wheel motors and the turntable slew motor. These
brakes are applied automatically when hydraulic power is not supplied to the drive motors. Never tow the
machine as it will damage the gearbox/brake assemblies.
Tiedown Equipment is used to stop the machine from overbalancing or moving while it is in operation or
being tested. These are critical components. Any damage to these components renders them
unserviceable. Refer also to Tiedown Equipment.
On either side of the grapple are amber lights that indicate the imminent movement of the boom or grapple.
These imminent motion lights are connected to the Operator's Hydraulic Controls (Page 101) and will
illuminate at any time a control lever is operated.
Boom position sensors (proximity switches) are used to prevent the machine from lifting more than its rated
load when the boom is retracted. This ensures the operator cannot inadvertently overload the equipment
and helps prevent equipment failure.
The primary function of the Console on Turntable (COT)-enabler is to stop the machine from sudden
movement at standstill. The hydraulic controls above the rotary union at the Operator's Controls (Page 101)
are disengaged unless the COT-enabler-button is pressed. When the operator's hydraulic-control-cover is
lifted the COT-enabler-button is pressed to start the machines operations. The lever cover proxy senses if
the hydraulic-control-cover is closed, and this will let the turntable pendant COT-enabler be available. Refer
also to Ancillary Panel (Page 105).
The baseframe drive function is not disabled until the base enable button is pressed once. This safety
function is used to prevent inadvertent movement of the Mill Relining Machine during the start-up process.
Each time the powerpack is started, the base enable button will need to be pressed once before the machine
can be moved.
The hydraulic valve set at the Baseframe Console (Page 79) is fitted with a lockout plate that enables
selected controls while locking the remaining controls. For example, the outer beam and all machine drive
controls are locked out when the Mill Relining Machine is set up in front of the mill and the linercart is being
used.
The Mill Relining Machine is fitted with a visual and audible alarm on the platform that activates at any time a
Baseframe Console (Page 79) function is operated. This includes basedrive, jacks and outer beam
functions. It also sounds when the linercart is being operated.
The primary pump is pressure compensated to a set maximum value and is also set for a maximum flow.
The cooling system pump is a gear pump and the oil cooler radiator has a bypass valve fitted. All control
valve banks have integral pressure relief valves. Counter balance and shock relief valves are set to
pressures rated to the appropriate load ratings. Critical settings are tamper resistant.
A sensor inside the tank detects low hydraulic oil level and shuts down the machine power pack, stopping all
machine motion. The machine cannot be restarted until oil is added to the tank.
A sensor inside the tank detects high hydraulic oil temperature and shuts down the machine power pack,
stopping all machine motion. The machine cannot be restarted until the temperature of the oil in the tank
has lowered.
Where required, hydraulic cylinders, actuators and motors on the machine are fitted with counterbalance
valves. If hydraulic power fails or is shutdown, these valves lock the machine in its last set position. This is
also the case if a hydraulic line bursts. All hydraulic movement would cease in that particular circuit
because the counterbalance valves are located as close as possible to the hydraulic actuator or cylinder.
Where hydraulic hoses are under pressure they are run in an enclosed area or they are sheathed in a
durable Cordura sleeve to protect personnel from hydraulic fluid if a hose bursts.
All hydraulic control levers are spring loaded to the neutral position. Releasing a lever will return the control
to a neutral position and stop the movement associated with that lever.
The RUSSELL 7 Mill Relining Machine connects to two independent sources of supply. A 480 V 60 Hz 3
phase main motor supply and a 120 V 60HZ supply for the motor heater.
The main electrical isolator on the machine is lockable. This isolator should be locked at any time
maintenance is carried out or when the machine is placed out-of-service. The main electrical cabinet cannot
be opened until the main isolator is turned to the OFF position. The machine cannot be started while the
main control cabinet door is not in the closed position.
A separate, lockable, 120 V supply isolator is fitted to the motor heater. During periods of storage this
supply would normally be connected, isolator in ON position, to ensure the motor remains warm and dry.
Protective metal and rubber covers are placed on sliding parts that present pinch or crush hazards. Other
locations that present pinch or crush hazards are addressed by distinctive safety labels, training and safe
working practices. Any protective covers that are removed for maintenance or any other purpose must be
replaced prior to any operation of the machine.
3.1.19 LIGHTING
Seven 18 W Light Emitting Diode (LED) 24 V work lights are provided. Six may be plugged in and used
together, while the remaining one is a spare unit. They are impact resistant, swivel mounted on magnetic
bases for illumination of the work area and operator's controls as required. If the machine is shut down with
an E-Stop then all these work lights will remain on.
In the event of a power failure the machine will shut down, all hydraulic motion will stop and remain set in its
final set position by the action of the counterbalance valves. Work lights will also turn off so crew inside the
mill should have an independent source of lighting available.
The machine does not restart automatically when power is restored. It can only be started in the normal
manner at the main control cabinet. Lights will automatically come on again if the main switch has been left
in the ON position.
The liner release function at the Operator's Controls (Page 101) is disabled unless the liner release enable
button is also operated at the same time as the lever. This helps prevent a liner being released
inadvertantly. Refer also to Ancillary Panel (Page 105).
The Liner Release Interlock Fault Indicator helps prevent the inadvertent release of a liner from the grapple
tool. Refer to Liner Release Interlock Fault Indicator (Page 129).
The grapple tool pins are prevented from releasing a liner by a safety bar which is fitted to the top of the
grapple tool. There is a lynch pin at each end of this safety bar and one of these is removed to allow the
tool pins to move apart. Both lynch pins must be secured in place each time a liner is picked up.
The top edge of the radio remote pendant is raised, to protect the levers from inadvertent operation.
Deadman switches are fitted, and unless one of these deadman switches is depressed while a control is
operated then that control remains disabled.
The radio remote control pendant is also fitted with its own E-Stop.
Each of the joystick controls has a deadman trigger fitted. Unless the operator is squeezing the deadman
trigger continuously while using the joystick, the control remains disabled.
The joystick control unit is also fitted with its own E-Stop and liner release enable button on the right hand
arm of the assembly.
Refer to Figure: Main Parts of the RUSSELL 7 Mill Relining Machine (Page 30).
Figure 4: Baseframe
1. Baseframe structure.
5. Lifting lugs.
7. Baseframe cableveyor.
10. Tiedowns.
3. Tiedown jack.
4. Extension arm.
5. Pinning hole.
2. Tiedown rod.
4. Tiedown shaft.
1. Rubber-tyred wheels.
2. Drive gearbox.
4. Hub axle.
1. Rubber-tyred wheels.
3. Stub axle.
4. King pin.
9. Rear axle
2. Linercart rails.
6. Beam rocker.
3. Cylinder clamps.
4. Cylinder pin.
6. Cableveyor.
7. Cableveyor tray.
9. Emergency lights.
2. Holding pin.
3. Electrical outlets.
1. Turntable body.
3. Pinion gear.
4. Slew ring.
2. Operator’s seat.
10. Platform leg housing. Two are used to support the operator’s platform.
11. Fixed blocks to engage with the lugs on the operator’s platform support legs and lock
the platform in place.
1. Inner boom.
2. Intermediate boom.
3. Outer boom.
4. Teardrop pins.
4. Grapple head.
6. Hydraulic fittings.
2. Load ring.
3. Lifting hook.
8. Protective plate.
2. Cabinet latches.
6. Cabinet drains.
9. JBox 2 seals.
1. Adjustable mirror.
4. Cabinet cover.
5. Gas strut.
1. Linercart trolley.
2. Linercart turntable.
4. Linercart wheels.
7. Anti-lift brackets.
4. Hydraulic manifold.
1. Breather/filter.
3. Sample point.
3. Motor pump.
5. Hydraulic manifold.
6. Powerpack covers
7. Baseframe Controls
2. Bell housing.
5. Vibration-isolating mounts.
7. Heat exchanger.
1. Hydraulic manifold.
1. Platform.
3. Safety gates.
2. Female Decontactor.
3. Rubber Flap.
1. Spool assembly
2. Electrical cable
4. Male decontactor
5. Fasteners
The lifting kit provides the equipment necessary to safely lift the Mill Relining Machine using either one or two
cranes. Refer also to Lifting the Machine (Page 62).
1. Spreader Bar.
2. Chain.
3. Shackle.
4. Operations
Within this section are operational procedures which must be followed each time the machine is used.
Procedures are presented in sequence from machine preparation to returning to storage. Operators should
be trained in and familiar with all procedures before using the machine. Each procedure will refer to a
paragraph with a more substantial explanation of the operation and safety procedures applying to that
particular operation.
If you are unsure of any safety issues, or the operational requirements relating to the procedure you should
read all other paragraphs referred to, so that you may gain a better understanding.
Mill Relining Operations are hazardous. It is imperative that all crew members become familiar with and
understand the requirements listed in this section.
All machine operators must be trained (Page 13). All relining crew members should understand and adhere
to the following safety measures:
3. Know the location and use of all Emergency Stops (Page 26).
4. Understand the risks from falling objects and Falling Object Protection. (Page 17)
6. Know the site power and Machine Isolation (Page 140) procedures.
7. Know how to Prepare the Site and Mill (Page 76) for relining.
At times the machine may need to be lifted, whether to relocate it, for example, during commissioning, or for
other reasons, for example, servicing. The following instructions must be followed whenever the machine is
lifted.
The machine must first be set up in the Transport Configuration (Page 77). The power cable is then
retracted on the cable reeler. A spreader bar must be placed across the machine as shown below.
The total machine mass is approximately 28500 kg. Ensure the lifting equipment used is appropriate for this
load. Refer to Figure: Lifting Requirements (Page 62).
2. Make sure the power cable is wound up and secured on the cable reeler.
7. Distance from front jack centreline to Centre of Gravity is approximately 2185 mm.
One crane may be attached to the two rear lifting lugs and the second crane attached to the two front lifting
lugs. All other requirements for lifting the machine are as given above for the single crane case.
The following checklist of operational procedures should be used each time the RUSSELL 7 Mill
Relining Machine is used:
4. Turn the machine isolator ‘ON’ at the Main Control Cabinet (Page 66).
8. Make sure the machine is in the Transport Configuration (Page 77) before it is relocated.
9. Use the Remote Transport Control (Page 81) to Manoeuvre the Machine (Page 87) to the front of
the mill.
10. Set up the machine in the Mill Entry Configuration (Page 89).
12. Initial Machine Entry (Page 91): align the machine with the front and rear tiedown points.
13. Tie Down the Machine (Page 92) to the mill floor.
14. Insert the Outer Beam (Page 93) into the mill.
16. Complete the Mill Relining Operations (Page 100) for the accessible liners.
17. Incremental Rotation of the Mill (Page 134) - Normal Charge Level or High Residual Charge
Level.
19. Manoeuvre the Machine (Page 87) to the storage or maintenance location.
20. Complete the Inspections After Use (Page 138) for the machine.
A pre-use check of the RUSSELL 7 should be carried out prior to the mill shutdown to ensure the machine is
in a serviceable condition for the reline process.
The purpose of this inspection is to identify any deterioration, wear or damage which may have occurred
during the storage period. When this inspection is complete the inspection forms will be given to the
maintenance controller to rectify any faults or problems.
These inspection forms should be kept as a record of the machine's maintenance history.
Pre-use Inspection and Lubrication – Refer to Detailed Inspection Requirements (Page 175) and Detailed
Lubrication Schedule (Page 154).
Before connecting the power supply, be sure you know the functions of the controls and indicators on the
main control cabinet.
Arc flash and shock hazard. At all times when operating the Main Electrical Isolator appropriate personal
protective equipment (PPE) is required.
1. Main electrical isolator. To isolate the machine: turn the main isolator to the OFF (O)
position and disconnect the site power supply.
The cabinet door cannot be opened until this isolator is in the OFF position. There
are also four other keyed door locks which must be released in order to open the
door.
2. Electric motor run indicator lights to show that the main electric motor is running.
4. Hour meter indicates the total machine operating hours since new.
8. Hydraulic oil low level indicator. This fault will also shut the machine down and it
cannot be started until more oil is added to the tank. Ensure all cylinders are
retracted before adding oil.
9. Hydraulic oil over-temperature indicator. This indicates that the oil temperature is
above 80°C. This will shut down the machine and it cannot be restarted until the oil
has cooled to below 65°C.
10. Overload tripped indicator. When illuminated, either the main electric motor or the
cooling fan motor is in a state of thermal overload. This fault will shut the machine
down and it cannot be started until the motor has cooled. An electrician may have to
reset the circuit breakers for the main electric motor or the cooling fan motor.
11. E-Stop engaged indicator. When illuminated, an E-Stop is engaged on this machine.
It cannot be started until all E-Stops are disengaged.
If the fault is not indicated on the front of the main electrical cabinet, an electrician should be called to
establish the nature of the fault and rectify or repair the problem. Refer to Troubleshooting Guide (Page
251).
Indicator lights on the door on the electrical cabinet are ‘Press to Test’ type, and will illuminate if pressed, to
check that the lights themselves are functioning.
The machine has two supply cables for connection to the site supply. If the machine is in storage then it will
already have the separate motor heater cable connected and the motor heater switched ‘ON’. This heater
must be switched ‘OFF’ before the motor is started.
Procedure for changing from the storage maintenance supply to the three phase main supply:
Arc flash and shock hazard. At all times when operating the Main Electrical Isolator appropriate personal
protective equipment (PPE) is required.
1. Turn the 120 V 60 Hz motor heater isolator to the OFF position and make sure the 120 V supply cable is
unplugged, rolled up and stored safely on the machine using the bracket provided.
Make sure the 120V Maintenance Supply is unplugged when the machine is operating on 480 V 60 Hz 3
phase power.
This is to avoid any possible problems which might occur due to two earth wires being connected and if an
electrical fault should also occur with the main motor.
2. Fully unwind the main electrical supply cable and plug it into the site supply outlet.
The machine power supply cable must be fully unwound prior to connection to the site power
supply socket.
Prior to connecting the site power supply to the machine, make sure the main electrical isolator is
turned to the ‘OFF’ position.
3. Switch ON the main three phase site supply switch at the site outlet and check that the control healthy
indicator lamp is OFF. Refer to Main Control Cabinet (Page 66).
4. Close the main electrical isolator on the door of the Main Control Cabinet (Page 66) - rotate to 'I'
position.
5. Make sure the Control Healthy indicator light is now ON, and the magnetic base work lights are also ON
(if plugged in).
If the control healthy indicator did not illuminate after closing the main isolator, then check all
indicators on the main control cabinet to identify the problem or refer to Troubleshooting Guide (Page
251).
6. Either turn the main isolator OFF ('O' position) or continue with Testing Emergency Stops (Page 70).
Emergency Stops, referred to as E-Stops throughout this manual, are placed near all control positions and
close to where personnel are working.
When an E-Stop is engaged, it shuts down the machine's power pack, and stops all machine motion. Any
time you see an emergency or dangerous situation, engage an E-Stop.
All E-Stops must be disengaged before the machine can be started. When the E-Stops are all disengaged,
the machine will not restart by itself. Start the Machine (Page 73) again in the normal manner.
Press the E-Stop until it locks in the active (in) position. The E-Stop activated indicator on the door of the
main cabinet will be on; the control healthy indicator will be off and the machine will not start.
Rotate the E-Stop clockwise, in the direction of the arrows, until it pops out by its own mechanism. Never
forcibly pull out an E-Stop.
The Control Healthy indicator is ON and the E-Stop Engaged indicator is OFF. Refer to Controls on the
Main Control Cabinet (Page 66)
This is the starting condition for the testing of E-Stops. A different condition may be due to an already
engaged E-Stop; refer below.
The E-Stop circuit of the RUSSELL 7 Mill Relining Machine may be tested without the need to start the
machine’s electric motor.
2. Check that the E-Stop engaged indicator on the Main Control Cabinet (Page 66) is ON and that the
control healthy indicator is OFF for this E-Stop;
4. Check that the E-Stop engaged indicator is now OFF and that the Control Healthy indicator is now ON.
E-Stops are essential safety equipment for avoiding harm to crew members. If any E-Stop fails any of the
steps above, the machine must be tagged ‘Out of Service’ until the fault is rectified.
A pendant or its loop back plug must be connected for the E-Stop circuit to be disengaged. An open
connection socket will be detected by the machine as an engaged E-Stop and the machine will not start.
This is a safety feature to ensure that the E-Stop on the pendant will function correctly. A loop back plug is
provided and tethered adjacent to each pendant connection socket.
If the machine is required for immediate operations or manoeuvring, it may now be started in the normal
manner, refer to Starting the Machine (Page 73).
OR
If it is not planned to continue operating the machine at this time, turn the machine’s main electrical isolator
to the ‘OFF’ position.
Arc flash and shock hazard. At all times when operating the Main Electrical Isolator appropriate personal
protective equipment (PPE) is required.
4. Press the motor start button. If the motor does not start, refer to the Troubleshooting Guide (Page 251).
5. Check the blocked filter indicator on the Hydraulic Pressure Filter (Page 55).
This filter indicator is checked each time the motor is started. It should normally show a green
indication.
If the hydraulic fluid is cold, then at start up, a false red indication could be shown. Only in this case (if the
hydraulic fluid is cold), the indicator may be reset (by pressing it) and checked again a short time later.
If this indicator shows red then machine must be shut down immediately, the filter changed and the
maintenance controller notified. The old filter element should be checked for contaminants.
This indicator will remain set, showing the red status, even when the machine is shut down. It may be
reset, by pressing it, after a new filter element is installed.
6. Check the system pressure. Correct pressures can be found on the Hydraulic Schematic Drawings
(Page 270).
7. Check the return filter pressure gauge on the Hydraulic Tank (Page 51) return filter.
This gauge is checked each time the motor is started. It should normally show a low pressure value
within the green range at all times. The higher the flow (more machine functions used) the higher
the reading.
If this gauge shows in the red range with no machine function being used, then the machine must be shut
down immediately, the filter changed and the maintenance controller notified. The old filter element should
be checked for contaminants.
This gauge does not retain the highest value and will revert to a zero indication when there is no hydraulic
fluid flow (motor is stopped).
If the oil level is low then this may first be noticed by the machine stopping for no apparent
reason.
When a cylinder (e.g. for the beam or boom) is fully extended then the oil level in the reservoir is
lowered and at the detection limit slight waves in the oil surface may be sufficient to shut down
the machine. Then, when the motor is stopped and the oil surface is calm, the low oil level may
not be detected. If these events are occurring then the low oil indicator on the main control
cabinet will flash briefly.
1. Press the Motor Stop button on the door of the main electrical cabinet to switch the hydraulic pumps off.
All machine motion will then cease.
2. Open the isolating switch on the door of the main electrical cabinet (rotate to ‘O’ position) when finished
with the machine for an extended time. Do not open this isolating switch if the machine and personnel
are still in the mill as the work lights will also be turned off. All personnel must evacuate the mill first.
Ensure all personnel have evacuated the mill before switching the machine off.
3. When the machine will not be restarted for an extended time, e.g. when it is going to be lifted or has
been stopped at its storage location after a mill reline is complete, the power cable must be
disconnected from the site supply, wound up and stored on the cable storage bracket mounted on the
rear of the left hand platform.
When the machine is stopped at any storage location, the separate motor heater supply cable must
also be connected to a suitable supply and the heaters turned on.
RME suggests that occasionally, an Emergency Stop button is used for routine stopping of the machine. By
selecting the switches in rotation, each will be given an in-service test in addition to the formal test procedure
outlined in Testing Emergency Stops (Page 70).
At this step the Mill Relining Machine has had a pre-use inspection and lubrication, Emergency Stop buttons
tested and has been test run. The machine can operate.
While the Mill Relining Machine is prepared, it is necessary for the mill and site to be in a condition for a
reline. Make sure that the site procedures are followed to prepare the mill. Do the site mill procedures and
the procedures that follows:
1. Inspect the RUSSELL 7 floor mounted tie down fittings for any damage. This includes the concrete
around the fittings.
Make sure that you do the pre-use inspection of the tiedown components and the concrete around them. If
either have damage then the machine can have uncontrolled movement.
2. Before you move the machine, make sure that the area at the front and around it is clear.
Before you move the machine, make sure that the area at the front of the machine is clear. This will help
to prevent damage to the machine wheels or rubber tyres.
3. Decrease the mill-charge to a safe quantity for the Mill Relining Machine to enter the mill and operate
successfully.
5. Disconnect the mill-feed-chute. Push the mill-feed-chute away from the Mill Relining Machine.
6. Remove the liner-bolts from the liners in the mill shell. The liners can fall on the mill-charge.
Do not enter the mill before a risk assessment is completed. Do a risk assessment before relining and after
inching. Grinding balls, rocks or other unwanted material can become bonded on the mill wall.
The Mill Relining Machine must be in its transport configuration prior to being moved, either under its own
power or by lifting. ‘Transport Configuration’ specifies the position of machine components as detailed in
this section.
The most important components to be positioned are the beams (inner and outer both retracted) and the
boom (retracted and facing the rear). Other components (e.g. tiedown fittings) are removed and stored
safely on the machine, e.g. on the platforms. If the machine is to be lifted, then these components must be
suitably secured.
The machine must be in its Transport Configuration while it is being stored, manoeuvred under its own
power or relocated by lifting.
3. Fully retract the outer beam and ensure it is pinned to the baseframe (by the outer beam cylinder pin at
the beam cylinder knuckle).
4. Set grapple roll and slew at midpoint and liner lift at full ‘UP’ position.
5. Fully retract the boom, face it rearward and rest the grapple on packing placed on top of the beam.
7. Lower the operator's hydraulic control levers and lower their cover over them, to protect them. Refer to
Raising and Lowering the Hydraulic Control Levers (Page 104). Secure the liner placement console
assembly close to (parallel with) the boom as specified in Operator's Console (Page 41).
8. Remove the operator’s seat, joystick controls assembly and platform and store them safely. (The seat
and joysticks assembly should be lifted off the platform and removed separately)
Hazard: Heavy objects. The combined operator’s seat and platform assembly weighs
approximately 48 kg. It is more easily lifted and installed when separated into two components.
Two persons are recommended for lifting for each component.
The outer beam must remain pinned to the baseframe at all times when the machine is in the transport
configuration. Being pinned means the outer beam is secured to the baseframe via the outer beam cylinder
pin.
If the outer beam is not pinned then it and everything attached to it (inner beam, turntable to grapple) is free
to move when the machine is manoeuvred or lifted. The only time this pin may be removed is when the
machine is tied down, e.g. is entering or exiting the mill. Refer to Insert the Outer Beam (Page 93).
Hazard: Sudden, unexpected movement. In the transport configuration, the outer beam must be pinned to
the baseframe, or the outer beam could slide on the baseframe without warning.
The Baseframe Console provides the operator with controls for all the baseframe functions and is mounted
on the Hydraulic Power Pack (Page 52). Controls are provided to enable the linercart pendant, extend and
retract the beam, operate the jacks and drive the machine.
The baseframe console has a lockout plate which enables selected controls while locking out those controls
not currently required. This lockout function is achieved by cut-outs in the plate for the hydraulic valve
levers. When the cut-out is aligned for a lever then that lever may move and allow that function.
The RUSSELL 7 Mill Relining Machine is fitted with a Remote Transport Control (Page 81) pendant for
added safety and ease of operation. The baseframe lockout plate position must be coordinated with the
pendant controls for successful machine operation. Also, the Hydraulic Power Pack (Page 52) cover must
remain in place for safety. This cover must be fitted to prevent conflicting operation of machine functions by
independent operators and to protect the lockout plate and levers from damage and debris which could
impair machine operation.
The baseframe lockout plate position must be coordinated with the remote transport pendant controls for
successful machine operation.
The basedrive lockout plate must be in the linercart position during liner placement operations.
The Hydraulic Power Pack (Page 52) cover must be fitted during all relining operations.
2. Drive Enable Button. The baseframe drive control lever function is disabled when the
power pack is first started. The drive enable button must be pressed once to enable the
baseframe drive function. If the hydraulic power pack is shut down, this button must be
pressed once after each motor start to enable the drive function to operate.
3. Lockout Plate Position Lever allows the control plate to be locked in any one of the three
positions for safety compliance at site:
Jacks and Drive With the plate in the left hand position, only four functions are available: jacks; drive
motors; front and rear wheel steering. These controls are used to manoeuvre and tie the
machine down in front of the mill, prior to relining operations.
Outer Beam In the centre lock position only the outer beam extend-retract function is available. This
position is used when the machine is tied down in front of the mill to extend or retract the
beam into or out of the mill.
Linercart With the plate in the right hand lock position, as shown in Figure: Baseframe Console
(Page 79), only the linercart function is available. This is a safety measure to prevent
inadvertent movement of the outer beam during the liner placement process.
The remote transport control pendant has been provided as a safety measure that allows the drive operator
to be positioned a short distance from the machine while it is in motion. The operator is then away from the
moving wheels and has better visibility around the machine. Alternatively, the drive operator may be on the
machine for best visibility and more precise manoeuvring.
The remote transport control pendant controls all functions on the base drive console except the linercart,
which has its own control pendant. When the remote transport control pendant is in use, the baseframe
console lockout plate must be manually set in the correct position. Refer to Baseframe Console (Page 79).
The operator of the remote transport control pendant must remain clear of the path of the wheels whenever
the machine is being moved.
If approved, via the outcome of site-specific risk analysis, the operator may manipulate the controls of the
remote transport control pendant while positioned on the machine itself. This may give the best visibility for
manoeuvring the machine.
In order to safely move the machine, travel speeds should be kept to a slow walking pace.
There should be a second person on the non control side of the machine to watch for any obstacles and
make sure the electrical cable is not in the machine path and is free to move.
All other personnel should be a minimum of three metres from the machine during motion.
The Relining mode and Beam mode functions cannot be operated at the same time. When the select switch
is moved between these two modes the machine will shutdown to prevent unexpected machine
movements.
The two position baseframe lockout plate must be manually set in the corresponding position for the mode
switch.
Whenever any remote transport control pendant function is used the corresponding baseframe hydraulic
control must be free to move. Refer to Baseframe Console (Page 79).
To operate the remote transport control pendant joysticks, the enable button on top of each joystick must be
held down throughout the required function.
1. Indicator light is illuminated when the E-stop is reset and the hydraulic pump is ready to
run. This light indicates that the pendant is active and ready for use. The drive enable
button may need to be pressed.
2. Mode Switch is a three-position switch for selecting the mode required to operate the
linercart, beam and the drive/jacks. These mode selects must match the lockout plate
position:
Relining mode (top position): the linercart functions operate. (Lockout plate
to right.).
Beam mode (centre position): the outer beam will retract or extend. (Lockout
plate to right.) The beam mode has two actions:
Action 1: On power-up the beam can be moved with the remote transport
pendant without having to press the beam-enable button. Refer to Ancillary
Panel (Page 105) and How to Operate the Outer Beam. The machine needs to
be switched on in either beam mode or drive/jack mode.
Action 2: When the remote transport pendant has been switched into relining
mode the beam-enable button must be pressed for the pendant to move the
beam. (Lockout plate to right.)
When the beam mode is required without the beam-enable button then follow
this procedure (beam mode, Action 1):
Press the stop button on the motor control cabinet (MCC) before changing
modes. Refer to Controls on the Main Control Cabinet (Page 66)
Choose either the beam mode or drive/jack mode on the remote transport
pendant.
To start the machine, press the Motor Start button on the door of the main
control cabinet.
Drive/Jack mode (bottom position): all drive and steering functions operate.
The jacks will operate. (Lockout plate to left.)
The remote transport control pendant E-Stop has an insert to indicate when it is engaged.
In the four windows on the top of the E-Stop, the green colour turns red. This E-Stop
engages and disengages in the same manner as all other E-Stops.
4. Joystick #1 has four functions available only when the mode switch is in the Drive mode
position:
The front steering does not centre when the control lever is released but remains in the
position where last set.
Drives the machine for manoeuvring up to or away from the mill. Control is proportional,
the further the lever is pushed the faster the machine will move. Movement will cease
when the lever is released.
5. Joystick #2 has two functions available only when the mode switch is in the Drive mode
position:
The rear steering does not centre when the control lever is released but remains in the
position where last set.
Beam Retract.
This control is used after the machine is tied down in front of the mill to extend or retract
the outer beam into or out of the mill. The outer beam must be fully extended to ensure
that the front beam clamps are engaged prior to relining operations, refer to Insert the
Outer Beam (Page 93).
During relining operations, this outer beam control may only be used when requested by
the operator inside the mill and this will be indicated by the beam enable beacon (Page
52). The beam enable beacon is activated from the Operator's Ancillary Panel (Page 105)
or Radio Remote Pendant (Page 111).
Jack control is available only when the mode switch is in the Jack mode position.
Pulling the lever of the front jack control to the jack down position raises the machine in
order to pin or tie down the machine in front of the mill, or place packing under the
machine support plates while it is in its storage location.
If the remote transport pendant and/or pendant cable is damaged, then this fault may show as an activated
E-Stop. This will stop the machine and prevent it from starting.
In this case, a spare pendant and cable should be fitted while the damaged one is being repaired or
replaced.
In an emergency, to allow the machine to be started when a spare pendant and cable is not available,
disconnect the pendant cable from the rear of junction box 1 and replace it with the loop back plug tethered
nearby. This will clear the E-Stop detection and allow the machine to be started. To move the machine,
the cover on the Lockout Plate (Page 79) may be removed to access the control levers. This is only an
emergency measure and the cover must be replaced when the pendant is again ready for use.
Before the machine is moved it should first be set up in the Transport Configuration (Page 77).
All functions for manoeuvring (driving) the machine are located on the Remote Transport Control Pendant
(Page 81) which has to be coordinated with the position of the Baseframe Console (Page 79) lockout plate.
In order to safely move the machine, travel speeds should be kept to a slow walking pace. The machine is
driven by an operator walking beside the machine using the Remote Transport Control Pendant (Page 81).
Alternatively, the operator may be on the machine for improved visibility.
The operator is assisted by a travel observer who is positioned to check any blind spots for the operator
(typically on the opposite side of the machine). The observer warns the driver of any obstructions and also
ensures that the electrical trailing lead does not pull tight, is not in the machine’s travel path and is free to
move. All other personnel should be a minimum of three metres from the machine as it is manoeuvred.
The operator and the travel observer must pay attention to the power cable and ensure it will not be
pulled tight or run over by the machine wheels during machine manoeuvring operations.
Ensure the front jacks are fully retracted at all times when the machine is being manoeuvred.
Towing
The machine must not be towed or moved without the hydraulic pump operating and supplying pressure to
each drive motor/gearbox (by operating the drive control) or damage will occur to the gearbox brake
assemblies.
Steering
The independent operation of the steering control for the front and rear wheel sets is operated by two
hydraulic cylinders. These cylinders do not automatically centre but remain set in position when their control
levers are released.
Hence a steering direction may be set, the machine moved a little, the machine position checked and then
the steering direction adjusted if necessary. This facilitates manoeuvring the machine around any obstacles
and also accurate alignment of the machine during Initial Machine Entry (Page 91).
The independent steering control also allows for the use of four distinct steering modes. Refer to Steering
Flexibility (Page 88).
1. Crab steering. Both front and rear steering set to the same angle. The machine’s axis remains parallel to one
direction. A series of short forward/reverse movements with alternate crab angles will move the machine
sideways.
2. All wheel steering. Both front and rear steering set to the same direction. This gives the smallest turning
radius for highest manoeuvrability.
3. Rear wheel steering. Changes the direction of the machine axis while moving the rear of the machine to the
left or right.
4. Front wheel steering. Changes the direction of the machine axis while moving the front of the machine left or
right. This would be the normal steering mode in areas of few obstacles.
1. Make sure the offside view mirror has been removed and stored safely.
2. Make sure the operator’s seat and platform assembly have been removed from the machine.
3. Make sure the operator's hydraulic control levers are still in their lowered position with their cover down.
Also make sure the console on turntable console is secured close to (parallel with) the boom.
These first three steps were completed in the transport configuration procedure. They have been repeated
here as a check. If these components are incorrectly positioned then they will clash with the mill trunnion
and be damaged on attempted entry. Damaged hydraulic control levers will make the machine inoperative.
4. Check the position of the machine. It must be in front of the mill, in-line with the mill axis and with
sufficient room in front of the machine to allow slewing of the boom to the forward position. In this
position the machine will also be in-line with the floor mounted tiedown fittings.
5. Switch the machine control to a radio remote pendant at the Ancillary Panel (Page 105) and Activate the
Remote Control (Page 115) for use.
During this step the machine will automatically stop. The operator's hydraulic levers must be in their
lowered position with their cover down and then the machine may be restarted in the normal manner once
the radio pendant has been activated for use.
To achieve this movement, the boom will need to be raised to avoid the grapple clashing with the
front safety rails, then slewed to the forward position and then lowered to the horizontal position. A
front safety rail section may be removed if necessary. Replace it immediately after this movement.
Do not extend the boom or beams (inner or outer).
Do not extend the boom or either beam section. Any one of these actions may cause the machine to
overbalance. It is not tied down yet.
The final boom position must be horizontal, parallel to the beams and facing forward, in line with the beams.
This position provides maximum clearances during entry through the mill trunnion.
The radio remote pendant may remain activated for setting up the machine inside the mill. It will not be
needed for the next steps in the mill entry procedure.
The floor mounted tiedown fittings in front of the mill will have been previously inspected (and repaired if
necessary) in Inspections Before Use (Page 65) and Prepare the Site and Mill (Page 76). The front and
rear tiedown equipment will also have been included in this inspection.
Before the machine enters the mill ensure that the mill has been prepared in accordance with Prepare the
Site and Mill (Page 76) above.
Make sure that all personnel are clear of the mill entry trunnion.
Make sure all personnel have evacuated the mill interior as access to or from the mill is blocked while the
Mill Relining Machine is entering through the trunnion.
1. Using the machine’s drive and steering functions for Manoeuvring the Machine (Page 87), drive the
machine into the mill with the machine axis parallel to the mill axis.
Ensure the machine front and rear tiedown equipment remains aligned with the floor mounted
tiedown assemblies. Refer to TQAMRM384 VDD 02 (Page 294), TQAMRM384 VDD 03 (Page 295)
and TQAMRM384VDD 05 (Page 297).
Align carefully the machine’s front tiedown plates with the floor-mounted front tiedown blocks.
If the tiedown plates hit the tiedown blocks, they can cause damage to the bolts and the concrete around
the blocks. Replace damaged tiedown equipment.
Ensure the front jacks are fully retracted at all times when the machine is being manoeuvred.
The Mill Relining Machine's boom has now entered the mill and the RUSSELL 7's axis is parallel with the mill
axis. The front pinning plates and rear baseframe tiedown rods are aligned (from above) with their
corresponding floor mounted fittings. Refer to Vendor Data Drawings (Page 265).
Currently the machine is positioned in front of the mill with the boom having entered the mill trunnion. The
front pinning plates and rear baseframe shafts have already been aligned (from above) with their
corresponding floor mounted fittings. Refer to Initial Machine Entry. (Page 91)
Carrying out this procedure correctly ensures the operating reactions of the machine are supported by the
machine frame and front tiedown pins, not the wheels or jack hydraulic oil.
Refer to Front Tiedown Equipment (Page 33) and Rear Tiedown Equipment (Page 34).
1. Extend the front jacks to align the holes in the floor mounted blocks with the holes in the machine
pinning plates, on both sides. Refer to Baseframe Console (Page 79).
2. Insert both tiedown pins fully through the pinning plates at the end of the extension arms. Check that
each pin is secured by the overcentre latch.
3. Fully retract the front jacks to release the hydraulic load on the front jacks. Load will be taken by the
tiedown pins.
4. Fit the tiedown rods to the rear baseframe tiedown shafts and using the lynch pins provided, attach the
rear tiedown rod clevises to the rear floor mounted tiedown plates.
Each rear tiedown rod weighs 55.9 kg and will require more than one person to lift and install.
5. Tighten the tiedown rod nuts to just bear against the tiedown shafts. Do not overtighten. Use the outer
nuts to lock each rod from becoming loose due to machine vibration.
6. Place the floor grate over the tiedown floor access hole.
Ensure front jacks are relieved of pressure (fully retracted). Ensure the rear tiedown rods have tightened
down correctly.
The mill relining machine must rest on the front tiedown pins supported by the floor mounted blocks before
any relining procedure begins.
The machine is now tied down in front of the mill, with the machine boom inserted into the mill trunnion.
Now that the machine is tied down the outer beam may be extended.
1. Outer Beam Cylinder is used to extend and retract the outer beam in three cylinder strokes.
2. Beam Cylinder Mounting Clamps are used to lock the position of the cylinder end on the baseframe.
3. Outer Beam Pinning Positions. The cylinder rod knuckle may be pinned to the outer beam at each of these
three positions.
The outer beam control is located at the Remote Transport Control Pendant (Page 81). Starting with the
beam fully retracted, as shown in Machine Rear - Beam Pinning Positions (Page 93).
1. Fully retract the outer beam cylinder. This extends the outer beam into the mill by one increment.
2. Remove the beam pin from the (front) first pinning position.
3. Extend the cylinder and align the cylinder rod knuckle with the second (next) pinning position and
replace the pin in this next pinning position and cylinder knuckle.
4. Repeat the above steps 1 through 3 once more. The pin is now in the rear pinning position. Rotate
the pin to engage the pin handle in the locking bracket on the outer beam, this ensures that the pin
cannot become loose or fall out during relining operations.
5. Fully retract the outer beam cylinder. This extends the outer beam into the mill by the final increment.
Hazard: Sudden, unexpected movement. At full extension the outer beam is vertically locked in place by the
beam clamps on the front baseframe end plate. Failure to extend the beam fully could result in dangerous,
unexpected beam movement.
Hazard: Sudden, unexpected movement. During relining operations, the beam cylinder pin must be
engaged with the cylinder rod knuckle and the beam at all times, or the beam could slide on the baseframe
without warning.
Figure 44: Typical Machine with Outer Beam Extended (into Mill)
Relining configuration is the arrangement of fittings and controls necessary to conduct mill relining
operations.
Before continuing, the stairs must be attached to the platform. They must only be attached at the access
point on the platform. They may be attached at any one of the three gateways at the top of the stairs.
1. Insert the two alignment lugs into the indents on the platform;
4. Close the two gates at the top of the stairs to cover the gateways not being used.
To remove the stairs: unlock the castors, lift the catch plate and carefully move the stairs to extract the
alignment lugs from the indents.
The stairs must be removed from the platform before the Mill Relining Machine is moved.
The observer’s pendant is fitted with an E-Stop button which functions to shut down the machine. The
designated safety observer uses this pendant if an emergency is occurring or about to occur.
The pendant is attached via electrical cable to the junction box mounted on the front of the inner beam.
In this case, a spare pendant and cable should be fitted while the damaged one is being repaired or
replaced.
To allow the machine to be started when a spare pendant and cable is not available, disconnect the pendant
cable from the side of the junction box and replace with the loop back plug provided. This will clear the E-
Stop detection and allow the machine to operate but will not allow the observer's pendant to be used.
Injury hazard. The potential risks to relining personnel are increased without an observer. Conduct a risk
assessment before allowing the machine to be used without this pendant.
1. Using the Radio Remote Control (Page 111), slew the turntable so that the operator’s seat and platform
assembly may easily be installed. Access to this position will normally be from the top of the outer
beam.
2. Transport the operator’s seat and platform into the mill. Refer to Operator’s Console (Page 41).
Attach the platform to the turntable deck, by tilting its rear upwards so that the platform frame legs
may be inserted into the mounts on the turntable, and the stop blocks on the underside of the frame
legs may clear the edge of the turntable retaining blocks. Lower the platform to engage the stop
blocks behind the retaining blocks. The operator’s seat may now be installed onto the platform
spigot.
3. Transport the offside view mirror into the mill and stand it in its socket on the hydraulic mount cabinet.
Adjust the mirror angle to view the grapple tool area on other side of the boom from the operator's
position and secure by using the screw locking pin in the pole socket.
4. Select and set up the operator's controls to be used for relining operations.
Changing the position of the radio-PVG-joystick switch or PVG lever cover may shut the machine down. It
will be started again (if necessary) in the normal manner from the main control cabinet at the conclusion of
this step.
a. Lift back the protective cover for the liner placement levers and raise the PVG control levers to their
operating position. Refer to Lowering and Raising PVG Control Levers. (Page 104) (proximity
sensor switches machine off, if it is not off already and the radio was selected.)
b. At the Operator's Ancillary Panel (Page 105), set the Joysticks-PVG-Radio select switch to the
centre "O" position. (If the radio was selected and this switch is operated first, before lifting the
cover, then the machine is still automatically switched off). The remote radio control pendant is
switched off, removed from the mill and stored safely for reuse at a later time. The joystick controls
may be left attached to the seat assembly or removed from the mill and stored safely for reuse at a
later time.
a. Ensure the Joysticks-PVG-Radio select switch on the ancillary panel is in the radio ON position.
The joystick controls may be left attached to the seat assembly or removed from the mill and stored
safely for reuse at a later time.
b. Ensure the liner placement console protective cover is closed over the PVG valve levers.
c. Activate a remote radio control unit. For operation of the radio control refer to Radio Remote
Control (Page 111).
OR
a. Transport the joystick controls assembly into the mill. Fit the joystick controls to the to the seat
assembly and secure at the rear to a suitable height with the linchpins provided. Refer to Joystick
Controls (Page 107).
b. Adjust the height of the operator's arm rests using the screw locking pins provided.
c. Unplug the loopback plug for the joystick controls (underneath the platform assembly). The
machine will stop. Plug in the cable for the joystick controls.
d. At the Operator's Ancillary Panel (Page 105), set the Joysticks-PVG-Radio select switch to
"Joysticks". This will disable the ancillary panel blue liner release enable button (only one, now on
the joysticks arm to be operational at any one time). The remote radio control pendant is switched
off, removed from the mill and stored safely for reuse at a later time.
5. Restart the machine from the main control cabinet using the normal Starting Sequence (Page 73).
Check that the following have been done before commencing relining operations:
b. Worklights are connected and light pole (if fitted) is switched on at the Ancillary Panel (Page 105).
The machine is now set up in mill relining configuration inside the mill and relining operations may
commence. Refer to Figure: Machine in Mill Relining Configuration (Page 99).
Crush hazard. When using any machine functions, the operator must be alert and constantly vigilant as to
the whereabouts of the other crew members in the mill.
The Mill Relining Machine will handle new mill liners under all load cases to the specified rated capacity
indicated on the main boom. It is only to be used for placing new liners on the mill shell and lifting used
liners from the mill charge. The various motions of the machine will permit the operator to place the new
liners in exact position against the mill shell, ready for liner bolt fit-up.
On the front of the grapple tool is a load ring which, in conjunction with slings, is used to lift old liners onto the
linercart for transport out of the mill. The hook assembly may be used with the load ring when required. It
should not be fitted when it is not in use. This allows the load ring to be safely secured while the grapple
tool is in use.
The Mill Relining Machine places the new liners using the grapple and grapple tool as an interface with the
liners.
This RUSSELL 7 Mill Relining Machine is to be used solely for the purpose of BALL Mill Liner
placement.
Never use the machine to dislodge or remove worn liners from the mill shell.
Never stand beneath a suspended load, as old liners are likely to be cracked and will fall if they break apart.
New liners may also have existing cracks.
Always stop the Mill Relining Machine when personnel enter or leave the mill as unexpected machine
movements create a risk for personnel within the confined space of the mill trunnion.
Worn liners may be removed from the mill floor and placed on the linercart with relative ease by using the
Russell Mineral Equipment O-ZONE tools in conjunction with the Mill Relining Machine. These tools may
also be used to reposition new liners so that their lifting lugs are up and may then be engaged with the
grapple tool for placement on the mill shell.
This section covers the controls available to the operator during relining operations.
The operator must wear the seatbelt at all times when seated at the operator’s console.
The operator may use these controls while at the Operator's Console (Page 41).
The liner pin-release lever is interlocked with a liner release enable button on the Ancillary Panel (Page
105). Also, the liner pin-release lever is shorter than the others. This is to give the operator a tactile
reminder that operating this lever could release a suspended liner.
When the liner lift lever is moved to the ‘raise’ position, the
rotation upward of the grapple head causes a locking action
between it and the grapple tool due to contact of the grapple tool
liner reaction foot with the liner. The liner reaction foot must be
correctly selected for each type of liner. This provides stability of
the liner for precise placement on the mill shell.
8. Grapple roll control. The grapple head and the grapple tool can
rotate about an axis parallel to the centreline of the boom.
Pushing the lever will result in counter-clockwise roll of the
grapple, and pulling the lever will give clockwise roll. The range
of movement is listed in VDD01 Placeholder Page (Page 293).
The hydraulic control levers at the Operator's Console (Page 41) must be raised before they can be used.
The above figure Raising the Hydraulic Control Levers (Page 104) shows the two roll pins (items #1 and #2)
and the flat surface (item #3), that lock the lever in its normal operating position.
Rotate the lever fully into the vertical position so that when it is lowered, the rear ends of the lever will pass
in front of the roll pins #2.
The hydraulic control levers at the operator's console must be lowered and covered whenever there is a
reasonable risk that they may be damaged. Refer to Insert the Outer Beam (Page 93) and Incremental
Rotation of the Mill (Page 134).
A safety interlock detects the position of the cover for the hydraulic levers. The levers and the cover must
be lowered before the radio remote control or the joysticks can be used.
Crush Hazard. When the seat and platform are situated directly above the outer beam, the linercart and/or
its load can clash with the operator’s platform. The linercart switch may be used to disable operation of the
linercart. Also, the linercart must be prevented from passing through the mill trunnion whenever personnel
are entering or exiting the mill.
2. "Boom-Beam Clash Warning" Indicator. When lit, this indicator is a warning that the boom
slew and boom raise functions have been made unavailable, because the rear of the boom
could have clashed with the inner beam. The boom will need to be lowered sufficiently to
enable the slew function to become available again. Alternatively, the boom will need to
be lowered slightly and then slewed to a non-clash position.
3. "Liner Release Enable" Button. The liner cannot be released from the grapple tool unless
this BLUE liner release enable button is pressed at the same time. This is a safety
measure.
The liner safety bar is also used to manually lock the tool pins, as explained in Grapple
Tool and Liner Pinning Operation (Page 127).
4. Liner Release Interlock Fault Indicator. This indicator is a vital safety feature and during
normal operations it is not illuminated. When illuminated it alerts the operator to a fault in
the Liner Release Control Interlock system that prevents inadvertent liner release.
Press “RESET” to clear the fault.
If the indicator comes back on immediately, a potentially dangerous fault has been
detected in the system and mill relining operations must cease until the cause of the fault
has been identified and rectified. Refer to Liner Release Interlock Fault Indicator (Page
129).
5. "Console on Turntable (COT ) Enable Fault Reset" button. The red indicator light comes on
if there is a fault with the COT-enable and/or the PVG-enable operations (joysticks and
pendant). This indicator has two modes. The red light will flash until the fault is repaired
and the COT-enable-fault-reset button is pushed. The red light is fully on until the COT-
enable solenoid is repaired.
6. Joystick - PVG Controls - Radio Remote Control, Selection Switch. Allows the operator to
select between using Joystick Controls, Operator Hydraulic Controls or the Radio Remote
Control. Only one set of controls may be selected and used at any one time. The middle
position disables both the joysticks and the radio remote control, allowing the use of the
operator's hydraulic controls at the operator’s console.
The select switch light will flash until a mode selection is completed or if JB2 safety relay
E-Stop is on. A JB2 safety relay E-Stop fault must be repaired. Then push the COT-
enable-fault-reset button.
7. "COT Enable" indicator light. The indicator light comes on when the operator's controls are
available to operate.
8. "COT Enable" button. Lift the hydraulic-control-cover and push the COT-enable-button.
This is done each time the hydraulic-control-cover is lifted or the machine is re-started.
When enabled, pressing this button will disable the COT.
The mill relining machine is equipped with joystick controls which may be installed at the operator's platform.
This permits the operator to carry out the same relining functions of the machine that are controlled at the
main console.
The joystick controls are only installed after the machine has been tied down and the outer beam has been
inserted through the mill trunnion. Once the joysticks have been installed onto the operator’s control
platform, the plug beneath the platform needs to be connected for the joysticks to operate.
3. "Console on Turntable (COT) Enable Fault Reset" button. The red indicator light comes on if there is a fault with
the COT-enable and/or the PVG-enable operations (joysticks and pendant). This indicator has two modes. The
red light will flash until the fault is repaired and the COT-enable-fault-reset button is pushed. The red light is fully
on until the COT-enable solenoid is repaired.
5. Liner Release Enable Button. Must be used in conjunction with the release button on top of the left hand
joystick, to enable opening of the grapple tool pins. This is a tactile reminder that the operator is about to
release the liner.
6. Joystick plug and loopback plug. Either the joystick plug or the loopback plug must be connected for the
machine to operate.
To operate the joystick controls, the three position switch on the Ancillary Panel (Page 105) must first be
turned to select the joystick controls. The joystick controls may be switched off by turning this selection
switch to the centre or to the right, pendant, position. In the centre position, the operator must use the PVG
Liner Placement Controls (Page 101) at the operator's console on the turntable.
When the joystick plug is disconnected, the loop back plug provided must be connected or the machine will
not operate, as the E-Stop circuit will be activated.
Each of the joysticks has a deadman trigger located on the front of the handle. The deadman trigger has to
be squeezed continuously for that joystick to be used.
Only one BLUE liner release enable button (for the selected control position) is activated for use. Liners
may only be released from one operator control position at any one time.
All E-Stops at all connected control locations remain useable at all times.
Ensure that all personnel are clear of the machine, including hands off all controls, before selecting
alternative controls.
2. Buttons on top of the left hand joystick control liner pinning (front button) and liner release (rear button). The liner
release function must be operated in conjunction with the Liner Release Enable Button.
Liner Raise.
Boom Extend;
Boom Retract;
Boom Raise.
2. Left hand toggle switch on top of the right hand joystick controls:
3. Right hand toggle switch on top of the right hand joystick controls:
The Mill Relining Machine is equipped with a radio remote control unit. This allows the operator to control
the mill relining functions from any location inside the mill. The operator can take advantage of being in the
best position to view the relining operations.
Always ensure that the remote is in clear line of sight of the machine and within 10 metres
Ensure that all personnel are clear of the machine before activating controls.
Do not use the radio remote control pendant if there is any doubt as to its serviceability.
Each of the joysticks has a red deadman button set into the top of the handle. One of the deadman buttons
has to be pressed continuously for any joystick or other control to be used. The tool interlock switch is the
deadman function only for the grapple tool release.
When the radio remote control is in use then the blue liner release enable button on the operator’s
placement console is deactivated. Liners may only be released from one operator control position at any
one time. This is an important safety feature.
1. Remote Control 'ON/OFF' switch is on the side of the pendant body. Insert the key and turn
it clockwise, then press the green button near it to activate the pendant.
2. Deadman buttons are located on each side of the unit. To operate any of the joystick
functions, depress and continue to hold either of the deadman buttons.
Boom Extend;
Boom Retract;
Boom Raise.
Liner Raise.
or N/A – no machine motion occurs when moving this joystick in these directions.
10. Liner Release Enable Toggle Switch. This switch must be used with the Liner Release Switch to release a liner
. Operate and hold the toggle switch while also operating the Liner Release Switch.
11. Liner Pinning and Release Toggle Switch has two functions:
Liner Release. The Liner Release Enable Switch (see above) must be held for this function to operate.
Both hands are used to remind the operator that a liner is about to be released.
Liner Pinning. Operate this switch to pin a liner with the grapple tool or to return the grapple tool pins to
their closed position.
12. Liner Release Interlock Fault Indicator. This indicator is a vital safety feature and during normal operations it is
not illuminated. When illuminated it alerts the operator to a fault in the Liner Release Control Interlock system
that prevents inadvertent liner release.
Press “RESET” on the Ancillary Panel (Page 105) to clear the fault.
If the indicator comes back on immediately, a potentially dangerous fault has been detected in the system and
mill relining operations must cease until the cause of the fault has been identified and rectified. Refer to Liner
Release Fault Indicator (Page 129).
The Liner Release Interlock Fault Indicator provides an alert that the liner release control system has
detected a fault. The integrity of the liner release system is essential for the continuation of safe mill
relining operations. Do not conduct mill relining operations with this indicator illuminated. Death or serious
injury to personnel could result.
The liner release functions at the console are still enabled when this fault indicator is lit.
For more information about the radio remote control unit, refer to the manufacturer's manual.
The radio remote control pendant must be activated to use any of its functions. To activate and use the
remote control unit:
2. Install the correct electronic key for the specific unit into the key position (see illustration below).
3. Turn the radio remote switch on the Ancillary Panel (Page 105) to the Radio position. This will
automatically stop the mill relining machine if it was already running.
4. Lower the Operator's Hydraulic Control levers and close the cover over them.
5. Make sure the E-Stop on the remote control pendant is not engaged.
6. On the Radio Remote Control, press the green START button on the transmitting unit (number 3 below)
until the green LED in the transmitting unit starts blinking slowly and the E-Stop light on the MCC goes
out. Refer to Figure: Radio Remote Control Functions (Page 111).
8. Once the remote control pendant is active, test the pendant E-Stop by engaging and disengaging it, then
restart the machine.
2. Electronic key is unique to each receiver. It must be inserted correctly before using the remote control.
3. Start button. Press this button to start the remote control. The green LED on the remote will start blinking
slowly when a link is established with the receiving unit in Junction Box 2.
The radio remote control requires basic maintenance and inspection prior to use to ensure that it is safe and
undamaged.
Pre-use Inspections
1. Rubber boots around joysticks, buttons and switches should be intact and remain weatherproof to
prevent the ingress of contaminants. Any tears or damage to the protective boots will require
replacement of the boots.
2. All joysticks, buttons and switches should work smoothly and correctly.
4. Clean any dirt from the radio remote with a damp cloth. Do not immerse in any liquid.
5. Ensure the battery terminals are clean and the battery is fully charged (charging takes about four hours).
1. Make sure the remote control is turned off and not active. Press the E-Stop and leave it engaged.
3. Push the battery sideways slightly and lift to disengage it from the base (A).
6. Disengage the E-Stop. Check that the machine is safe to start. To test the unit, use the procedure for
Activating the Remote Control (Page 115).
This is not a complete guide to the Liner-Release-Enable system. If a persistent fault occurs, call the RME
Help Hotline (Page 10) for technical assistance.
When a mill is relined, one of the main safety hazards is that a liner could be released accidentally from the
grapple tool. This could seriously injure or kill a crew member.
This mill relining machine has been fitted with a programmed Liner-Release-Enable System (LRE system).
The purpose of the LRE system is to reduce the risk of a liner being released accidentally.
With this system, the operation of two devices is needed to release a liner:
The main radio is used by the operator. The LRE radio is used by a member of the relining crew who is
located on the mill charge in proximity to the grapple tool.
Before and during each reline, do the Checks of the Liner-Release-Enable System (Page 122).
This section will refer to the following topics in this manual. The parts of the LRE system for that topic are
shown.
Liner-release-enable switch
Liner-release switch
Liner-release-enable button
Liner-release-enable button
This is not a complete guide to the Liner-Release-Enable system. If a persistent fault occurs, call the RME
Help Hotline (Page 10) for technical assistance.
2. Liner-Release-Enable button. Refer to the Liner Release Enable System (Page 117).
2. Start button.
The main radio is used by the operator. The LRE radio is operated by a relining crew member on the mill
charge.
Terminology:
Operator: The person operating the mill relining machine with the radio remote control pendant (main radio).
Crew member: The person operating the Liner-Release-Enable radio pendant (LRE radio).
Cycle: The length of time that the system allows for the entire procedure for releasing a liner, before it
engages a fault condition.
Procedure: The entire procedure for releasing a liner from the grapple tool, as shown below.
Fault condition: A condition caused by the Liner-Release-Enable system that disables the liner-release
function or engages an E-Stop, or both. Error codes are displayed on the liner-release safety relay. The
procedure cannot be restarted until the fault condition is reset.
1. Make sure all hydraulic movement has stopped for at least two seconds.
2. The crew member decides that it is safe to release a liner. The crew member presses the liner-release-
enable button on the LRE radio. The LRE sounder comes on intermittently.
3. Within five seconds, the operator pushes the liner-release-enable switch on the main radio. The LRE
sounder comes on continuously.
4. The operator pushes the liner-release switch on the main radio to release the liner.
The entire procedure must be completed within 12 seconds, or the cycle will stop.
Crush Hazard. The liner-release-enable system is essential to the safe operation of the mill relining
machine. Do not attempt to reline if the system has a persistent fault condition.
In this case, the system will reset if the operator and the crew member release the controls.
a. If the operator or crew member continues to hold the controls for a total of 20 seconds:
an error code is displayed on the liner-release safety relay inside Junction Box 2 (Page 46)
In this case, one of the crew members must press the liner-release-enable fault indicator on the Ancillary
Panel (Page 105) to unlatch it and reset the system. This will also disengage the E-Stop condition.
The operator may operate other hydraulic functions while a liner is released. This does not extend the
cycle time.
If any of the liner-release functions on the main radio or the LRE radio are released during a cycle, that
cycle will stop and you will have to start the operation again.
A number of other situations can cause a fault condition in the liner-release-enable system. If a fault
condition occurs:
an error code is displayed on the liner-release safety relay inside Junction Box 2 (Page 46)
One of the crew members must press the liner-release-enable fault indicator on the Ancillary Panel (Page
105) to unlatch it and reset the system. This may clear the fault.
Persistent Fault
See if the liner-release-enable safety relay inside Junction Box 2 (Page 46) shows any fault codes
If any of the inspections give unsatisfactory results:
a. Do any repairs that are needed
b. If a fault code shows on the safety relay, try to reset it using the method shown above in Fault
Conditions (Page 121). If a persistent fault occurs, call the RME Help Hotline (Page 10) for technical
assistance.
a. Remove the cover of the operator's console and install a hydraulic lever in the valve for the liner-
release function. Operate the liner-release valve: make sure the grapple tool pins do not move.
Remove the hydraulic lever and replace the cover of the console.
b. Stay in Console mode and operate the liner-release-enable (blue) button: make sure the grapple
tool pins do not move
a. do the procedure to enable a liner to be released (Page 120), i.e. steps 1 through 3 (the sounder
operates continuously): make sure the grapple tool pins do not move
d. Call the RME Help Hotline (Page 10) for technical assistance.
Crush Hazard. The liner-release-enable system is essential to the safe operation of the mill relining
machine. Do not continue if the system has a persistent fault condition.
The linercart is used to transport new liners into the mill and worn liners out of the mill for disposal. Controls
for the linercart are located on the linercart pendant. The Baseframe Console (Page 79) lockout plate must
be positioned fully to the right before the Linercart Radio Remote Control Pendant may be used.
The linercart operator must ensure the linercart path is clear of personnel or any obstruction, particularly in
the confined space of the mill trunnion.
The linercart operator must ensure the linercart rated capacity is never exceeded.
The linercart load must be stacked in a stable configuration. If loading multiple used liners on the linercart,
they must be loaded in a stable manner.
Linercart motion can cause the load to move and become unstable. Ensure the liner stack can clear the
mill trunnion.
Drive the linercart carefully; the slow speed detent should be used when the linercart approaches either end
of the beam. Stop the linercart before it hits the beam stop; a sudden jolt could dislodge the linercart load.
Do not ride on the linercart or attempt to enter the mill while the linercart is operating.
1. Place the new liner on the linercart with its lifting lugs up.
a. The liner must be placed lengthways on the linercart, this ensures it can pass through the mill
trunnion. The linercart would typically be positioned at the rear of the beam and the linercart
turntable may also be rotated to assist with loading.
b. Check that the liner is stable and correctly aligned to fit through the mill trunnion. The turntable
hydraulic slew motor will prevent rotation while the linercart is moving.
The linercart pendant is used for operation of the linercart and is attached via electrical cable to the main
control cabinet. It is normally stored with its cable looped on the bracket provided underneath the platform
near the cabinet. This hand held pendant may also be located in and operated from the platform handrail
bracket which is fixed to the top of the handrail. Never let the connecting cable lie on the ground where it is
likely to be damaged.
The pendant is fitted with dual position press buttons for linercart movement. The first detent position
results in a slow speed; pressing the button further to the second detent increases the linercart speed. This
provides control over the speed of the linercart as it approaches the stops at the end of the beam.
1. Pendant Enclosure. IP65 rated to stop ingress of dirt and moisture into the pendant.
3. Two-position Motion Button. Pressing this button operates the linercart out of the mill.
4. Two-position Motion Button. Pressing this button operates the linercart into the mill.
5. Pendant ON Indicator. When illuminated it indicates that the pendant is available for use.
If the indicator is ‘OFF’, the pendant control may be disconnected or may have been
disabled at the Ancillary Panel (Page 105).
If the pendant and/or pendant cable is damaged, then this fault may be detected as an activated E-Stop
which will stop the machine and prevent it from starting.
In this case a spare pendant and cable should be fitted while this one is being repaired or replaced.
To allow the machine to be started when a spare pendant and cable is not available, disconnect the pendant
cable from the side of the main electrical cabinet and replace with the loop back plug provided. This will
clear the E-Stop and allow the machine to be started, but will not allow the linercart to operate.
The grapple tool attaches the liners to the machine. This is one of the most important functions of the
machine and the grapple tool enables fast, safe and secure attachment. It also allows liners to be readily
released when required. Only approved liner castings may be picked up by the grapple tool.
All parts of the grapple and grapple tool assembly present a pinch or crush hazard. Do not touch the grapple
or grapple tool assembly while the machine is operating.
For all grapple and grapple tool control functions refer to Operator's Hydraulic Controls (Page 101).
Refer to Figure: Grapple Tool and Liner Pinning Operation (Page 127):
1. Retract the grapple tool pins and align with the liner using the grapple function levers on the operator’s
console:
a. Remove one (1) of the lynch pins from the liner safety bar and open (retract) the grapple tool pins.
b. Lower the liner lift function until the grapple tool hangs vertically and loose from the grapple.
c. Align the inside of the grapple tool guide lugs with the outside of the liner lugs.
Crush Hazard. Incorrect lug spacing may cause a liner to fall from the grapple
tool.
Only the correctly manufactured and tested grapple tool and liners are to be used.
If any changes are made to the specifications of the mill liners, contact Russell
Mineral Equipment to assess the liner and grapple tool engagement integrity.
2. Align the grapple tool pins with the holes in the liner lugs:
a. Lower the grapple tool over the liner lugs, align the pins and lug holes.
b. An assistant may use the handles provided on the grapple tool to help with alignment.
Crush Hazard. Grapple tool operation exposes crew members to several pinch
and crush hazards, especially when pinning or releasing liners. Exercise extreme
caution at all times when working around the grapple tool.
a. Use the controls to close the grapple tool pins and pin the liner to the grapple tool.
b. Replace the lynch pin (removed in step 1a) in the liner safety bar.
a. When the correct liner reaction foot is attached and the liner lift function is used the liner should
hang from the grapple tool at the correct angle for liner to fit up to the mill shell.
5. When the liner is fitted to the mill shell, insert the liner bolts and secure the liner to the mill shell.
6. Remove the lynch pin from the liner safety bar and release (unpin) the liner from the grapple tool.
The Liner Release Interlock Fault indicator is an important safety feature. When illuminated it alerts the
operator to a fault in the liner release control interlock system which prevents inadvertent liner release. The
indicator is located on the Ancillary Panel (Page 105).
The Liner Release Interlock Fault Indicator provides an alert that the liner release
control has detected a fault. The integrity of the liner release system is essential for
the continuation of safe mill relining operations. Do not conduct mill relining
operations with this indicator illuminated. Death or serious injury to personnel could
result.
If the indicator illuminates during normal mill relining operations, a fault has been detected. The fault has two
possible causes and each requires a different course of action, as follows:
1. The Liner Release Enable solenoid in the hydraulic cabinet has been detected as being “open” when it
should be “closed”. This is a potentially dangerous fault and all mill relining operations should cease.
The liner release control system has a fault. Liner crews should exit the mill and the machine should be
shut down. No further relining can be carried out until the cause has been identified and rectified by a
service technician.
OR
2. When using the radio remote control, the Liner Release Enable has entered a faulty state after the
detection of signal interruption. In this case, the operator could be remote from the ancillary panel, but
will be alerted by a red LED indicator on the Radio Remote Control (Page 111). The radio remote control
should be switched “OFF” and another control mode selected using either PVG controls or joysticks.
Press the “RESET” function of the indicator. If the light in the indicator is extinguished and remains off,
the liner release interlock is functioning correctly and full mill relining operations may continue.
In any case, if the light remains illuminated after pressing the “RESET” button, then the liner release control
system has a fault. No further relining can be carried out until the cause has been identified and rectified by a
service technician.
Liner interface attachments help the operator to position the liners precisely at the mill shell. Each liner
interface attachment will match one or more liners in your mill(s). For the actual attachments supplied with
your machine, refer to the List of Assembly Drawings (Page 266).
Crush hazard. Using worn or faulty liner interface attachments could cause a liner to be dropped from the
grapple tool. Inspect liner interface attachments regularly.
The following figures show a typical selection of liner interface attachments for some mill liners. The last
figure shows a pulp lifter adaptor bolted to a typical pulp lifter liner. Again, the correct choice of reaction foot
must be made: different pulp lifter liners may require different adaptors.
If a liner shape is changed, contact Russell Mineral Equipment for supply of the correct load-rated
attachments.
The liner reaction foot contacts the liner during the liner lift procedure and holds the liner in a stable position.
This gives the operator precise control during the liner placement process. The RUSSELL 7 Mill Relining
Machine is supplied with liner feet of different lengths. The correct length liner foot must be used. Refer to
Grapple Tool and Liner Pinning Operation (Page 127).
2. Lynch pin is used to lock the foot in position on the grapple tool.
Both the boom and beam assemblies have spare hydraulic hose capacity fitted. In the event of an internal
boom or beam hose failing during a reline, another hose may be used to allow the reline to continue with
minimum delay. As soon as the reline is completed, the damaged hose must be replaced with a new one.
There is easy access to all other hoses which may simply be replaced as required.
The boom has two spare hydraulic hoses installed through its internal cableveyor. There is one spare hose
of each hose size and all boom hoses, including the spares, have the same 9/16 JIC connectors fitted. The
spare hose ends are capped to prevent ingress of contaminants. The rear ends of both spare hoses are
located behind the rear boom cover and the other ends are located behind the grapple attachment flange at
the front of the boom. If a hose fails then disconnect it and use one of the spare hoses to replace it.
The beam has two tank return hoses within the inner beam cableveyor. Tank hoses are not under pressure
and so should not burst. If a pressure hose fails, then disconnect it at the rotary union and at the JIC
connectors underneath the beam. All hoses have the same sized JIC connectors at these two locations.
Then use one of the tank hoses to replace the failed pressure hose. Ensure the tank return fittings at the
rotary union and underneath the beam are capped to prevent further fluid loss or contamination. The
machine will operate and is capable of completing the reline with only one beam tank return hose.
Ensure that the maintenance controller is aware of the need to replace the failed hose after the post-reline
inspection.
The mill may be relined from the first liners that are clear above the mill’s residual ore charge to as high on
the shell as is practical to reach. Once the accessible liners have been replaced and before ‘inching’ the
mill, the Mill Relining Machine must be set up for mill inching.
This is a neutral machine position inside the mill and is aimed at minimising any damage that might occur
due to falling objects. In addition, all local mill safety rules must be followed.
Do not allow the mill charge to be raised above the mill relining machine. If there
is a risk of this occurring then remove the machine from the mill prior to inching.
Mill Inching:
During this procedure the machine’s centre of gravity is forward of the front jacks. The rear of the machine
must remain tied down to the floor anchor plates at all times.
a. Set the grapple roll and slew at midpoint and liner lift at full ‘UP’ positions.
d. Lower the operator's hydraulic controls and fold the protective cover over them. Refer to Raising
and Lowering the Hydraulic Control Levers (Page 104).
e. The radio remote control unit should be removed from the mill, even if it is not currently in use.
All personnel must evacuate the mill while it is being incrementally rotated. (Inched)
If using the THUNDERBOLT Recoilless Hammer to remove the liner bolts, all personnel must evacuate the
mill; and the machine should be protected from damage.
2. If using the THUNDERBOLT Recoilless Hammer to remove liner bolts the above precautions must be
followed.
3. The mill can now be incrementally rotated ready to remove the liner bolts and liners for the next relining
procedure.
When all liner bolts and liners have been removed from the mill shell ready for the next stage of
relining, the machine should again be made operational.
If the residual ore level in the mill is too high, Remove the machine from the Mill (Page 136) before
incremental rotation is carried out.
When the inching process has been carried out the machine may be inserted back into the mill. Refer to
Initial Machine Entry (Page 91) through Relining Configuration (Page 95).
The Mill Relining Machine is only removed from the mill when the mill reline process is complete, or the mill
has a high residual ore charge level and the machine is to be removed prior to incremental rotation.
1. Set the machine up in the Mill Entry Configuration (Page 89). To achieve this from the relining
configuration:
a. Remove the offside view mirror (rotate the turntable if necessary) and transport it out of the mill for
safe storage.
b. Set the grapple roll and slew at midpoint and liner lift at full ‘UP’ positions.
e. Ensure that all operator's hydraulic control levers are in their folded down position with their
protective cover lowered over them.
f. Change control to a radio remote pendant (if it is not currently in use) and restart the machine.
g. Rotate the turntable to position the operator’s seat and platform over the beam. Then remove and
transport the joysticks assembly, seat and platform out of the mill. Store them safely.
i. Remove the radio remote pendant from the mill. It may remain activated for use outside the mill.
a. Fully extend the outer beam cylinder – this retracts the outer beam from the mill by one increment.
c. Retract the outer beam cylinder and align the cylinder knuckle with the next pinning position and
replace the pin through this pinning position and cylinder knuckle.
d. Repeat steps “a” through “c” once more. The pin is now in the front beam pinning position.
Rotate the pin to engage the pin handle in the locking bracket on the outer beam, this ensures that
the pin cannot become loose or fall out during manoeuvring the machine.
e. Fully extend the outer beam cylinder – this retracts the outer beam from the mill by the final
increment.
a. Extend the front jacks just sufficiently to release the weight from the front tiedown pins. Refer to
Remote Transport Control Pendant (Page 81).
b. Remove both front tiedown pins and store them on the two brackets located on the inside face of
the baseframe front end plate.
d. Release the rear tiedown rods and lift them off of the floor mounted plates. Store the tiedown rods
safely.
e. Fully retract the front jacks to lower the machine onto the front wheels.
4. Use the Remote Transport Control Pendant (Page 81) to move the machine straight back until the boom
exits the mill trunnion.
Leave the machine in this position if it has been removed from the mill to allow for an incremental rotation. It
is now ready for reinsertion into the mill after the incremental rotation. Refer to Initial Machine Entry (Page
91).
OR
5. Using the Radio Remote Control (Page 111) set the machine up in the Transport Configuration (Page
77).
The machine is now ready to be manoeuvred and repositioned away from the mill.
Follow techniques given in Manoeuvring the Machine (Page 87) to manoeuvre the machine away from the
mill.
A post-use inspection of the RUSSELL 7 should be carried out after the reline is complete and before the
machine is placed in storage.
The purpose of this inspection is to identify any wear or damage that may have occurred during the reline
process. When this inspection is complete the inspection forms will be given to the technician or
maintenance controller to check and rectify any faults or problems.
This will allow ample time for any repairs or spare parts to be ordered, received and rectification work to be
carried out before the next scheduled reline.
These inspection forms should be kept as a record of the machine's maintenance history.
Refer to Lubrication, Inspection and Servicing (Page 141) for post-use check and lubrication forms.
Crush Hazard. The machine may move unexpectedly while it is being operated. At all times, access to
and operation of the RUSSELL 7 is restricted to personnel authorised by the owner.
When the machine is stopped, connect the separate motor heater supply cable to a suitable supply and
switch the motor heaters ‘ON’.
The machine should be stored in a manner in which it is protected from extreme environmental conditions
and/or vermin and insect attack.
If the machine is to be in storage for periods greater than 6 months, RME can provide a procedure for long
term storage of the machine.
Site personnel should assess site storage conditions with respect to:
period of storage;
1. Get the baseframe side cover and put each flat-hook fastener onto the platform rail, as the cover is
wrapped around the baseframe.
2. Get the baseframe top cover and put it on the top of the machine. Clip the baseframe top cover and the
baseframe side cover together with the fasteners.
3. Get the boom and grapple cover and put it over these parts. Clip the boom and grapple cover and the
baseframe cover together with the fasteners.
4. Get the outer beam rear cover and put it over this part of the machine. Clip the outer beam rear cover
and the baseframe cover together with the fastener.
This RUSSELL 7 Mill Relining Machine has two separate sources of supply, and during normal operation or
storage only one supply will be connected and switched ‘ON’. Both supplies must be disconnected to fully
isolate the machine.
a. Opening the main isolation switch (rotate to ‘O’ position) on the door of the main electrical cabinet.
b. Switching off the site supply and disconnecting the site power supply cable plug from its supply
socket.
b. Switching off the site supply and disconnecting the heater power supply cable plug from its supply
socket.
The following information is provided to assist in the service and maintenance of the Mill Relining Machine
and details general practices and requirements of servicing:
A site, safety and risk assessment should be made of all steps in each inspection/repair procedure.
The machine should be in the Transport Configuration and appropriately secured, e.g. Tied down, before
commencing any maintenance or repair procedures.
Removal of any component or assembly of the machine may make the Mill Relining Machine less stable.
Where components have been removed ensure they are positioned in a stable position.
During all maintenance procedures the machine will be taken out of service and electrically isolated, except
where function tests are required within the procedures.
The machine must be tagged “OUT OF SERVICE” in accordance with site safety procedures.
All lifting equipment used during servicing must have adequate Working Load Limits.
All Mill Relining Machine guards and covers removed for servicing must be replaced before power is
reconnected to the machine.
Be careful when you do work with pressurized hydraulic fluid. It can cause injury. Release the pressure in
the system before you remove hoses or other hydraulic components. Do not use a hand or any other body
part to check for leaks in a pressurized line. Get medical aid immediately if hydraulic fluid causes an injury.
The torque values for critical fasteners are noted on the assembly drawings. These values are supplied to
assist when conducting maintenance on the machine. If the torque value is not on the drawings, then tighten
the fastener until it is snug-tight. (Snug-tight means the tightness of a bolt achieved by a few impacts of an
impact wrench or by the full effort of a person using a standard podgier spanner.)
There may be different specifications for different size bolts, bolts in different positions or tightening bolts in
several stages. Use a good torque wrench, properly calibrated, and follow exact specifications for the proper
torque. The basic tightening procedure is to first snug up bolts, then tighten in stages, and then complete
with the final torque specified. If the hardware threads are lubricated, use only 70% of the torque values.
(e.g. for M12 – Grade 8.8 when lubricated: use 77 Nm x 0.7 = 54 Nm).
Torque values for critical fasteners are noted on assembly drawings. Refer to Assembly Drawings (Page 265).
Do not exceed the given value.
If torque values are not specified on the drawings then tighten the fastener until it is snug-tight.
The following torque charts and specifications are default values to be used when the particular fitting does
not have a torque value specified on the assembly or hydraulic drawing. These values are supplied to
assist when conducting maintenance on the machine.
5/16" 7.9mm ½ 20 2 23
½" 12.7mm ¾ 16 1½ 57
5/16" 18tpi 15 20
3/8" 16tpi 18 25
7/16" 14tpi 35 50
1/2" 13tpi 60 80
Before reassembly of any components occurs, the following will have been carried out:
1. Any bolts, hardware or seals replaced must be of the same grade and specification as originally
installed.
2. All required spare parts, bearings and seals have been obtained.
3. All components will have been cleaned and inspected for damage, distortion and wear and replaced as
required. All threads in components will be cleaned, inspected and in good condition.
4. Tolerances of bushes, bores and pins in components and assemblies have been checked and bushes
or pins replaced as required.
5. All hydraulic components (cylinders, hoses, actuators, gearboxes and motors etc.) have been checked
for leakage and serviced or replaced as required.
6. Non-destructive testing will have been carried out on all reusable pins and fabricated components in
accordance with Non Destructive Examination (Page 231)
7. Condition of any associated electrical cables should have been checked and replaced as required.
8. Any required corrosion protection requirements of the components will have been carried out.
9. All hardware torques will be in accordance with the Assembly Drawings (Page 265) and Torque
Specifications (Page 143).
5.1.4.1 INSPECTION
Wire rope is tough and durable, but nonetheless expendable and eventually reaches the end of its safe
service life. Wire ropes should periodically be inspected for signs of deterioration.
The inner boom section is controlled solely by the boom wire rope.
Rope deterioration becomes noticeable through the presence of broken wires, surface wear, corrosion, wire
or strand distortion due to mechanical abuse, or drastic reduction in diameter and lengthening of the lay.
Also deterioration can be detected by the use of modern non-destructive testing techniques.
While Statutory Regulations govern the inspection and discarding of certain ropes, the same rules cannot be
applied to all ropes. The proper frequency and degree of inspection depends largely on the possible risk to
personnel and machinery in the event of rope failure. The determination of the point at which a rope should
be discarded for reasons of safety requires judgment and experience in rope inspection, in addition to
knowledge of the performance of previous ropes used in the same application.
Where Statutory Regulations are laid down for the inspection and discarding of wire ropes and their
attachments, wire rope users should become fully acquainted with the regulations and see that they are
carried out.
Inspection of both operated and discarded ropes frequently indicates other equipment faults. It is therefore
essential to inspect the equipment on which the rope is installed as well as the rope itself.
6 x 19S (9/9/1) 10 3
Maximum allowable Outer wires should not be worn down more than one-third
wear ONLY: (33per cent) of their diameter.
Total loss of area: The maximum allowable loss of metallic area due to visible
combined wire wear and broken or cracked wires = 15 per
cent.
The frequency of lubrication in the field is determined by the operating conditions of the rope e.g.: high-speed
heavy duty operation calls for more frequent lubrication, as do wet and/or corrosive conditions.
For all conditions a high penetrating, water-repellent rust-inhibiting oil should be used.
For all lubrication requirements on the Mill Relining Machine refer to Lubrication Summary (Page 150) and
Detailed Lubrication Schedule. (Page 154)
The lubrication schedule following should be regarded as a guide for lubrication requirements for the Mill
Relining Machine.
Site specific conditions may require more frequent lubrication of the machine.
The following table provides definitions for the symbols used in this Manual.
Symbol Meaning
Make a thorough visual inspection of the component(s) for damage, excess wear
and security of fitting.
Make a thorough visual inspection of the component(s) for damage, excess wear
and security of fitting.
Using a grease gun, grease at each nipple, purge old grease and clean excess
away.
Penetrating oil – spray wire ropes. Wipe excess from the rope.
Lubricant Specifications
Lubricant Specification
Grease GP NLGI 2
(grease nipples or by hand)
The target cleanliness level of particulate contamination per millilitre of hydraulic fluid for 2μm, 5μm and
15μm sizes is 17/15/13 respectively.
use NLGI 2
Use in grease by hand
applications – use a
spatula and PPE.
10 year Inspection:
1. Remove all old gearboxes and replace.
2. Check level and fill new gearbox (Refer to Slew Motor and
Gearbox Lubrication (Page 158) and Front Basedrive Lubrication
(Page 162)).
use OGL 2
Slew ring and pinion
gear.
In the event of mechanical damage to hydraulic hoses or bursting of hydraulic hoses, or during gearbox oil or
filter element changing procedures, spillage of hydraulic oil could occur. It is recommended that a supply of
diatomaceous earth absorbent pellets should be kept on hand. These can be poured onto an oil spill, and
will absorb most of it. Final clean up should be with waste cloth.
Any oil-soaked diatomaceous earth and waste clothes should be disposed of at the mine site’s disposal area
for contaminated products, following site procedures for such disposal.
For those who are initially unfamiliar with the machine, the following sections detail where on the machine all
the grease nipples are located, areas to apply grease by hand (or brush) and when to apply lubricants. All
other inspections and servicing requirements are also included here.
Each section (for a machine assembly) has a Figure and a table. The table may be copied and used as a
check sheet to be filled in as the lubrication or inspection work is carried out.
Figure Sample Hydraulic Reservoir Lubrication Table (Page 153) shows a lubrication check sheet for the
hydraulic reservoir filled in for a Post-use lubrication. This Figure shows that:
1. Each task is initialled or ticked when completed (empty boxes filled-in for Post-use column).
2. Greyed-out boxes in this column are not required, i.e. not done, and not initialled or ticked.
3. Columns not required are not used, e.g. the "250 Hours or Annual" column in this example is not used.
4. As the final step, the completed sheet is signed off on the bottom row. This would not be done (as in
this example) if there were any outstanding (incomplete) tasks and so allows for a quick check for the
completeness of all the tasks.
5. Notes may be recorded in the space below the table and the completed check sheet given to the
maintenance controller for record keeping.
250
Pre- Post-
No. Symbol Lubrication Task Hours
use use
Annual
1. Examine the manifold and filter fittings for hydraulic oil leaks.
Signature:
250
Pre- Post- 5
No. Symbol Lubrication Task Hours
use use Years
Annual
2. If necessary to fill the oil in the tank, then only use this
filling-point (fitting attached to filter input, on front
side).
Signature:
250
Post-
No. Symbol Lubrication Task Hours
use
Annual
1. Check motor and brake hydraulic fittings for any sign of hydraulic oil leaks.
2. Inspect gearbox breather for free air flow. Clean surrounding area as
required.
To check, remove the sight glass (side of gearbox) and the filling plug (top
of gearbox). Slowly put oil in the filling plug hole until oil is seen to come
out of the sight glass hole, then replace the sight glass and filling plug.
Oil can become trapped in the sight glass and give a false reading. Do not
rely on sight glass, without removal, for oil level.
4. Drain the slew gearbox. Flush with fresh oil and refill.
Signature:
250
Pre-
No. Symbol Lubrication Task Hours
use
Annual
1. Using a grease gun, grease the boom cylinder pivot bearings at each
nipple, purge old grease and clean away excess.
2. Remove the pinion gear cover under the turntable. Grease the slew ring
and pinion gear by hand using a spatula or brush while the operator
incrementally turns the turntable between applications. Use personal
protective equipment.
Lubrication of the slew ring and pinion gear is more easily carried out if an
operator moves the turntable between applications of grease.
3. Using a grease gun, grease the slew ring bearing at each of the four nipples
fitted to the mounting block fixed on the inside rear corner of the hydraulic
mount cabinet.
4. Inspect the slew and pinion gears for any signs of damage.
Signature:
250
Pre- 5
No. Symbol Lubrication Task Hours
use Years
Annual
2. Using a grease gun, grease at each nipple, purge old grease and
clean excess away.
3. Remove the pivot pins, clean and inspect for damage. Grease
by hand and reassemble.
5. The gearboxes must be drained, flushed, and filled with new oil. Refer
Note
Drive gearbox full oil level is approximately 3/4 full. Lift and
support front of machine so that drive wheels just clear floor and
use hydraulic motor to rotate gearbox to obtain inspection holes
in drain and filling positions.
Signature:
250
Pre- 5
No. Symbol Lubrication Task Hours
use Years
Annual
2. Using a grease gun, grease at each nipple, purge old grease and
clean excess away.
3. Remove the pivot pins, clean and inspect for damage. Grease
by hand and reassemble.
4. Using a grease gun, grease the rear axle pivot pin at the grease
nipple, purge old grease and clean excess away.
6. The gearboxes must be drained, flushed, and filled with new oil. Refer
Note
Drive gearbox full oil level is approximately 3/4 full. Lift and
support front of machine so that drive wheels just clear floor and
use hydraulic motor to rotate gearbox to obtain inspection holes
in drain and filling positions.
Signature:
Lubrication of the inner and outer beams is more easily carried out if an operator moves the beams between
and during applications of grease.
The machine must be tied down before extending beams. Otherwise it will overbalance.
250
Pre-
No. Symbol Lubrication Task Hours
use
Annual
2. On each side of the outer beam, remove the two cap screw covers and
apply grease through the two grease nipples. Replace all cap screw
covers. This lubricates the rocker slide pads that support the rear of the
inner beam.
Signature:
Lubrication of the inner and intermediate boom sections is more easily carried out if an operator moves the
boom between and during applications of grease.
The boom must be slewed over the beam, facing the rear of the machine, before being extended
OR
the machine must be tied down before extending the boom.
250
Pre-
No. Symbol Lubrication Task Hours
use
Annual
1. Grease nipple points on both sides of the boom, clean away excess grease.
Include the two front sheave bearings.
2. Grease both boom pivot points, purge old grease and clean away excess
grease.
3. Grease nipple points on the underside of the boom, clean away excess
grease.
4. Remove the plugs on both sides at the rear of the outer boom. Position the
boom (almost fully retracted) so that the rear sheave bearing is revealed
through the opening. Grease nipple on sheave bearing, clean away
excess grease. Replace both plugs.
Pay careful attention to the lower outside surfaces of the inner and
intermediate boom sections. Also remove the rear boom cover and grease
the inner upper surfaces of the outer and intermediate boom sections.
Replace the cover.
6. Grease nipple points in the centre of the teardrop flange pins attaching both
boom raise-lower cylinders to the outer boom. The other end of these
cylinders are lubricated in the turntable section.
Signature:
250
5 10
No. Symbol Lubrication Task Hours
Years Years
Annual
The injection of all the grease with the motor in standstill can make
the grease penetrate into the motor, through the inner seal of the
bearing housing. Only use a manual grease gun. Do not use a
powered grease gun.
Signature:
All grapple rotary actuators are sealed and lubricated by hydraulic oil flow only. There are no grease nipples
or oil levels to check. Also, the grapple tool itself does not require lubrication in addition to maintenance
overhaul servicing.
The information in this section details the Scheduled Servicing Program. It is a preventative maintenance
program recommended by RME for its Mill Relining Machine. It describes the various major components
and the normal life expectancy but there are many variables that affect their life span, such as environmental
factors, usage rate and adherence to the service program.
An essential part of the regular servicing program must include Non-Destructive Examination (NDE) for the
safe and effective operation of the RUSSELL 7. Testing of equipment is conducted at various intervals. If
NDE tasks are ignored, then it could lead to serious injury or death of personnel, or premature failure of the
equipment.
The NDE requirements within the scheduled service program are in NDE Inspections (Page 233).
5.5.1 STORAGE
To ensure that the equipment is given the best opportunity to perform its required operations it is
recommended that between relines it is stored correctly.
The equipment should be cleaned, given a Post-use service (refer to Detailed Inspection Requirements
(Page 175)), then stored either undercover or covered by a tarpaulin or similar type of cover if possible.
The environment the equipment operates in determines the level of corrosion protection required. The
following definitions are provided as a guideline:
Severe – high quantities of powder-fine dust; cloudy high salt content process water; high humidity or
wet environment; cold (below 0º C) or hot (between 30ºC and 40º C) environment.
Extreme – poor visibility due to high dust content in the surrounding air; dirty, high salinity or extremely
low quality bore process water; high humidity or wet environment; other corrosive materials falling on
machine; cold (below –10ºC) or hot (above 40ºC) environment.
The Corrosive Environment Maintenance program is detailed as part of the scheduled service requirements.
To reduce the likelihood of failure, components on the Mill Relining Machine are replaced or overhauled at
the intervals recommended by the Original Equipment Manufacturer (OEM) or by RME, based on experience
of operators of the equipment from around the world.
The accurate recording of operations and maintenance data will ensure the Mill Relining Machine is
maintained to requirements and should assist in reliability of the equipment.
To assist in improving the capability and reliability of the Mill Relining Machine, RME continuously monitors
feedback from operators and technicians. It is recommended that at overhaul or major repair, any upgrades
or modifications that have been developed should be applied to the equipment.
Owners of equipment will be notified of any upgrades or modifications required prior to their machine being
refurbished. Whilst these changes are not mandatory unless they are safety related, they are
recommended, as they will keep future costs down due to obsolescence of components.
During construction RME makes every effort to install components that are reliable and supportable.
Unfortunately with the advance of technology some components, particularly electrical equipment, become
obsolete in a short time (3-5 years) and replacement parts may not be available.
It is recommended that customers undertake the 10 year overhaul to reduce the problems associated with
obsolete parts and ensure the asset meets its intended service life.
If any defects are revealed by the inspections nominated in the Detailed Inspection Requirements (Page
175), then faulty components should be either repaired or replaced as soon as possible.
Refer to the Non-Destructive Examination (Page 231) requirements to identify possible faults.
This Routine Servicing Program has been developed by RME to ensure the Mill Relining Machine has had
basic servicing requirements at the specified intervals. Failure to carry out this servicing could lead to
premature failure of the equipment and injury to personnel.
Intervals for each servicing are based on either (whichever comes first):
Elapsed time - which is applied to account for periods of equipment inactivity and commences from
time of machine commissioning; or
Hours of operation - as recorded by the hour-run meter on the door of the main electrical cabinet.
The detailed requirements for checks, inspections and services are in Detailed Inspection Requirements
(Page 175). Service summary sheets are also found in this section.
Site trained operators may perform pre- and post-use checks. Any maintenance or repairs required after
these checks should be carried out by a site technician or Russell Mineral Equipment technician.
All other checks, inspections or repair and maintenance requirements should be carried out by RME or site
technicians.
250
Pre- Post- 5 10
No. Symbol Inspection Hours
use use Years Years
Annual
250
Pre- Post- 5 10
No. Symbol Inspection Hours
use use Years Years
Annual
Signature:
Hydraulic fittings – for connection of the grapple tool to the grapple. These two hydraulic ports are marked
‘A’ and ‘B’ on both the grapple and grapple tool. If they ever become disconnected then they must be
reconnected to the correct ports on the grapple tool and a function check carried out to ensure the movement
directions of the operator’s control lever and the grapple tool pins agree.
Port A Port A
Port B Port B
Test functions to ensure direction of grapple tool motion agrees with control lever.
Signature:
250
Pre- Post- 5 10
No. Symbol Inspection Hours
use use Years Years
Annual
250
Pre- Post- 5 10
No. Symbol Inspection Hours
use use Years Years
Annual
Signature:
250
Pre- Post- 5 10
No. Symbol Inspection Hours
use use Years Years
Annual
Signature:
250
Pre- Post- 5 10
No. Symbol Inspection Hours
use use Years Years
Annual
Signature:
250
Pre- Post- 5 10
No. Symbol Inspection Hours
use use Years Years
Annual
250
Pre- Post- 5 10
No. Symbol Inspection Hours
use use Years Years
Annual
Signature:
250
Pre- Post- 5 10
No. Symbol Inspection Hours
use use Years Years
Annual
Signature:
250
Pre- Post- 5 10
No. Symbol Inspection Hours
use use Years Years
Annual
Signature:
250
Pre- Post- 5 10
No. Symbol Inspection Hours
use use Years Years
Annual
Signature:
250
Pre- Post- 5 10
No. Symbol Inspection Hours
use use Years Years
Annual
Signature:
250
Pre- Post- 5 10
No. Symbol Inspection Hours
use use Years Years
Annual
Signature:
250
Pre- Post- 5 10
No. Symbol Inspection Hours
use use Years Years
Annual
Signature:
250
Pre- Post- 2 5
No. Symbol Inspection Hours
use use Years Years
Annual
Signature:
Signature:
250
Pre- Post- 5 10
No. Symbol Inspection Hours
use use Years Years
Annual
250
Pre- Post- 5 10
No. Symbol Inspection Hours
use use Years Years
Annual
Signature:
250
Pre- Post- 5 10
No. Symbol Inspection Hours
use use Years Years
Annual
Signature:
250
Pre- Post- 5 10
No. Symbol Inspection Hours
use use Years Years
Annual
Signature:
250
Pre- Post- 5 10
No. Symbol Inspection Hours
use use Years Years
Annual
Signature:
Signature:
The machine function test is required to be carried out after all post-use and higher inspections. Function
tests should be full range movements unless otherwise stated in the schedule.
Do not operate the Mill Relining Machine unless authorised by the owner.
Read manual for safety precautions and operations, refer to Safety (Page 13) and Operations (Page 61).
3. Start machine.
9. Both grapple tool safety bar lynch pins tethered to tool and
usable. (safety bar undamaged)
14. Repeat all the above machine function tests using the joystick
controls.
Repeat function tests 5, 6 and 7 using the turntable pendant.
For the following six tests also check that the baseframe
light/sound beacon functions correctly for all six tests.
For the following four tests, ensure machine is not tied down and
is in the transport configuration.
1. Safety cover.
3. Adjustment bolt.
4. Adjustment marker.
Adjustment Procedure:
2. Tighten or loosen the adjustment nut until the last belleville washer is in line with the adjustment marker
(refer to inset).
3. Operate the linercart to examine the tension of the wire rope. Make sure that the tension of the wire
rope is sufficient to prevent any slip between the linercart drive sheave and the wire rope.
4. If there is any slip, then replace the full set of belleville washers. Read the Assembly Drawings (Page
266) for the correct number of washers.
Inspections of the linercart wire rope should be carried out in accordance with Wire Rope Care and Service
(Page 146).
Do not extend boom unless boom is facing rear of machine or machine is tied down.
4. With the boom horizontal, extend and retract the boom slightly.
Both the inner and intermediate boom sections should move simultaneously. If the intermediate
boom moves and there is a delay before the inner boom moves then the rope requires tensioning.
5. To confirm if adjustment is required, extend the boom slightly and then raise it.
If the inner section drops back a little when the boom is raised this also indicates that there is slack in
the boom rope and it should be tensioned up.
1. Identify the Rope Tensioning Mount and threaded swaged ends of the rope on top of the outer boom,
refer to Boom Wire Rope Tension Adjustment (Page 226). The two threaded swaged ends of the boom
extend rope are held in a tensioning mount by hexagon nuts and lock nuts.
2. Release the lock nuts (these are either 7/8"UNF or 1"UNF depending on machine size), and with a
suitable spanner, tighten each of the retaining nuts by three turns.
3. Use the check procedure above (extending and raising the boom and observing if there is any drop back
of the inner boom).
4. Repeat the tightening of the adjustment nuts as required followed by checking, until there is no drop
back of the boom sections.
5. Tighten the lock nuts, and then proceed to adjusting the position of the boom sections.
The position of the inner boom section, relative to the intermediate boom section, moves whenever the rope
tension is adjusted. The relative position of the inner and intermediate boom sections should be checked
periodically. To check position:
1. Partially extend the boom and measure the two dimensions ‘A’ and ‘B’ from the front and rear flanges of
the boom ends as depicted below in Boom Dimension Points (Page 227).
2. Fully retract the booms and again measure the two dimensions ‘A’ and ‘B’.
The two measurements, ‘A’ and ‘B’, should be equal when made at any boom extension position.
1. Loosen the lock nuts and then the retaining nuts (#2) on the Rope Tensioning Mount (#1) on the Outer
Boom.
2. Remove the protective cover (#3) over the rope reeving guide.
3. Loosen the four socket head cap screws on the clamps (#4) that secure the semi-circular rope-reeving
guide to the clamps.
a. Adjust the two wire rope tension adjuster bolts (#5) to push the front rope reeving guide clamps
forward far enough to increase dimension ‘A’ to the required value.
a. Loosen the two wire rope tension adjuster bolts (#5) to allow the front rope reeving guide clamps to
come toward the rear of the boom to decrease dimension ‘A’ to the required value.
b. Tighten the retaining nuts (#2) on the rope tensioning mount to bring the reeving guide back in
contact with the tension adjuster bolts.
6. Tighten the Rope Tension Mount retaining nuts (#2) to take up any slack after the adjustment, and then
tighten the lock nuts.
7. Extend and retract the boom to ensure that the rope is adjusted correctly and then check dimensions ‘A’
and ‘B’ at various extensions, refer to Boom Dimension Points (Page 227). They should be equal
measurements, for any boom extension.
8. Replace the protective cover (#3) before placing the machine back into service.
Check the torque of bolts on the slew ring bearings used on the turntable and linercart after the first reline
use and then at 1000 hr (or five yearly) intervals. This is to preserve the life of each bearing by ensuring
that it is not deformed by bolts losing their torque. The following information is taken from the Rollix slew
bearing manual. Check the size of the bolts and then use the correct torque for the bolt size as detailed:
Diameter 10 12 14 16 18 20 22 24 27 30 33
(mm)
Torque 69 117 185 280 390 560 750 960 1400 1900 2600
(Nm)
The bolts should also have torque applied in a ‘star’ pattern as depicted:
Both of the front extension arms are secured to the baseframe using bolts with cone lock nuts. Refer to the
baseframe assembly drawing in Assembly Drawings (Page 265) for the correct quantity of bolts, high tensile
washers and cone lock nuts to be fitted.
Replace the M30 bolts, high tensile washers and cone lock nuts at 1000 hr (or five yearly) intervals. These
are located at the bottom of the baseframe to extension arm flange on both sides of the baseframe. Check
the torque of the remaining M24 bolts on this flange. This is to preserve the life of the baseframe and each
extension arm by ensuring that they are not deformed by bolts losing their torque.
For the required bolt torques refer to the Torque Specifications (Page 143). Before replacing bolts and
checking the bolt torques ensure that the baseframe and extension arm flange mating surfaces are correctly
prepared and aligned.
1. Baseframe Flange. One on each side of the baseframe front end plate.
3. M30 bolts, high tensile washers and cone lock nuts to be replaced. Eight on
each side.
The Non-Destructive Examination (NDE) program is carried out in conjunction with the scheduled
inspections. Due to the associated safety risks it is imperative that all documentation associated with NDE
is retained with the logbook and copies with RME for establishing and maintaining future NDE intervals. All
inspections are to be carried out by RME or a certified NDE Inspector.
The NDE Program is applied to all lifting and critical components fitted to the Mill Relining Machine. The
test program enables detection of early signs of damage or cracking that could cause component failure
leading to serious injury to personnel and/or damage to equipment.
2. All clevises;
3. Welded joints (clamping points, platform mounting legs, cylinder attachment points, linercart rails);
4. All cylinders;
The following methods are considered acceptable for NDE testing of the critical components:
The Figure for each major machine assembly, contained within this NDE section, shows the components that
are required to have NDE. The associated table also indicates any NDE and the "Areas" on the machine
that require visual examination at the lesser intervals of Pre and Post-use and 12 months or 250 hours.
Initial visual examination of the components should be conducted using the following inspection criteria:
1. Cracks. If any cracking is identified it will require either replacement or repair. If it is considered that
the item may be repaired and there are possible structural implications, contact RME for further advice.
a. Pins. If a pin has 1% or more material worn off the overall diameter or if any protective plating has
worn off then the pin should be replaced as it will compound wear on other components.
b. Pin Bores. Any eccentric wear in the bore is cause to replace the pin, and also contact RME for
repair advice.
c. Wire Rope Sheaves. Any wear that decreases the diameter or that can cause an increase in wear
on the wire rope is cause for replacement.
Procedure:
If the visual examination identifies any cracking, wear, deformation or damage, then:
3. the next most intensive NDE testing method employed to confirm (or otherwise) the part’s condition.
4. If any doubt still exists as to the part’s condition then use the next most intensive NDE testing method or
replace the part (this could be the most cost effective option).
Do the non-destructive examinations on these components, at the given intervals. Use the method of
examination shown for that interval.
If there is an indication of a fault, use a method of examination that is more intensive or replace the part.
Contact RME for any further advice.
3. Grapple Slew Rotary VE all welds for cracks where actuator is attached.
Actuator Inspect entire unit for damage and wear. Replace
if necessary.
6. Grapple Roll Rotary VE all welds for cracks where actuator is attached.
Actuator Inspect entire unit for damage and wear. Replace
if necessary.
8. Liner Lift Rotary VE all welds for cracks where actuator is attached.
Actuator Inspect entire unit for damage and wear. Replace
if necessary.
10. Bolts, Nuts and Inspect all bolts for any damage. Any damage is
Studs cause for replacement. All bolts in the grapple
have specific torques which may be found on the
assembly drawing.
Signature:
1. Grapple Tool Inspect around centre and end bosses for cracks,
Retention Pin deformation and wear. Replace on condition.
*CRITICAL*
2. Grapple Tool Body Inspect all welds for cracks around the grapple
body. Pay attention to the liner/pin guide arm
welds. Check the body looking for deformation,
wear and cracks. Measure internal wear in slide
arm bearings – wear limit 1.0% of diameter.
3. Slide Arms Inspect for cracks and bending. Wear limit 1.0% of
diameter.
4. Liner Pins Inspect for cracks and bending. Wear limit 1.0% of
*CRITICAL* diameter. Replace if wear or damage is present.
7. Protective shield plate Inspect for cracks and bending. Replace if any
present.
9. Grapple tool foot and Inspect for deformation and cracking. Replace on
foot Bracket condition.
10. Liner Safety Bar. Inspect for bending or deformation. Replace lynch
pins each year.
Signature:
1. Rear Tiedown Rods. VE whole rod and around welds for cracks.
Inspect for damage, corrosion, ‘necking’ or bending
to shank or threads. VE clevis bores for wear and
deformation. Wear limit for holes is 2.0% of
diameter. Replace if repair needed.
5. Rear Tiedown Plate. Wear limit for bolt holes is 2.0% of diameter. VE
around welds for cracks. VE for deformation.
Replace if repair needed.
8. Front pinning blocks Inspect all welds for cracks. Wear limit for holes is
2.0% of diameter. Inspect for damage and
corrosion. Contact RME if cracking is found.
Signature:
The inspections shown below are specific for the boom raise-lower cylinders. These cylinders are critical to
the safe operation of the machine. Similar inspections may also be applied to all other cylinders. All
attachment and lift points should also be inspected.
The boom raise-lower cylinders are attached at the outer boom and to the turntable assembly.
1. Cylinder to turntable VE for cracks along all welds and threaded areas.
clevis mounts VE whole area for damage, deformation or wear.
3. Cylinder manifold. VE for cracks along all welds and threaded areas.
VE whole area for damage, deformation or wear.
5. Rod end clevis. VE for cracks along all welds and threaded areas.
VE whole area for damage, deformation or wear.
Signature:
The baseframe requires the inspections detailed, with particular attention to be paid to the forward supports
and tiedown areas.
There is no life limit on the baseframe; replacement is on condition. If the baseframe is damaged in any
way, RME should be contacted for advice on approved repair methods.
1000 2000
Hours Hours
No. Components Remarks
or 5 or 10
Years Years
1. Rear beam clamp mounts VE for cracks. VE each unit for damage,
deformation or wear
3. Front beam clamp mounts VE for cracks. Inspect whole area for damage,
deformation or wear
5. Axle attachment mounts VE all vertical welds for cracks, VE all welds.
Signature:
The Beams comprise an outer and inner beam that requires the inspections detailed.
There is no life limit on the beams. Replacement is on condition. If any beam is damaged in any way,
RME should be contacted for advice on approved repair methods.
1000 2000
Hours Hours
No. Components Remarks
or 5 or 10
Years Years
1. Outer beam rear flange. Inspect for cracks along all welds. VE whole area
for damage, deformation or wear.
2. Outer beam – beam lower flange Inspect for cracks along all welds. VE whole area
(and also top edge). for damage, deformation or wear.
3. Outer beam cradle. Inspect for cracks forward of mounting bolt holes.
VE whole unit for damage, deformation or wear.
4. Inner beam – beam corners. Inspect for cracks along all welds. VE whole area
for damage, deformation or wear.
5. Slew ring mounting to Inspect for cracks around all welds and bolt holes.
turntable well. VE whole area for damage, deformation or wear.
Signature:
The Boom is comprised of an Outer, Intermediate and Inner assemblies which require these inspections.
There is no life limit on the boom. Replacement is on condition. If any boom assembly is damaged in any
way, RME should be contacted for advice on approved repair methods.
1000 2000
Hours Hours
No. Components Remarks
or 5 or 10
Years Years
1. Outer Boom. Boom and VE pins and matching machined bores. Damage,
boom cylinder pivot pins and deformation or eccentric wear of more than 2% of
bores. the pin or bore diameter is cause for pin
replacement. For wear or damage to the
machined bore contact RME for repair advice.
2. Outer Boom. Pad mounts VE for cracks along all welds. VE whole area for
and lower plate. damage, deformation or wear.
3. Intermediate Boom. All side VE for cracks along all welds. VE whole area for
welds. damage, deformation or wear.
4. Intermediate Boom. Front VE for cracks along all welds. VE whole area for
flange. damage, deformation or wear.
5. Inner Boom. Rear VE for cracks around the radius and any areas that
end of boom in radius areas. are welded. VE whole area for damage,
deformation or wear.
6. Inner Boom. Grapple VE for cracks around all welds and bolt holes.
attachment flange. Inspect whole area for damage, deformation or
wear.
7. Inner Boom. All upper and Inspect for cracks along all welds. Inspect whole
lower side welds area for damage, deformation or wear
8. Internal Boom Cylinder (not Inspect cylinder for bulging, deformation and wear.
shown). Overhaul or replace as required.
Signature:
The turntable is mounted to the front of the inner beam and requires these inspections. There is no life limit
on the turntable. Replacement is on condition. If the turntable is damaged in any way, RME should be
contacted for advice on approved repair methods.
1000 2000
Hours Hours
No. Components Remarks
or 5 or 10
Years Years
1. Boom cylinder attachment Inspect all welds around the turntable legs.
bracket to platen. Inspect the flat panel for any distortion or
deformation. Inspect the bolt holes for any sign of
wear or movement.
2. Boom attachment points Inspect for cracks along all welds. VE whole area
(internal sides). for damage, deformation or wear.
3. Boom raise-lower cylinder Inspect for cracks around holes and radiating from
mounts – upper portion of mount holes. VE whole area for damage, deformation or
surrounding holes. wear.
4. Turntable base to stiffening ring. Inspect for cracks around the welds where the base
is welded to the stiffening ring. VE whole area for
damage, deformation or wear.
6. Inspect support structure. Inspect for cracks in welds and surrounding flat
panels for deformation.
Signature:
6. Troubleshooting Guide
If troubleshooting requires the use of schematic drawings for either hydraulic or electric circuits these are in
Electrical and Hydraulic Schematics (Page 269).
Anyone may perform the initial checks, but if any electrical enclosure needs to be opened a qualified
electrician is required. If any hydraulic fittings need to be adjusted a qualified technician is required.
If the problem has not been resolved after checking through the troubleshooting procedures, then
contact:
Always consider safety precautions before beginning a service procedure. Protect yourself and others from
injury. Take the following general precautions whenever servicing a hydraulic system.
Unintended movement of the machine or mechanism may cause injury to the technician or bystanders. To
protect against unintended movement, secure the machine or disable/disconnect the mechanism while
servicing.
Some cleaning solvents are flammable. To avoid possible fire, do not use cleaning solvents in an area
where a source of ignition may be present.
Be careful when you do work with pressurized hydraulic fluid. It can cause injury. Release the pressure in
the system before you remove hoses or other hydraulic components. Do not use a hand or any other body
part to check for leaks in a pressurized line. Get medical aid immediately if hydraulic fluid causes an injury.
Protect yourself from injury. Use proper safety equipment, including safety glasses, at all times.
Hydraulic fluid contains hazardous material. Avoid prolonged contact with hydraulic fluid. Always dispose
of used hydraulic fluid according to state, and federal environmental regulations.
The machine may only be started at the main electrical cabinet. The first chart guides the operator where to
look if it will not start, stops immediately when the "motor start" button is released or stops after it has been
running. Note that whenever the power supply is first connected or restored, the machine will not re-start
automatically. This is a safety feature to prevent uncontrolled motion of any part of the machine.
The phase failure relay in the Main Control Cabinet monitors the voltage supply for correct supply. This is
protection for the machine circuitry. Incorrect three-phase rotation connection will cause this relay to trip.
The site electrician should check site outlet connections and change if necessary.
The site supply should be kept within the correct parameters required. If the site supply voltage is
permanently low, then the contactors won’t pull in. If the 24 V ac from the transformer is low, then this will
also cause starting problems. Also check for dirty or burnt contacts, refer to Check Site Power Outlet and
Relay Contacts (Page 258) below.
Indicator lights on the electrical cabinet door are of the ‘press to test’ type. They will illuminate when their
lenses are pressed to show that the lights themselves are functional.
If any E-Stop button was engaged during operation, then find out the reason and ensure safe working
procedures are consistently followed. If all E-Stops are disengaged (in the ‘out’ position) then:
1. Check all E-Stop button assemblies for any damage. Refer to Emergency Stops (Page 26) for the
location of all E-Stops;
2. Check continuity from the Main Control Cabinet terminals to Junction Box 4 located inside the well under
the turntable and from Junction Box 4 through the rotary union to junction box 2 on the turntable;
3. Check pendant control cables and plugs for integrity and damage; and
4. Check the E-Stop monitoring relay which is used to detect errors in the E-Stop circuit or in the main
motor contactors. Open the main isolator (‘O’ position), then close it (‘I’ position). Check to see if the
E-Stop monitoring relay has reset. If it has not, then check both main motor contactors for failure, e.g. a
‘welded’ contact.
Include all pendant control E-Stops in these checks. Check that either the pendants or their loop back plugs
are correctly connected. A damaged pendant cable, e.g. one having been overstretched, may have the
effect of an engaged E-Stop. Temporarily replacing the pendant with the loop back plug will test this
possibility. If the linercart pendant cable is damaged, then it must be replaced by a qualified electrician.
Also include the radio switch located on the Ancillary Panel (Page 105) and the E-Stops on any active radio
pendants, refer to Activating the Remote Control (Page 115).
If level has become low then check the whole machine for any oil leaks, burst hydraulic hoses or damaged
fittings. Repair and add oil as required. Boom and inner beam cylinders must be retracted when adding
oil, to avoid an overflow the next time they are retracted. When oil is added, the oil level light on the main
control cabinet should turn off. Keep adding oil, up to the level mark labelled on the reservoir.
Check the oil temperature gauge reading (on oil tank). If the ‘High Oil Temp’ light on the main electrical
cabinet is illuminated and the gauge reading is above 75°C, then wait for the oil temperature to become
lower than 65°C and then restart machine.
1. Ensure the heat exchanger is not blocked with foreign material and the fan is operating;
3. a more serious fault e.g. worn main pump, is indicated. In this case a qualified technician will be
required for further testing.
If the main electric motor has overheated, then the thermistor sensors will prevent the motor from starting
until it has cooled and the relay reset button is pressed. Also check that the thermal overload relay is not
being tripped by a motor over current condition.
If the electric motor thermal overload relay trips again within a short time interval, then a more serious fault,
e.g. with the motor, control relays and/or site voltage level, is indicated.
Also check if either the main or cooling fan motor over current circuit breakers has tripped. Tripping of the
main electric motor circuit breaker will give a thermal overload indication and it will not allow the machine to
start until it is reset. Tripping of the cooling fan circuit breaker will also give a thermal overload indication
and will also remove power from the phase protection relay which in turn will prevent the machine from being
started. If this condition persists on restart, check electric motor and hydraulic pump condition.
Inside the main control cabinet, a phase rotation/phase failure relay is fitted to the machine. The indicator
lights on the relay should indicate correct phase rotation. If not, rectify phase connections on the site supply
outlet being used.
A dirty or burnt contact in the site power outlet or machine plug can cause the phase protection relay to trip,
stopping the motor. This problem can occur during start up as well as during operation under load. Also,
this can be a transitory problem and after tripping, the relay indicator lights may return to normal. Refer to
Check for Momentary Lowering/Increase in Supply Voltage (Page 256). The electrician should open the
cabinet door (temporarily bypass the interlock) and observe the indicator lights during load running or an
attempted start up to see if this problem is occurring.
The circuit breakers or main isolator may be tripped. The electrician should open the cabinet door
(temporarily bypass the interlock) and probe the incoming main cable to establish that there is correct power
supply (voltage and phases) available. Check that all circuit breakers are set. If any have tripped, test
those circuits for ground faults or short circuits. If neither fault is found, check that all breakers are reset.
6.3.1 OVERVIEW
This section provides general steps to follow if undesirable system conditions are observed. Follow the
steps listed until the problem is solved. Some of the items will be system specific. Always observe the
safety precautions listed above, and those related to your specific equipment.
This troubleshooting guide for the PVG valve assemblies does not cover valves
that have been altered from original valve build specifications.
Every fault location process should follow a logical and systematic order:
The Electrical and Hydraulic schematics (Page 269) show the order of, and the connections between, the
individual components.
3. Seal all holes, hoses and pipe ends with numbered plugs after removal to avoid the entry of dirt during
repairs and to assist with reassembly.
5. Perform repairs in a workshop on a clean workbench (covered with clean cloth or newspaper).
6. Make sure that a Sauer-Danfoss service manual for the product is handy.
7. Follow the instructions word for word during disassembly and assembly.
If these instructions are not followed closely, the system may not operate correctly after repairs are
completed.
In some cases special tools are necessary for assembling the product.
The Assembly drawings are referred to in the Maintenance procedures and are used to assist in assembly
and disassembly.
When ordering spare parts from an Assembly drawing it is important to supply the following information:
3. Part Number
4. Quantity Required
8.1 Schematics
The following schematic drawings are presented in the sequence as listed and should be used in conjunction
with:
1. Troubleshooting Guide (Page 251)
2. Vendor Data and Spare Parts (Page 265)
TQAMRM384-ELE-19 (Page 450) JBox JB1 JB2a and JBox 3 Terminal Assemblies
Appendixes
Appendix B: Joystick Pendant COT Enable Control System User Information (Page 279)
Client:
Project:
Lifting Capacity:
Date:
This Pre Reline Checklist is applicable to RUSSELL 7 and RUSSELL 8 Mill Relining Machines.
Minimum Requirements: For completion of Pre Reline Inspection.
1. All functions to be tested and their relevant safety functions demonstrated to be operating.
● Tasks that do not test satisfactorily must be entered on the action sheet and if possible must be completed before
signing off the Pre Reline Inspection, or both parties must be in agreement that the machine is in a safe,
satisfactory condition to be operated.
● If in the opinion of the RME technician the machine cannot be operated safely without repair, immediate verbal
and written notification via the Action Item list below must be made by the RME technician to both the customer
and to RME Head Office. The RME technician must record the date and time of notification.
● If the machine is found to be unsafe to operate the RME technician is to tag the machine "Out of Service" using
the correct site lockout procedure or RME "Out of Service" tags.
● If the customer continues to use the machine unsafely, despite the notification to the customer, this should be
reported to RME Head Office. The customer is also required to sign off their acceptance of this in the Action Item
list and above in the Client Representative section.
Action List
Items requiring action before further use.
Priority: 1 – Immediate action required.
2 – Monitor and repair before next reline.
3 – Monitor and repair as required.
Item # Priority Action Requirement Signed Date
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12
This information is for the use of the safety related parts of the control system above the turntable. Its
objective is to ensure that the safety performance level of the safety control system does not deteriorate over
time, with a resulting increase in risk and potential harm to personnel. It is intended for site personnel
involved in the maintenance and repair of the SRP/CS.
Console on Turntable safety functions implemented are:
SF1: Emergency Stop supplementary protection from dangerous motion via Enable Safety relay:
Power shall be removed from the machine by the Enable Safety relay emergency stop contacts
opening. This is a sub part of the main emergency stop system, required by COT enable safety
function failure. ISO 13849-1:2006 Category 3 Pl d.
SF2: Enable function dropping of liner hazard: The release of the liner via the PVG bank solenoid
valve shall be permitted only when the Liner Release Enable solenoid is opened. The safe (de-
energized) state shall be the Liner Release Enable solenoid closed. ISO 13849-1:2006 Category 2, 3
Pl d.
SF3: Mode control operation from one source: Mode selection shall only permit Liner Release
Enable, COT Enable or PVG control from one location. ISO 13849-1:2006 Category 1, 2 Pl c.
SF5: Prevention of unexpected motion on hydraulic start-up in any mode: At start-up of the machine,
a Console on Turntable (COT) Enable function shall ensure that no hydraulic pressure is available
until a separate enable action by the operator occurs from any location. ISO 13849-1:2006 Category
2, 3 Pl d.
SF6: Prevention of unexpected motion of PVG while in Joystick or Pendant mode during operation:
Once the COT is enabled it is possible that PVG failure can cause unexpected operation. When both
joysticks are released the PVG bank solenoids should be closed. Motion pressure should be used as
feedback to check this. It is important to understand that once a requested motion is in progress due
to one joystick, this safety function cannot monitor the other joysticks PVG induced motion due to
pressure feedback already being on. The prevention of unexpected motion therefore consists of two
parts, prevention of motion start while no joystick triggers or pendant enable is active and safe stop
when all joystick triggers or pendant enable is released. ISO 13849-1:2006 Category 2, 3 Pl d.
SF7: Unexpected energization of PVG while in Joystick or Pendant mode due to joystick or pendant
bump: Once the COT is enabled it is possible that a joystick or pendant bump can cause unexpected
motion. The energization function shall ensure that no PVG power is available to that part of the
PVG bank associated with the bumped motion until a separate enable action by the operator occurs
from the joystick trigger or the pendant enable. This safety function ensures a bumped joystick will
not cause unexpected motion even if the other joystick is in use. It also ensures that the part of the
PVG bank not being used remains unpowered, the unpowered state having a higher MTTFd (Mean
time to failure dangerous). ISO 13849-1:2006 Category 2, 3 Pl d.
Refer to the MRM electrical schematics to identify and understand these components and signal paths in
detail.
Over-voltage and under-voltage can produce unpredictable actions, or cause damage. Normally the safety
control system will fail to a safe state. Extreme overvoltage, i.e. above 30Vdc, could cause damage. Refer to
the ABB error code table (part of electrical drawings) for the appropriate action to clear the fault in the Enable
Safety relay.
Changing the MRM DC power supply from the part specified could result in higher overvoltage under some
power supply failure modes, with resulting unexpected behavior. The maintainer should recognize that this is
an example of a typical common cause that could take out both channels in the Enable Safety relay in an
unsafe way (and both radio receiver channels of a radio pair if used).
Overcurrent in the Enable Safety relay output contacts can cause welding closed, an unsafe condition. The
miniature circuit breakers used to protect these circuits should not be changed to another size or curve type
(the Z curve used is specifically for this purpose, and is not to be replaced with B, C, D or K).
Freewheeling diode suppressors on relays should not be removed. This could cause subsequent overvoltage
damage to the driver circuits.
Solenoids use Hirschmann connectors with built in surge suppression diodes to handle solenoid flyback
voltages (a high voltage that occurs when the solenoid is switched off). This protection is essential.
To maintain the MTTFd of the safety control system, certain assumptions have been made for the number of
cycles before the Enable Safety relay, Selector Switch module and joysticks need replacing. This information
is part or RME’s ASP (Asset Service Platform) database. This replacement interval should be observed.
In the case of programmed parts like the Enable Safety relay, shelf life should be observed, since memory
can degrade. This information is part of RME’s ASP (Asset Service Platform) database. This shelf live should
be observed.
In designing the safety system various fault exclusions are made. In this design fault exclusions have been
made for shorts between wires in enclosures and connectors, by ensuring creepage and clearance distances
are maintained. Electrical wiring in cabinets and connectors must be maintained securely. If rewiring or fault
finding ensure terminals are tight and wiring is replaced correctly in ducts. When re-ferruling ensure strands
of wire are not left out of the crimp.
In Console mode, with the main Liner Release valve held open by moving the hydraulic lever, the release
pins should not drift open.
Still in Console mode, with the Liner Release Enable solenoid valve open by pressing the console enable
push button, the release pins should not drift open.
Incorrect part replacement or wiring will normally be detected due to the extensive fault detection in the
Enable Safety relay. This part must have the appropriate software installed, to perform that purpose.
To ensure correct Enable Safety relay replacement the installed software must agree with the ID tag located
in JB2. The identifier is a separate component connected to the ID terminal (by black lead) and 0V terminal
(by blue lead) of the Enable Safety relay. The circuit contains a unique ID number that is read by the relay on
start-up. The function gives protection against a relay being exchanged with an incorrectly programmed part
by mistake. The identifier circuit should always be securely located in the nearby duct.
ID code 10118021 is used for this Enable Safety relay, encompassing:
Joysticks
Turntable pendant
The Select Switch module integrates many mechanically linked safety relays. The module eliminates much
wiring by using the circuit board. It includes the mode change over select switch relays with their feedback,
the Liner Release Permission relay with its feedback and the multiplying
relays that take the small motion signals from the joysticks and switch
the heavier PVG power current. Also included are the vital PVG Power
safety relays that are part of SF6 and SF7 and their feedback. All
motion signals are diode ORed on this module, as Group 1 and Group 2
& 3 before being sent to the Enable Safety relay. Group 2 &3 are joined
externally. LED’s in the module can be used for diagnosis.
External wiring to the Enable Safety relay is also connected via removable
screw terminal blocks to avoid incorrect connection when the module is
exchanged. If corrosion is present the terminal blocks should also be
replaced. The power shall be off during connection and disconnection.
Important: Do not twist the terminal blocks over when levering, lever them
upwards gently, using leverage against the cover, while pressing them
inwards towards the cover center with the other hand.
Keys are used to ensure correct location otherwise the safety function will
be compromised even though it may still work. Be aware that it is possible
to force the blocks into the incorrect location.
When fault finding it is useful to observe the status of the relays on the Select Switch module using the
LED’s. Use the above template to identify the relays and the following table for the relay functions. The
template also identifies the Key locations if any become dislodged.
K2 Liner Release Permission This relay turns on whenever the Liner Release Enable solenoid is turned on
relay by the Enable Safety relay.
K3 Radio SAF2 relay Radio SAF2 signal. When using radio the relay is used for isolation.
K4 Left Joystick X-Axis motion When this axis is moved the relay turns on to switch power to the path
relay through K13 and K21.
K5 Left Joystick Y-Axis motion When this axis is moved the relay turns on to switch power to the path
relay through K13 and K21.
K6 Left Joystick Right Hand When this axis is moved the relay turns on to switch power to the path
Rocker motion relay through K13 and K21.
K7 Right Joystick X-Axis motion When this axis is moved the relay turns on to switch power to the path
relay through K14 and K22.
K8 Right Joystick Y-Axis motion When this axis is moved the relay turns on to switch power to the path
relay through K14 and K22.
K9 Right Joystick Left Hand When this axis is moved the relay turns on to switch power to the path
Rocker motion relay through K15 and K22.
K10 Right Joystick Right Hand When this axis is moved the relay turns on to switch power to the path
Rocker motion relay through K15 and K22.
K11 Left Joystick lower When this axis is moved the relay turns on to switch power to the path
pushbutton through K15 and K22.
K12 Left Joystick upper When this button is pressed the relay turns on to switch power to the path
pushbutton through K16 and K2.
K13 to Joystick Select Switch relays When the console Mode switch is in Joystick position these relay are on and
K16 K17, K18, K19 and K20 (the pendant switch relays) will be off.
K17 to Pendant Select Switch relays When the console Mode switch is in Pendant position these relay are on and
K20 K13, K14, K15 and K16 (the joystick switch relays) should be off. If both
Mode switch contacts are closed due to a fault K13 to K16 (Joystick
selection) take precedent.
K21 PVG Group 1 Power relay This relay is turned on by the Enable Safety relay whenever PVG group 1
power is required. Group 1 is defined as those motions that can be caused
by the left joystick (and the pendant equivalent motions)
K22 PVG Group 2&3 Power These relays are turned on by the Enable Safety relay whenever PVG group
K23 relays 2 or 3 power is required. Group 2 is defined as those motions that can be
caused by the right joystick (and the pendant equivalent motions) and Group
3 are those motions caused by the mini-joystick (as used on an 8-axis
machine).
A pulse and B pulse refer to two outputs on the Enable Safety relay. They are used to allow the detection of
short circuits when fed through input contacts and so aid in fault detection. If the wrong pulse appears on a
circuit (in time) there must be a short circuit between channels.
A pulse and B pulse are used on the left and right joystick triggers. It means that short circuit between these
triggers or to +24V can be detected easily since the correct pulses will no longer arrive. Putting a millimeter
on a pulse signal will only show a voltage of about 12V due to the low duty cycle.
The right illustration also shows another use for A Pulse. To save I/O terminals on the Enable Safety relay,
IQ24 and IQ26 are used as both an input and an output. While A pulse is on the safety relay reads the status
of the pushbutton. When A pulse is off the safety relay outputs the status of the lamp. It also means the lamp
will be on (powered by A pulse duty cycle) whenever the button is pressed, so serving as a lamp test.
2. Revise and resubmit as indicated. LINER PICKUP GRAPPLE BOOM FRONT REAR
Work may proceed subject to PINS SLEW CL SLEW CL TIEDOWN CL TIEDOWN CL
incorporation of changes requested.
700 3300
21253 B0
FULLY EXTENDED
NOTE: ITEMS MARKED ** ARE DESIGN CRITICAL LINER PICKUP GRAPPLE BOOM FRONT REAR
AND MUST BE VERIFIED BY CUSTOMER PINS SLEW CL SLEW CL TIEDOWN CL TIEDOWN CL
MACHINE MASS 10% 28500 kg
LIFTING CAPACITY 2500 kg
GRAPPLE SLEW ±75 deg
GRAPPLE ROLL ±40 deg
LINER LIFT +25 to -125 deg
BOOM RAISE/LOWER +39 to -33 deg
BOOM SLEW 360 CONTINUOUS deg
BOOM EXTEND 3000 mm
B0
INNER BEAM EXTEND 4365 mm
840 2036 895 1418 4800 3900
OUTER BEAM EXTEND 3400 mm
LINER CART CAPACITY 2500 kg
13888 B0
DRIVE STYLE 2 WHEEL DRIVE
STEER STYLE 4 WHEEL STEER FULLY RETRACTED
SITE ALTITUDE **3500 m
SITE FREQUENCY **60 Hz DO NOT SCALE
3 PHASE MOTOR VOLTAGE **460 Volts IF IN DOUBT - ASK
This drawing remains the property of
REV Description DWN CHK APD DATE SOUTHERN PERU COPPER CORPORATION 3rd ANGLE PROJECTION U.N.O.
RUSSELL MINERAL EQUIPMENT
PTY LTD and must not be SCALE 1:100 UNO
A4
P0 PRELIMINARY DRAWING - - - -
A0 ISSUED FOR CLIENT APPROVAL BMS AM LO 10/11/16
manufactured from, copied, or
transmitted to a third party without TOQUEPALA Equip #: 293200-LH-001
prior written approval from RUSSELL
B0 UPDATED DIMENSIONS & ADDED EQUIPMENT No. AM SP LO 07/12/16 MINERAL EQUIPMENT PTY LTD RME DRAWING NUMBER REV
- -
Copyright Russell Mineral Equipment RUSSELL 7 MILL RELINING MACHINE
- -
Pty Ltd
TEMPLATE REVISION B0 ELEVATION - WORKING RANGE DIMENSIONS TQAMRM384-VDD01 B0
CLIENT DOCUMENT REVIEW
Please review and return with the following
information completed and return within 10
working days;
1. Approved for Manufacture
C0 C0 C0
FLOOR
75
1278 REAR
1961 FRONT WHEEL CTRS TIEDOWN CTRS
1486 REAR
2261 OS FRONT WHEELS WHEEL CTRS
2880 TIEDOWN CLEARANCE 1786 OS REAR WHEEL
3300 FRONT TIEDOWN CTRS
DO NOT SCALE
IF IN DOUBT - ASK
This drawing remains the property of
REV Description DWN CHK APD DATE SOUTHERN PERU COPPER CORPORATION
3rd ANGLE PROJECTION U.N.O.
RUSSELL MINERAL EQUIPMENT
PTY LTD and must not be SCALE 1:45 UNO
A4
P0 PRELIMINARY DRAWING - - - -
A0 ISSUED FOR CLIENT APPROVAL BMS AM LO 10/11/16
manufactured from, copied, or
transmitted to a third party without TOQUEPALA Equip #: 293200-LH-001
prior written approval from RUSSELL
B0 UPDATED DIMS, ADDED EQUIP No. & VERIFIED MILL DIMS AM SP LO 15/12/16 MINERAL EQUIPMENT PTY LTD RME DRAWING NUMBER REV
C0 UPDATED DIMENSIONS AM BDS BMS 16/01/17
Copyright Russell Mineral Equipment RUSSELL 7 MILL RELINING MACHINE
- -
Pty Ltd
TEMPLATE REVISION B0 END VIEWS - MILL ENTRY DETAILS TQAMRM384-VDD02 C0
4365 5713 B0 ~ CERTIFIED ~
R2875 Russell Mineral Equipment Pty Ltd
Brent Stevenson 19/12/2016
R5875
3300
7600 - MILL DIAMETER I/S SHELL
R4y
R4x R4z
R3y
R3 R4 R3x R3z
24'-11"
R1
R2y
R3
670 ±50 R2x R2z
R1y
41'-7" 4800
12685 MILL LENGTH R2 R1x R1z
(12840 CENTRE TO CENTRE OF END PLATES) 1620 ±25
PLAN VIEW R1
ARCS SHOW MACHINE LIMITS
3728
C0
12284
TRANSPORT AND LIFTING - BOOM REAR
WHEEL REACTIONS DRIVING INTO MILL
BOOM FORWARD AND FULLY RETRACTED R7260 EXTREMITY NOM
(REFER TO DIAGRAM ON VDD01) RNING REAR R7400.5
ONT TU TURN
NOM FR ING E
LOAD 10% CONTACT AREA XTREM
R2848 NOM ITY
(kN) (mm) R1 R3
R1 95 300 x 194 R2956 NOM
R2 95 300 x 194
3700 OA WIDTH
R3 45 300 x 136
R4 45 300 x 136
TRANSPORT WHEEL REACTIONS
BOOM REARWARD
(REFER TO DIAGRAM ON THIS DRAWING)
LOAD 10% CONTACT AREA
(kN) (mm)
R1 81 300 x 184
R2 R4
R2 81 300 x 184
APPROX TURNING CIRCLES - BOOM REAR
R3 59 300 x 149 DO NOT SCALE
R4 59 300 x 149 IF IN DOUBT - ASK
This drawing remains the property of
REV Description DWN CHK APD DATE SOUTHERN PERU COPPER CORPORATION
3rd ANGLE PROJECTION U.N.O.
RUSSELL MINERAL EQUIPMENT
PTY LTD and must not be SCALE 1:85 UNO
A4
P0 PRELIMINARY DRAWING - - - -
A0 ISSUED FOR CLIENT APPROVAL BMS AM LO 10/11/16
manufactured from, copied, or
transmitted to a third party without TOQUEPALA Equip #: 293200-LH-001
prior written approval from RUSSELL
B0 UPDATED DIMS & WHEEL REACTIONS, ADDED EQUIP No. AM SP LO 07/12/16 MINERAL EQUIPMENT PTY LTD RME DRAWING NUMBER REV
C0 UPDATED DIMENSION AM BDS BMS 16/01/17
Copyright Russell Mineral Equipment RUSSELL 7 MILL RELINING MACHINE
- -
Pty Ltd
TEMPLATE REVISION B0 MANOEUVRING AND FLOOR LOADING TQAMRM384-VDD04 C0
TIEDOWN ANCHOR PLATES INSTALLED BY CUSTOMER.
1620 ±25 4800 ±5 PLANT FLOORING MUST BE DESIGNED FOR
MAXIMUM FORCES SHOWN ON VDD 03.
FRONT TIEDOWN REAR TIEDOWN TIEDOWN ANCHOR PLATES WILL BE PAINTED TO
PIN CL LUG CL RME'S STANDARD 3 COAT SYSTEM.
6x 36
FIX WITH
1278 ±5 M30 Gr8.8 BOLTS
REAR TIEDOWN CTRS BOLTS NOT SUPPLIED
2270
50 150 150 50 BY RME
A RAIL CTRS
45
30
REAR TIEDOWN
A PIN CL
500 RECESS
590 STEP
300
200
30 75
TIEDOWN LAYOUT
45 REAR TIEDOWN
PIN CL
PIN REMOVED THIS SIDE
150 4 x 26 HOLES
65 FIX WITH M24 Gr 8.8 BOLTS
PIN CL 65
BOLTS NOT SUPPLIED BY RME STEP FOR COVER PLATE
(COVER SUPPLIED BY RME) 75 DESIGN
60
16 STEP
420
300
MRM FRONT
FRONT TIEDOWN TIEDOWN CL REAR TIEDOWN
ANCHOR PLATE ANCHOR PLATE
SCALE 1:20 1x LH - AS SHOWN +15
1x LH - AS SHOWN 300 1x RH - OPP HAND 200 0
1x RH - OPP HAND SUPPLIED BY RME REAR TIEDOWN
SUPPLIED BY RME JACK PLATE PIN SUPPLIED BY RME TO SUIT MOUNT
25 ALLOWANCE SECTION A-A
268
202
PIN CL
300
289
SHORT FOOT (PREFERRED)
190
LONG FOOT
40 MIN
+38 kN
84 MAX
IN 18 kN.M
65 M
40 MIN
GRAPPLE TOOL CLOSED POSITION GRAPPLE TOOL OPEN POSITION
- -
Pty Ltd 2010
GRAPPLE TOOL INTERFACE REQUIREMENTS GRT-2500-2-VDD01 B0
CoG OFFSET
CoG SHOULD BE
ON OR BELOW
LUG CENTRELINE.
• THE LINER CoG OFFSET IS THE HORIZONTAL DISTANCE FROM THE LUG HOLE CENTRE TO THE
CoG OF THE LINER WHEN HELD IN THE VERTICAL POSITION AS SHOWN.
• LINERS THAT WEIGH LESS THAN THE CAPACITY OF THE GRAPPLE MAY HAVE THE CoG FURTHER
FROM THE CENTRE OF THE LUG. FOR EXAMPLE: USING A 2500kg GRAPPLE, A 2000kg LINER MAY
HAVE THE CoG 250mm AWAY FROM THE CENTRE OF THE LUG.
• RME PROVIDES A LINER INTERFACE CHECK AND REQUEST 3D LINER MODELS BE SUPPLIED.
DO NOT SCALE
IF IN DOUBT - ASK
No. Description DWN CHK APD DATE 3rd ANGLE PROJECTION U.N.O.
-
This drawing remains the property of
RUSSELL MINERAL EQUIPMENT STANDARD 1500kg/2000kg/2500kg SCALE 1:10 UNO
A4
P0 PRELIMINARY DRAWING - - - PTY LTD and must not be
A0 APPROVED FOR CONSTRUCTION AM DH LO 03/10/11 manufactured from, copied, or
transmitted to a third party without
2 PIN GRAPPLE TOOL
B0 UPDATED DRAWING AM DH LO 07/07/15 prior written approval from RUSSELL
RME Drawing Number REV
MINERAL EQUIPMENT PTY LTD
- - - Copyright Russell Mineral Equipment
- - -
Pty Ltd 2010
GRAPPLE RAISE CAPACITY GRT-2500-2-VDD02 B0
LUG CENTRE PLANE
CoG OFFSET
• THE LINER CoG OFFSET IS THE HORIZONTAL DISTANCE FROM THE LUG CENTRE PLANE TO THE
CoG OF THE LINER
• LINERS THAT WEIGH LESS THAN THE CAPACITY OF THE GRAPPLE MAY HAVE THE CoG FURTHER
FROM THE LUG CENTRE PLAN. FOR EXAMPLE: USING A 2500kg GRAPPLE, A 2000kg LINER MAY
HAVE THE CoG 425mm AWAY FROM THE LUG CENTRE PLANE.
• RME PROVIDES A LINER INTERFACE CHECK AND REQUEST 3D LINER MODELS BE SUPPLIED
DO NOT SCALE
IF IN DOUBT - ASK
No. Description DWN CHK APD DATE 3rd ANGLE PROJECTION U.N.O.
-
This drawing remains the property of
RUSSELL MINERAL EQUIPMENT STANDARD 1500kg/2000k/2500kg SCALE 1:20 UNO
A4
P0 PRELIMINARY DRAWING - - - PTY LTD and must not be
A0 APPROVED FOR CONSTRUCTION AM DH LO 03/10/11 manufactured from, copied, or
transmitted to a third party without
2 PIN GRAPPLE TOOL
B0 UPDATED DRAWING AM DH LO 07/07/15 prior written approval from RUSSELL
RME Drawing Number REV
MINERAL EQUIPMENT PTY LTD
- - - Copyright Russell Mineral Equipment
- - -
Pty Ltd 2010
GRAPPLE ROLL CAPACITY GRT-2500-2-VDD03 B0
500
55
200
• FOR LINERS THAT DO NOT ALLOW DIRECT GRAPPLE TOOL INTERFACE WITH LINER
LUGS, 2 x Ø55mm HOLES CAN BE CAST THROUGH TO ALLOW A PULP LIFTER
ADAPTOR TO ENGAGE THE LINER.
• LINER CoG MUST NOT FALL OUTSIDE THE GRAPPLE LIFTING CAPACITY CURVES
(REFER TO FIGURES ON VDD02 & VDD03).
- - -
Pty Ltd 2010
GRAPPLE TOOL PULP LIFTER ADAPTER GRT-2500-2-VDD04 B0
ITEM PART No. QTY TITLE M(kg)ea ITEM QTY
No. PART No. TITLE M(kg)ea
No.
1 12R4798 1 BASEFRAME ARRANGEMENT 3483.7 26 12R4812 1 PACKING GROUP 1175.5
2 12R4118 1 BASEDRIVE GROUP 852.1 27 12R4816 1 PACKING GROUP 614.7
3 11R0219 1 BASEDRIVE GROUP 901.6 28 12R4187 1 PACKING GROUP 812.4
4 12R4823 1 POWERPACK ARRANGEMENT 979.1 29 12R4819 1 LINER INTERFACE GROUP 22.4
5 12R4834 1 ENCLOSURE ARRANGEMENT 69.6 31 12R4839 1 RADIO CONTROL GROUP 13.6
6 12R4828 1 TANK ARRANGEMENT 248.5 32 12R3364 1 REMOTE TRANSPORT CONTROL GROUP 38.1
7 12R4806 1 OUTER BEAM ARRANGEMENT 7649.1 33 12R4840 1 CABLE REELER GROUP 114.9
8 12R4804 1 INNER BEAM ARRANGEMENT 5521.8 34 23R1477 1 LABEL 3.0
9 12R4770 1 LINERCART ARRANGEMENT 972.6 35 10135832 1 LABEL -
10 10R9837 1 LINERCART DRIVE GROUP 57.8 36 10124715 2 LABEL -
11 12R1651 1 TURNTABLE ARRANGEMENT 1054.6 37 01B2268 1 SCREW -
12 12R2363 1 ROTARY UNION GROUP 67.5 38 12R5098 1 JOYSTICK ARRANGEMENT 28.3
13 12R4799 1 BOOM ARRANGEMENT 2792.8 39 12R5456 1 PROXIMITY GROUP 1.2
15 12R4818 1 GRAPPLE ARRANGEMENT 1403.0
16 12R2614 1 GRAPPLE TOOL GROUP 177.7 34 37 36 4 32 8 7 9 10
17 12R4766 1 ADAPTER GROUP 29.8
18 12R4764 1 ENCLOSURE ARRANGEMENT 78.5
19 12R4824 1 CONSOLE ARRANGEMENT 127.7
20 12R4809 1 SEAT ARRANGEMENT 65.5
21 12R1667 1 DUAL SEATING GROUP 18.9
22 12R4825 1 CABINET ARRANGEMENT 82.3
23 12R4810 1 PLATFORM GROUP 600.2
24 12R4811 1 PLATFORM GROUP 584.7
25 10106188 7 LIGHT GROUP 4.1
19 38 20 13 17 18 11 22 24
27
33
31 2 28 1 23 6 36 5 35
29 16 15 25 39 21 8 12 26
EXPLODED ISOMETRIC VIEW
- - - - - - - - SCALE 1:60 UNO 3rd ANGLE PROJECTION U.N.O. A3
- - - - MASS: 30671.4kg RUSSELL 7 MILL RELINING DRAWING STATUS
- - - - DO NOT SCALE DESIGN JLP 26/09/2016
- - - - MACHINE RELEASED
- - - -
IF IN DOUBT- ASK DRAWN JLP 05/12/16 TQAMRM384 RUSSELL 7 2500kg RT4x2
RME DRAWING NUMBER REV
- - - - This drawing remains the property of RUSSELL
28524
MINERAL EQUIPMENT PTY LTD and must not be CHECK BAS 05/12/16
B0
B0 ITEM 30 REPLACED BY ITEM 38, ITEM 14 REPLACED BY ITEM 39 WS SP BDS 22/02/17 2 manufactured from, copied, or transmitted to a third party
- A0 APPROVED FOR CONSTRUCTION AS PER APPROVAL without prior written approval from RUSSELL MINERAL
APP'D LO 6/12/2016 SHEET 1 of 2 12R4751 VER
CODE
50
20
20
146
6
12
LOCATE SYMMETRIC
106 ABOUT THE CL
36 34
512
LABEL ITEMS
- - - - - - - - SCALE 1:7.5 UNO 3rd ANGLE PROJECTION U.N.O. A3
- - - - MASS: 30671.4kg RUSSELL 7 MILL RELINING DRAWING STATUS
- - - - DO NOT SCALE DESIGN JLP 26/09/2016
- - - - MACHINE RELEASED
- - - -
IF IN DOUBT- ASK DRAWN JLP 05/12/16 TQAMRM384 RUSSELL 7 2500kg RT4x2
RME DRAWING NUMBER REV
- - - - This drawing remains the property of RUSSELL
28524
MINERAL EQUIPMENT PTY LTD and must not be CHECK BAS 05/12/16
B0
B0 ITEM 30 REPLACED BY ITEM 38, ITEM 14 REPLACED BY ITEM 39 WS SP BDS 22/02/17 2 manufactured from, copied, or transmitted to a third party
- A0 APPROVED FOR CONSTRUCTION AS PER APPROVAL without prior written approval from RUSSELL MINERAL
APP'D LO 6/12/2016 SHEET 2 of 2 12R4751 VER
CODE
100
6
5
REAR VIEW
670
120
10
2 9
85
4 2
3 8
7
EXPLODED
ISOMETRIC VIEW FRONT VIEW
SCALE 1:35
10
10
8 8
20
TOP VIEW
CROPPED
40
SCALE 1:10
DETAIL A
SCALE 1 : 5 DETAIL B
SCALE 1 : 5
A B
LABEL ITEMS
- - - - - - - - SCALE 1:20 UNO 3rd ANGLE PROJECTION U.N.O. A3
- - - - MASS: 3527.8kg BASEFRAME ARRANGEMENT DRAWING STATUS
- - - - DO NOT SCALE DESIGN NB 23/11/16
- - - -
IF IN DOUBT- ASK
RELEASED
- - - - DRAWN KKS 28/11/16 0823 PIN 4x2 ES/EN
RME DRAWING NUMBER REV
- - - - This drawing remains the property of RUSSELL
- -
MINERAL EQUIPMENT PTY LTD and must not be CHECK SP 28/11/16
A0
- - manufactured from, copied, or transmitted to a third party
- A0 APPROVED FOR CONSTRUCTION AS PER APPROVAL without prior written approval from RUSSELL MINERAL
APP'D LO 28/11/16 SHEET 2 of 2 12R4798 VER
CODE
ISOMETRIC VIEW
37
19
62 50 50 63 61 59 60
21
8 9 12
17
10 11
27 36 35
58 13 14 15
56 57
28 29
68
45 23 30 49 48 24
53 46
47 41 43 2
30 68
70
3
1 2
43 41 42 46 44
31
TORQUE TO 914 N.m.
34
33 32
56 57
40 38 39
51 46
TORQUE TO 1300 N.m.
67 66 65 7
TORQUE TO 640 N.m. 6
5
4
TOP VIEW
CROPPED
EXPLODED ISOMETRIC VIEW SCALE 1:10
- - - - - - - - SCALE 1:25 UNO 3rd ANGLE PROJECTION U.N.O. A3
- - - - MASS: 3514.4kg BASEFRAME GROUP DRAWING STATUS
- - - - DO NOT SCALE DESIGN NB 23/11/16
- - - -
IF IN DOUBT- ASK
RELEASED
- - - - DRAWN KKS 25/11/16 0823 PIN 4x2
RME DRAWING NUMBER REV
- - - - This drawing remains the property of RUSSELL
- -
MINERAL EQUIPMENT PTY LTD and must not be CHECK SP 28/11/16
A0
- - manufactured from, copied, or transmitted to a third party
- A0 APPROVED FOR CONSTRUCTION AS PER APPROVAL without prior written approval from RUSSELL MINERAL
APP'D LO 28/11/16 SHEET 2 of 2 12R4797 VER
CODE
ISOMETRIC VIEW
137 2548
56
FRONT VIEW
LEFT SIDE VIEW CHAIN PITCH = 91mm
5 3
4 1 2
2 1
2
1 7
ISOMETRIC VIEW
7 3 6 2
10104654
CONTACT ARRANGEMENT
AS VIEWED FROM TERMINATION SIDE
BROKEN OUT SECTION
2 3
ISOMETRIC VIEW
25
23
18
19
2 2
17
11
13 1 7
13 16
30 27 14
12 14
29 31 9 22
24
16
20 21 28
8
17
16 15
5 10
3
25
26
15 3 SECTION C-C
26 25 19
4 STEERING LINK ASSEMBLY DETAILS
23
6 2
7 15 10
18
1
17
30
17
16 30
29
20
28
SECTION B-B
21 CYLINDER ASSEMBLY DETAILS
24
16
17 C C
17
B
25
26 5 16 8 A A
PLAN VIEW
SCALE 1:10
SECTION A-A
NOTE: SEAL KIT SUPPLIED WITH HYDRAULIC MOTOR TO BE FITTED ON ASSEMBLY WHEEL ASSEMBLY DETAILS
- - - - - - - - SCALE 1:5 UNO 3rd ANGLE PROJECTION U.N.O. A3
- - - - MASS: 852.1kg BASEDRIVE GROUP DRAWING STATUS
- - - - DO NOT SCALE DESIGN NB 06/06/16
- - - -
IF IN DOUBT- ASK
RELEASED
- - - - DRAWN NB 06/06/16 BSD DRIVEN 113kN Ø830
RME DRAWING NUMBER REV
- - - - This drawing remains the property of RUSSELL
28333 B0
MINERAL EQUIPMENT PTY LTD and must not be CHECK AM 15/06/16
B0
REMOVED 1x ITEM 15: QTY NOW 3, WAS 4 NB SP BDS 28/11/16 1 manufactured from, copied, or transmitted to a third party
- A0 APPROVED FOR CONSTRUCTION AS PER APPROVAL without prior written approval from RUSSELL MINERAL
APP'D SDL 11/07/16 SHEET 3 of 3 12R4118 VER
CODE
2
3
17
7
6
21
EXPLODED
ISOMETRIC VIEW
ISOMETRIC VIEW
SECTION A-A 3 9 18 19
SCALE 1 : 10 16 18 9 3 20 SECTION C-C
SCALE 1 : 10
SECTION B-B
22 18 13 12
16
17
A
1
4 D D
1
C
7 A C
17
6
B B
8 16 PLAN VIEW
SCALE 1:10
SECTION D-D
- - SCALE 1:5 UNO 3rd ANGLE PROJECTION U.N.O. A3
- - - - RME Underground Pty Ltd MASS: 901.6kg BASEDRIVE GROUP DRAWING STATUS
- - - - ACN 098 444 332
DO NOT SCALE DESIGN JMT 2/04/2012
- - - - 149 Hursley Road, Glenvale, Toowoomba IF IN DOUBT- ASK
RELEASED
- - - - DRAWN JMT 02/04/12 BSD NON-DRIVEN 100kN
PO Box 100 RME DRAWING NUMBER REV
- - - - This drawing remains the property of RME
26406
TOOWOOMBA QLD 4350 UNDERGROUND PTY LTD and must not be CHECK MTM 10/04/12
B0
B0 ADDED ITEM 23 NB SP SDL 13/03/17 1 AUSTRALIA manufactured from, copied, or transmitted to a third party
- A0 APPROVED FOR CONSTRUCTION AS PER APPROVAL without prior written approval from RME
APP'D AJL 11/04/2012 SHEET 2 of 2 11R0219 VER
CODE
ISOMETRIC VIEW
REAR ISOMETRIC VIEW
39
38
38
41
29
42
36
35
37
39
19
8
40 5 2
18
12
17
1
25
23
22
1
10
PLACED ONTO ELECTRICAL
ENCLOSURE COVER
10
CENTRED WITH BUTTON 20 45
17
18
25
30
30 FRONT VIEW
90
70
28
29
PLACE CENTRED
ON FLAT FACE 43 PLACE ON TOP 24
OF MOTOR
42
PLACE CENTRED
26 ON FLAT FACE
FRONT VIEW
COVERS REMOVED LABEL DETAIL
- - - - - - - - SCALE 1:10 UNO 3rd ANGLE PROJECTION U.N.O. A3
- - - - MASS: 1084.8kg POWERPACK ARRANGEMENT DRAWING STATUS
- - - - DO NOT SCALE DESIGN BAS 01/12/16
- - - -
IF IN DOUBT- ASK
RELEASED
- - - - DRAWN KKS 05/12/16 HYP 37kW 225S/M 100/44cc BEA 125/80
ES/EN RME DRAWING NUMBER REV
- - - - This drawing remains the property of RUSSELL
- -
MINERAL EQUIPMENT PTY LTD and must not be CHECK BAS 05/12/16
A0
- - manufactured from, copied, or transmitted to a third party
- A0 APPROVED FOR CONSTRUCTION AS PER APPROVAL without prior written approval from RUSSELL MINERAL
APP'D BDS 05/12/16 SHEET 3 of 3 12R4823 VER
CODE
12
13
14
ISOMETRIC VIEW
SCALE 1:20
- - - - - - - - SCALE 1:20 UNO 3rd ANGLE PROJECTION U.N.O. A3
- - - - MASS: 251.6kg FRAME GROUP DRAWING STATUS
- - - - DO NOT SCALE DESIGN BAS 29/11/16
- - - -
IF IN DOUBT- ASK
RELEASED
- - - - DRAWN KKS 1/12/2016 HYP POWERPACK
RME DRAWING NUMBER REV
- - - - This drawing remains the property of RUSSELL
28850
MINERAL EQUIPMENT PTY LTD and must not be CHECK SP 1/12/2016
B0
B0 IT 3 REP BY IT 40; IT 20 REP BY IT 41; QTY IT's 22 & 23 REDUCED; ITEMS 41 & 42 ADDED SL SP SDL 20/04/2017 2 manufactured from, copied, or transmitted to a third party
- A0 APPROVED FOR CONSTRUCTION AS PER APPROVAL without prior written approval from RUSSELL MINERAL
APP'D BDS 05/12/16 SHEET 1 of 2 12R4822 VER
CODE
42
23
6
5
8 22
28
32
27 30
6 40
19
32
27 21
9
37
36 2
22
6
7 4
32
41
27
DETAIL B
SCALE 1 : 5
DETAIL A
SCALE 1 : 5
14
16
15
4
13
11
7
ISOMETRIC VIEW
2
15
19
15
14
10
8
9
8
10
9
8 8
9
8
9
8 EXPLODED ISOMETRIC VIEW
ISOMETRIC VIEW 63
10
TO CLEAR
TE
LOCK PLA
14
8 9 8 9 8
11
26
29 17
21
19 5
18 3 16
28 21
4
23
6
14
7 8 9
15
13
3
ISOMETRIC VIEW
SCALE 1:2
6
POSITION ON ASSEMBLY
8
5
10
20
(DOOR OPEN)
ALIGN WITH
ISOLATOR 7 6 ALIGN WITH BUTTONS
50
50
ISOMETRIC VIEW
FRONT VIEW RIGHT SIDE VIEW
- - - - - - - - SCALE 1:12.5 UNO 3rd ANGLE PROJECTION U.N.O. A3
- - - - MASS: 69.6kg ENCLOSURE ARRANGEMENT DRAWING STATUS
- - - - DO NOT SCALE DESIGN BAS 05/12/16
- - - -
IF IN DOUBT- ASK
RELEASED
- - - - DRAWN BAS 05/12/16 480V 60Hz 37kW ES/EN
RME DRAWING NUMBER REV
- - - - This drawing remains the property of RUSSELL
- -
MINERAL EQUIPMENT PTY LTD and must not be CHECK SP 05/12/16
A0
- - manufactured from, copied, or transmitted to a third party
- A0 APPROVED FOR CONSTRUCTION AS PER APPROVAL without prior written approval from RUSSELL MINERAL
APP'D DD 05/12/16 SHEET 1 of 1 12R4834 VER
CODE
ISOMETRIC VIEW
1 22 11
22
10
12 13
17
31 49 40
49
28
27
47 48
2
26
33
3 41 34 40 39
46
47
36 37 37 43 30
32
29 43 37 37 36
38 37 37 36
35 EXPLODED ISOMETRIC VIEW
- - - - - - - - SCALE 1:7.5 UNO 3rd ANGLE PROJECTION U.N.O. A3
- - - - MASS: 62.4kg ENCLOSURE GROUP DRAWING STATUS
- - - - DO NOT SCALE DESIGN BAS 01/12/16
- - - -
IF IN DOUBT- ASK
RELEASED
- - - - DRAWN KKS 01/12/16 HYP MRM RUSSELL 7/8 UL
RME DRAWING NUMBER REV
- - - - This drawing remains the property of RUSSELL
- -
MINERAL EQUIPMENT PTY LTD and must not be CHECK SP 02/12/16
A0
- - manufactured from, copied, or transmitted to a third party
- A0 APPROVED FOR CONSTRUCTION AS PER APPROVAL without prior written approval from RUSSELL MINERAL
APP'D DD 02/12/16 SHEET 2 of 3 12R4833 VER
CODE
ISOMETRIC VIEW
17
15
4
11
1
3 16
6
5
7
13
14 8
13
14
13
12 14
13
12
14
9 12
11
12
9
11
9
11
9
11
10
45
13 10101881 1 LABEL -
14 10105385 1 LABEL -
15 31R6945 1 ENCLOSURE 0.7
16 10104013 1 LOCKNUT -
17 10102012 1 FITTING 0.1
18 10101998 1 FITTING 0.1 5
19 10100688 2 GLAND -
20 01B1374 2 SCREW - 9
21 01B1045 4 WASHER - CROPPED REAR VIEW
22 01B0952 4 SCREW - SCALE 1:7.5
23 03B2026 2 ELBOW 0.1
70
45
40 TYP
12 4
170
280
482
3
7 50
63.5
23
15
13
210.5
17
10
18 21
16
22 7
26
3
10
14
20
20
19
11
45
13 45 14
20
375
11
EXPLODED ISOMETRIC VIEW CROPPED LEFT SIDE VIEW CROPPED FRONT VIEW
SCALE 1:20
LABEL ITEMS
- - - - - - - - SCALE 1:10 UNO 3rd ANGLE PROJECTION U.N.O. A3
- - - - MASS: 248.4kg TANK ARRANGEMENT DRAWING STATUS
- - - - DO NOT SCALE DESIGN BAS 21/09/16
- - - -
IF IN DOUBT- ASK
RELEASED
- - - - DRAWN KKS 01/12/16 HYP OK-EL5S 380-415/50Hz 440-480/60Hz 167L
RUSSELL 7 ES/EN RME DRAWING NUMBER REV
- - - - This drawing remains the property of RUSSELL
- -
MINERAL EQUIPMENT PTY LTD and must not be CHECK SP 01/12/16
A0
- - manufactured from, copied, or transmitted to a third party
- A0 APPROVED FOR CONSTRUCTION AS PER APPROVAL without prior written approval from RUSSELL MINERAL
APP'D DD 02/12/16 SHEET 1 of 2 12R4828 VER
CODE
2 3
11
14
15
20
10
19
13
16
A
17
18
ISOMETRIC VIEW
SCALE 1:20
COVER ITEMS
- - - - - - - - SCALE 1:12.5 UNO 3rd ANGLE PROJECTION U.N.O. A3
- - - - MASS: 207.2kg TANK GROUP DRAWING STATUS
- - - - DO NOT SCALE DESIGN BAS 13/10/16
- - - -
IF IN DOUBT- ASK
RELEASED
- - - - DRAWN KKS 14/10/16 HYP 167L RUSSELL 7
RME DRAWING NUMBER REV
- - - - This drawing remains the property of RUSSELL
- -
MINERAL EQUIPMENT PTY LTD and must not be CHECK SP 17/10/16
A0
- - manufactured from, copied, or transmitted to a third party
- A0 APPROVED FOR CONSTRUCTION AS PER APPROVAL without prior written approval from RUSSELL MINERAL
APP'D BDS 20/10/16 SHEET 1 of 2 12R4588 VER
CODE
35
6
20 19 21 22
5
26 12 12 12 12 12 10
34 27
33
INSIDE 28
12
30
11
29
12 36
9 35
4 13 11
10
39 3
CROPPED LEFT SIDE
SCALE 1:5
2
37
38
8 35 12
31
32
17 41
15
16 40 13
18 1
42 CROPPED REAR VIEW
11
13 SCALE 1:5
25 24 23
14
245 TYP 4
2
384 TYP
300
10
3
REAR VIEW
LEFT SIDE VIEW
59
45
60
31
27 61
3
62
26 57
48
B
41 40 44
46 2
47
30
1 49 50 31
48
48 33
69
8
63 46
46 47 25 32 52 53
48 52 54 45
38
A 34 39 47 46 48 47 46
2
79
48 47 46 80
C
82
81
32
35 71
20 22
70
21
50
49
11
9
3
41 DETAIL B
40
51 67
44
29
24
60 59
76
83 75
12
29 69
51 MAX NO. OF SHIMS IN 62
THIS RETAINER IS 5
45
23 36
48 47 46
19
15 14 13 59 60 68
42
73
16 DETAIL A
66
DETAIL C
1 5
26
22
21
23
1 20
13
12 18
A 16
17
14
25 7 9 10
15
5
8
4
11
24 DETAIL A
2 3
EXPLODED ISOMETRIC VIEW SCALE 1 : 10
41
87
18
200
21
49
86
33
5 8 4 2 3
LABEL ITEMS
- - - - - - - - SCALE 1:5 UNO 3rd ANGLE PROJECTION U.N.O. A3
- - - - MASS: 5521.8kg INNER BEAM ARRANGEMENT DRAWING STATUS
- - - - DO NOT SCALE DESIGN SRM 24/11/16
- - - -
IF IN DOUBT- ASK
RELEASED
- - - - DRAWN SRM 24/11/2016 BEA 0823 MID LONG ES/EN
RME DRAWING NUMBER REV
- - - - This drawing remains the property of RUSSELL
28779
MINERAL EQUIPMENT PTY LTD and must not be CHECK SP 28/11/2016
B0
B0 REPLACED ITEM 6 WITH ITEM 25 SRM SP SDL 31/03/2017 1 manufactured from, copied, or transmitted to a third party
- A0 APPROVED FOR CONSTRUCTION AS PER APPROVAL without prior written approval from RUSSELL MINERAL
APP'D LO 28/11/16 SHEET 2 of 2 12R4804 VER
CODE
10 3
29
26
24
5 27
23
13 28
23
24
20
25 23
19
15 12
4 11
12
1
14 1 10
6 DETAIL A 9
7 17
16
8
DETAIL B
ISOMETRIC VIEW
SCALE 1:15
125
56
2269.7
1
6
MARK CABLE WITH ITEM NUMBER
"12R4152 - 1 OF 2" 5
USING HEATSHRINK LABEL "08B1584"
COVER WITH CLEAR
HEATSHRINK "10131562"
3
10102830 10104654
CONTACT ARRANGEMENT CONTACT ARRANGEMENT
AS VIEWED FROM TERMINATION SIDE AS VIEWED FROM TERMINATION SIDE
BROKEN OUT SECTION BROKEN OUT SECTION
4 3
1 3
CABLE TERMINATION SCHEDULE
Cable Core No. Pin No. of Male
1 1
2 2 PE
3 3
4 4 4 6
5 5
6 6
green / yellow PE
10117444
TERMINATE GREEN / YELLOW EARTH CONDUCTOR
AT PE TERMINAL CONTACT ARRANGEMENT
AS VIEWED FROM TERMINATION SIDE
BROKEN OUT SECTION
2 3 1
4
4
2 3
4
1
28
6 5
36
23
10
12
11 33
25 21
11 35
12 34
10 26 8
9 27 7
EXPLODED ISOMETRIC VIEW
- - - - - - - - SCALE 1:12.5 UNO 3rd ANGLE PROJECTION U.N.O. A3
- - - - MASS: 972.4kg LINERCART GROUP DRAWING STATUS
- - - - DO NOT SCALE DESIGN SP 20/05/14
- - - -
IF IN DOUBT- ASK
RELEASED
- - - - DRAWN SP 27/05/14 LCA 4500kg 0823
RME DRAWING NUMBER REV
27072 C0 REPLACED ITEM 30 WITH ITEM 39 SL AM LO 11/08/15 2 This drawing remains the property of RUSSELL
26421 B0
MINERAL EQUIPMENT PTY LTD and must not be CHECK BAS 27/05/14
C0
REPLACED ITEM 29 WITH ITEM 38 SP BAS OF 7/10/14 1 manufactured from, copied, or transmitted to a third party
- A0 APPROVED FOR CONSTRUCTION AS PER APPROVAL without prior written approval from RUSSELL MINERAL
APP'D OF 03/06/14 SHEET 1 of 1 12R1618 VER
CODE
ISOMETRIC VIEW
18
20
23 1 7
16
8 6
1 3 5 4 2
ISOMETRIC VIEW
SCALE 1:20
TOP VIEW
2 3 5 4
FRONT VIEW
LABEL ITEMS
- - - - - - - - SCALE 1:10 UNO 3rd ANGLE PROJECTION U.N.O. A3
- - - - MASS: 1054.6kg TURNTABLE ARRANGEMENT DRAWING STATUS
- - - - DO NOT SCALE DESIGN BDS 26/05/14
- - - -
IF IN DOUBT- ASK
RELEASED
- - - - DRAWN SC 30/05/14 TTU 4 0823
RME DRAWING NUMBER REV
- - - - This drawing remains the property of RUSSELL
-
MINERAL EQUIPMENT PTY LTD and must not be CHECK SP 05/06/14
A0
- - - manufactured from, copied, or transmitted to a third party
- A0 APPROVED FOR CONSTRUCTION AS PER APPROVAL without prior written approval from RUSSELL MINERAL
APP'D BDS 05/06/14 SHEET 1 of 1 12R1651 VER
CODE
10
TORQUE TO 528N.m
9
14
8
25
11
35 27
7 12
25 29
19
12
14
ISOMETRIC VIEW
19
SCALE 1:20
TORQUE TO 528N.m EXPLODED ISOMETRIC VIEW
- - - - - - - - SCALE 1:10 UNO 3rd ANGLE PROJECTION U.N.O. A3
- - - - MASS: 1054.0kg TURNTABLE GROUP DRAWING STATUS
- - - - DO NOT SCALE DESIGN BDS 26/05/14
- - - -
IF IN DOUBT- ASK
RELEASED
- - - - DRAWN SC 30/05/14 TTU 4 0823
RME DRAWING NUMBER REV
- - - - This drawing remains the property of RUSSELL
-
MINERAL EQUIPMENT PTY LTD and must not be CHECK SP 03/06/14
A0
- - - manufactured from, copied, or transmitted to a third party
- A0 APPROVED FOR CONSTRUCTION AS PER APPROVAL without prior written approval from RUSSELL MINERAL
APP'D OF 04/06/14 SHEET 1 of 1 12R1650 VER
CODE
INSTALL THIS
SIDE FACING
TOWARDS THE
GRAPPLE
ASSEMBLED VIEW
6
2
10
4
5
0.5
3±
9 6
2 7
FRONT VIEW
10
SECTION A-A
SCALE 1 : 2
ISOMETRIC VIEW
9 17
7
10
9
6
10
9 20
10 42
5 13
9 22
10 28
9 21 19
18
10
2
12
9 19
4
10
35 33 34 36
3 16
41
1
37 34 33 39 38 40 REUSE
15 27 ORIGINAL
FASTENERS
30
32 30
31 32 23
14 32
8
34
EXPLODED ISOMETRIC VIEW
24 25
42
12
27
16 5
35
6 4
A
10
2
9
10
23
9
10
9
A 10
9
10
TOP VIEW
9
32
32 30 1
24 SECTION A-A 24
SCALE 1 : 2
- - SCALE 1:5 UNO 3rd ANGLE PROJECTION U.N.O. A3
- - - - MASS: 64.8kg ROTARY UNION GROUP DRAWING STATUS
- - - - DO NOT SCALE DESIGN ARC 08/09/11
28630 E0 ITEM 11 REPLACED BY ITEM 42 WS SP JLP 24/03/17 -
IF IN DOUBT- ASK
RELEASED
19302 D0 RPLACE ITEM 26 WITH 41 JLP MTM RH 06/12/12 2 DRAWN ARC 08/09/11 TRU 9-PORT
RME DRAWING NUMBER REV
18477 C0 ADDED ITEMS 36 - 40, INCREASED QTY OF ITEMS 33 & 34 BY 1 HK MTM HK 25/10/12 2 This drawing remains the property of RUSSELL
15418
MINERAL EQUIPMENT PTY LTD and must not be CHECK SJF 09/09/11
E0
B0 REMOVED ITEM 29 & ADDED ITEMS 30 - 35 HK MTM HK 23/08/12 2 manufactured from, copied, or transmitted to a third party
- A0 APPROVED FOR CONSTRUCTION AS PER APPROVAL without prior written approval from RUSSELL MINERAL
APP'D ARC 16/09/11 SHEET 3 of 3 11R0201 VER
CODE
1 3
3
105
13
4
90
210.5
2 70
2
4
3
RIGHT SIDE VIEW
4
1 3
108 240
1 2
85
194
210.5
70 2
4
LABELS DETAIL
- - - - - - - - SCALE 1:17.5 UNO 3rd ANGLE PROJECTION U.N.O. A3
- - - - MASS: 2792.0kg BOOM ARRANGEMENT DRAWING STATUS
- - - - DO NOT SCALE DESIGN DSS 01/12/16
- - - -
IF IN DOUBT- ASK
RELEASED
- - - - DRAWN DSS 01/12/16 BMA 2 3000-1800-4-3 2500kg ES/EN
RME DRAWING NUMBER REV
- - - - This drawing remains the property of RUSSELL
- -
MINERAL EQUIPMENT PTY LTD and must not be CHECK SP 01/12/16
A0
- - manufactured from, copied, or transmitted to a third party
- A0 APPROVED FOR CONSTRUCTION AS PER APPROVAL without prior written approval from RUSSELL MINERAL
APP'D LO 01/12/16 SHEET 1 of 2 12R4799 VER
CODE
10
9
8
11
7
8
11
9
10
5
6
DETAIL A
SCALE 1 : 5
ELECTRICAL DETAIL
- - - - - - - - SCALE 1:15 UNO 3rd ANGLE PROJECTION U.N.O. A3
- - - - MASS: 2792.0kg BOOM ARRANGEMENT DRAWING STATUS
- - - - DO NOT SCALE DESIGN DSS 01/12/16
- - - -
IF IN DOUBT- ASK
RELEASED
- - - - DRAWN DSS 01/12/16 BMA 2 3000-1800-4-3 2500kg ES/EN
RME DRAWING NUMBER REV
- - - - This drawing remains the property of RUSSELL
- -
MINERAL EQUIPMENT PTY LTD and must not be CHECK SP 01/12/16
A0
- - manufactured from, copied, or transmitted to a third party
- A0 APPROVED FOR CONSTRUCTION AS PER APPROVAL without prior written approval from RUSSELL MINERAL
APP'D LO 01/12/16 SHEET 2 of 2 12R4799 VER
CODE
34 35
4 31
32
36
31
36
1 15
14
47
28
46
44 7
6
13 12 37
3 45
27
33
38
39
49
48
5 41
25 26
11
26
10 20
25
43 17
9 31
32
43
8 30 29 23 40
31 32 48
21 19
20 17 31 32 48
42 22 48 18 24 29
EXPLODED ISOMETRIC VIEW
- - - - - - - - SCALE 1:10 UNO 3rd ANGLE PROJECTION U.N.O. A3
- - - - MASS: 1077.2kg OUTER BOOM GROUP DRAWING STATUS
- - - - DO NOT SCALE DESIGN BJ 19/05/14
- - - -
IF IN DOUBT- ASK
RELEASED
- - - - DRAWN BJ 19/05/14 BMA 2 3000-1800-4
RME DRAWING NUMBER REV
- - - - This drawing remains the property of RUSSELL
27990 B0
MINERAL EQUIPMENT PTY LTD and must not be CHECK BAS 21/05/14
B0
ITEM 16 HOSE COVER REPLACED WITH ITEM 49 DSS SP LO 23/11/16 - manufactured from, copied, or transmitted to a third party
- A0 APPROVED FOR CONSTRUCTION AS PER APPROVAL without prior written approval from RUSSELL MINERAL
APP'D OF 03/06/14 SHEET 2 of 2 12R1589 VER
CODE
23
23
10
11 18
13
12 29
22
15
29
19
3 27 20 2 28 29
14
9
23
14
8 2 13 12
TORQUE TO 650 Nm 10 9
15
1
11
1 7 6 5
ISOMETRIC VIEW
7 4 3
2
4
5
10 9
8
10
1
10
6 8
13
7
3 12 4 5
11 10
17
22
16
10
6
9
12 13
3
ISOMETRIC VIEW
SCALE 1:15 1
ISOMETRIC VIEW
2375 OA
2211
123
45
12 3 15 20 21 13 6 7 24 27
29
28
26
46.5 TYP
BOTH SIDES
120 51.5 TYP
45 TYP
57
1
40
27
92
25
26
24
RIGHT SIDE VIEW
27
296
1
20
29
28 25
26
FRONT VIEW
LABELS DETAIL
- - - - - - - - SCALE 1:10 UNO 3rd ANGLE PROJECTION U.N.O. A3
- - - - MASS: 1402.4kg GRAPPLE ARRANGEMENT DRAWING STATUS
- - - - DO NOT SCALE DESIGN AM 28/11/16
- - - -
IF IN DOUBT- ASK
RELEASED
- - - - DRAWN AM 28/11/16 GRP RUSSELL 7 2500kg DC ES/EN
RME DRAWING NUMBER REV
- - - - This drawing remains the property of RUSSELL
- -
MINERAL EQUIPMENT PTY LTD and must not be CHECK SP 29/11/16
A0
- - manufactured from, copied, or transmitted to a third party
- A0 APPROVED FOR CONSTRUCTION AS PER APPROVAL without prior written approval from RUSSELL MINERAL
APP'D LO 30/11/16 SHEET 2 of 3 12R4818 VER
CODE
14
10
11
A
5
22
17
18
23 9
19
8
3
4
15 2
12
3 16 6 21 20 13 7
DETAIL A
SCALE 1 : 5
ELECTRICAL DETAIL
- - - - - - - - SCALE 1:20 UNO 3rd ANGLE PROJECTION U.N.O. A3
- - - - MASS: 1402.4kg GRAPPLE ARRANGEMENT DRAWING STATUS
- - - - DO NOT SCALE DESIGN AM 28/11/16
- - - -
IF IN DOUBT- ASK
RELEASED
- - - - DRAWN AM 28/11/16 GRP RUSSELL 7 2500kg DC ES/EN
RME DRAWING NUMBER REV
- - - - This drawing remains the property of RUSSELL
- -
MINERAL EQUIPMENT PTY LTD and must not be CHECK SP 29/11/16
A0
- - manufactured from, copied, or transmitted to a third party
- A0 APPROVED FOR CONSTRUCTION AS PER APPROVAL without prior written approval from RUSSELL MINERAL
APP'D LO 30/11/16 SHEET 3 of 3 12R4818 VER
CODE
ISOMETRIC VIEW
30
21
13
21 9 20
17
17
19 18
16
26 15
2
ISOMETRIC VIEW
SCALE 1:10
3 5
7
22 9 20
19 18 13
17 EXPLODED ISOMETRIC VIEW
23
- - - - - - - - SCALE 1:7.5 UNO 3rd ANGLE PROJECTION U.N.O. A3
- - - - MASS: 177.7kg GRAPPLE TOOL GROUP DRAWING STATUS
- - - - DO NOT SCALE DESIGN BJ 11/02/15
- - - -
IF IN DOUBT- ASK
RELEASED
- - - - DRAWN BAS 11/02/15 GRT 2 2500kg
RME DRAWING NUMBER REV
- - - - This drawing remains the property of RUSSELL
-
MINERAL EQUIPMENT PTY LTD and must not be CHECK SP 11/02/15
A0
- - - manufactured from, copied, or transmitted to a third party
- A0 APPROVED FOR CONSTRUCTION AS PER APPROVAL without prior written approval from RUSSELL MINERAL
APP'D BMS 11/02/15 SHEET 1 of 1 12R2614 VER
CODE
3
1
2
7
2 1
11 12 12 13
9 10
5 4
7
1
17 16
18 15
39
32 33 35 33 34
38
40 36
6
41
36 18
37
29
30 31
48
10
9
47 47
50
49
48 8
12
11 56
46 56 50 50
50
51 55 53
46 13
45 50
42 14 51 54 51
9 8 7 42 54 51 54
53 51
51 52
44
BUTTON PANEL REAR
PICTORIAL EXPLODED VIEW
BUTTON PANEL
10 ISOMETRIC EXPLODED VIEW
12
13
11
14
36
36
37 16 17
29
15
22 22 19 19 24 24 24 24 58 27 27 58 19 22
23 23 19 19 25 25 25 25 24 28 28 24 20 23
26 26 26 26 26 26 26 26 21
23
RIGHT SIDE VIEW REAR VIEW
2
6
10
3
101
7
3
28
621
LOCATION OF LABELS
- - - - - - - - SCALE 1:5 UNO 3rd ANGLE PROJECTION U.N.O. A3
- - - - MASS: 78.5kg ENCLOSURE ARRANGEMENT DRAWING STATUS
- - - - DO NOT SCALE DESIGN DSS 22/11/16
- - - -
IF IN DOUBT- ASK
RELEASED
- - - - DRAWN DSS 29/11/16 COT JBOX2 PENDANT TURNTABLE 4 JOYSTICK
LIGHT RME DRAWING NUMBER REV
- - - - This drawing remains the property of RUSSELL
- -
MINERAL EQUIPMENT PTY LTD and must not be CHECK SP 01/12/16
A0
- - manufactured from, copied, or transmitted to a third party
- A0 APPROVED FOR CONSTRUCTION AS PER APPROVAL without prior written approval from RUSSELL MINERAL
APP'D DD 02/12/16 SHEET 5 of 5 12R4764 VER
CODE
13
11
14
5
2
9
12
10
6
EXPLODED ISOMETRIC VIEW
8
ISOMETRIC VIEW 7
9 10 11
4
6
5 8 2
7
1
25
VIEW A
4
27.6
20
30
30.1
6 5
97
167
22 23 17
24 17
15 14 8
13
12
26 16
3
1
15
20 21 21 20
10
18
20
19
9
9
11
15
9 10
26 22 23 21 13 12 14
ISOMETRIC VIEW
11 10 8 9
4 6 7 5
10
9 4
7
6
11
12
ISOMETRIC VIEW
8 1
3
EXPLODED ISOMETRIC VIEW
5
ISOMETRIC VIEW 7
SCALE 1:5
18
21
20
9 ISOMETRIC VIEW
SCALE 1:10
2
2
3
5
5
11
10 6 1
ISOMETRIC VIEW
SCALE 1:10
12
9
10
11
4
8
1
2
6
5
15
16
13 12
14
3
9
POSITION LABEL 15
CENTRALLY
120
ON THIS FACE
36
3 9
7
RIGHT SIDE VIEW RIGHT SIDE VIEW
CABINET SHOWN WITH COVER REMOVED
LABEL ITEMS
- - - - - - - - SCALE 1:7.5 UNO 3rd ANGLE PROJECTION U.N.O. A3
- - - - - - - - MASS: 82.3kg CABINET ARRANGEMENT DRAWING STATUS
- - - - - - - - DO NOT SCALE DESIGN DSS 29/11/16
- - - - - - - -
IF IN DOUBT- ASK
RELEASED
- - - - - - - - DRAWN DSS 29/11/16 COT 4/6
RME DRAWING NUMBER REV
- - - - - - - - This drawing remains the property of RUSSELL
- -
MINERAL EQUIPMENT PTY LTD and must not be CHECK SP 30/11/16
A0
- - - - - - manufactured from, copied, or transmitted to a third party
- A0 APPROVED FOR CONSTRUCTION AS PER APPROVAL without prior written approval from RUSSELL MINERAL
APP'D LO 30/11/16 SHEET 2 of 2 12R4825 VER
CODE
12
11 2
6
12
11
17 4
9
10
ISOMETRIC VIEW
3
UNDER ISOMETRIC VIEW ISOMETRIC VIEW
SCALE 1:5 SCALE 1:5
4
6
14
12
13 15
7
6 10 11 7 12
8
EXPLODED
EXPLODED ISOMETRIC VIEW UNDER ISOMETRIC VIEW
- - - - - - - - SCALE 1:3 UNO 3rd ANGLE PROJECTION U.N.O. A3
- - - - MASS: 11.5kg MANIFOLD GROUP DRAWING STATUS
- - - - DO NOT SCALE DESIGN DSS 29/11/16
- - - -
IF IN DOUBT- ASK MRM TTU SUPER W/ POS. SENSOR BOOM RELEASED
- - - - DRAWN KKS 30/11/16
CLASH RME DRAWING NUMBER REV
- - - - This drawing remains the property of RUSSELL
- -
MINERAL EQUIPMENT PTY LTD and must not be CHECK SP 30/11/16
A0
- - manufactured from, copied, or transmitted to a third party
- A0 APPROVED FOR CONSTRUCTION AS PER APPROVAL without prior written approval from RUSSELL MINERAL
APP'D LO 30/11/16 SHEET 1 of 1 12R4829 VER
CODE
3 1
22
12
4 21 8
1 11
19
20
3
13
2
23
24
ISOMETRIC VIEW
SCALE 1:50
DETAIL A
SCALE 1 : 5 EXPLODED ISOMETRIC VIEW
TYP 3 PLACES
4
EXPLODED ISOMETRIC VIEW
4
1
7 10
8 11
12
3
2
13
12
ISOMETRIC VIEW 4
SCALE 1:20
2
4
11
18 21
5
9
17
13
A 10
ISOMETRIC VIEW
SCALE 1:50 7
8
20 22 18
19
18
2
6
22.5
TYP
1
2
27.5 TYP
2
CROPPED
SECTION A-A
SCALE 1 : 2
2
20 20
A
A
8
8
2 1 2
LABEL ITEMS
- - - - - - - - SCALE 1:30 UNO 3rd ANGLE PROJECTION U.N.O. A3
- - - - MASS: 296.2kg REMOVABLE STAIRS DRAWING STATUS
- - - - DO NOT SCALE DESIGN SC 24/11/16 ARRANGEMENT
- - - -
IF IN DOUBT- ASK
RELEASED
- - - - DRAWN SC 28/11/16
RME DRAWING NUMBER REV
- - - - This drawing remains the property of RUSSELL ORS ALUMINIUM PORTABLE 1704 ES/EN
- -
MINERAL EQUIPMENT PTY LTD and must not be CHECK SP 29/11/16
A0
- - manufactured from, copied, or transmitted to a third party
- A0 APPROVED FOR CONSTRUCTION AS PER APPROVAL without prior written approval from RUSSELL MINERAL
APP'D LO 30/11/16 SHEET 1 of 1 12R4755 VER
CODE
ISOMETRIC VIEW
14 33
A 32
9 35 11
28 15
32
31
29
25
26
3
25 19 B
26 20 39 29 30 DETAIL A
21 SCALE 1 : 10
27 26 37
12 26 6 26
27 26 25
27 26
25 20 13 27 7
26
26 5
18
26
27 2
27
26 28 29
26
27 27
29 27 26 18 29 30 11 26
4
38 26 25
28 26
25
8 27
37 26
27 26
26
10 16
22 26
26 2
23 27 25
16 27 26
17 23 24 26
26 25 25
26 DETAIL B
SCALE 1 : 12.5
25
EXPLODED ISOMETRIC VIEW
ISOMETRIC VIEW
ISOMETRIC VIEW
3 1 2
5
1
8
7
2
3
6
ISOMETRIC VIEW
SCALE 1:10
7
- - - - - - - - SCALE 1:5 UNO 3rd ANGLE PROJECTION U.N.O. A3
- - - - MASS: 107.8kg CABLE REELER GROUP DRAWING STATUS
- - - - DO NOT SCALE DESIGN BAS 05/12/16
- - - -
IF IN DOUBT- ASK
RELEASED
- - - - DRAWN BAS 05/12/16 OCR 23m CW 745mm 25mm² DS9 480V
RME DRAWING NUMBER REV
- - - - This drawing remains the property of RUSSELL
- -
MINERAL EQUIPMENT PTY LTD and must not be CHECK SP 05/12/16
A0
- - manufactured from, copied, or transmitted to a third party
- A0 APPROVED FOR CONSTRUCTION AS PER APPROVAL without prior written approval from RUSSELL MINERAL
APP'D DD 05/12/16 SHEET 1 of 1 12R4840 VER
CODE
ISOMETRIC VIEW
1
4
6
7
8
5
4
2
6 3
ISOMETRIC VIEW
EXPLODED ISOMETRIC VIEW
1
ISOMETRIC VIEW
SCALE 1:100
2
11
10
9 5
7
1
8
1 7 6 5
ISOMETRIC VIEW
H1 H2 HR1 S1 S2 S3
H3 H4 H5 H6
480V 60Hz Q1
This drawing remains the property of RUSSELL MINERAL Client No. Approvals
EQUIPMENT PTY. LTD. and must not be manufactured from,
copied, or transmitted to a third party without prior written
approval from RUSSELL MINERAL EQUIPMENT PTY. LTD.
DESIGN DD 24.11.16
Copyright Russell Mineral Equipment Pty. Ltd. 2016 Drawing Not to Scale DRAWN BP 28.11.16
CHECK DD 02.12.16
Russell Mineral Equipment P/L
149 Hursley Road
PO Box 100
TOQUEPALA PROJECT APP'D DD 02.12.16
Dwg Status: RELEASED
RUSSELL 7 MILL RELINING MACHINE
Toowoomba QLD
B0 As Built BP DD DD 17.05.17 AUSTRALIA 4350
P. +61 7 4698 9100 RME Drawing No. Rev
A0 Approved for Construction As per Approvals F. +61 7 4639 2116
E. rme@rmeGlobal.com
W. rmeGlobal.com MCC LAYOUT ASSEMBLY TQAMRM384-ELE-20 B0
Rev Description DWN CHK APP'D DATE ABN 20 010 708 406
S40
COT ENABLED
S22 S36
S20
MOTION WARNING
This drawing remains the property of RUSSELL MINERAL Client No. Approvals
EQUIPMENT PTY. LTD. and must not be manufactured from,
copied, or transmitted to a third party without prior written
approval from RUSSELL MINERAL EQUIPMENT PTY. LTD.
DESIGN DD 24.11.16
Copyright Russell Mineral Equipment Pty. Ltd. 2016 Drawing Not to Scale DRAWN BP 28.11.16
CHECK DD 02.12.16
Russell Mineral Equipment P/L
149 Hursley Road
PO Box 100
TOQUEPALA PROJECT APP'D DD 02.12.16
Dwg Status: RELEASED
RUSSELL 7 MILL RELINING MACHINE
Toowoomba QLD
B0 As Built BP DD DD 17.05.17 AUSTRALIA 4350
P. +61 7 4698 9100 RME Drawing No. Rev
A0 Approved for Construction As per Approvals F. +61 7 4639 2116
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Rev Description DWN CHK APP'D DATE ABN 20 010 708 406
JS1 JS2
RD BU
S19
This drawing remains the property of RUSSELL MINERAL Client No. Approvals
EQUIPMENT PTY. LTD. and must not be manufactured from,
copied, or transmitted to a third party without prior written
approval from RUSSELL MINERAL EQUIPMENT PTY. LTD.
DESIGN DD 24.11.16
Copyright Russell Mineral Equipment Pty. Ltd. 2016 Drawing Not to Scale DRAWN BP 28.11.16
CHECK DD 02.12.16
Russell Mineral Equipment P/L
149 Hursley Road
PO Box 100
TOQUEPALA PROJECT APP'D DD 02.12.16
Dwg Status: RELEASED
RUSSELL 7 MILL RELINING MACHINE
Toowoomba QLD
B0 As Built BP DD DD 17.05.17 AUSTRALIA 4350
P. +61 7 4698 9100 RME Drawing No. Rev
A0 Approved for Construction As per Approvals F. +61 7 4639 2116
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W. rmeGlobal.com JOYSTICK CONTROL LAYOUT ASSEMBLY TQAMRM384-ELE-22 B0
Rev Description DWN CHK APP'D DATE ABN 20 010 708 406
This drawing remains the property of RUSSELL MINERAL Client No. Approvals
EQUIPMENT PTY. LTD. and must not be manufactured from,
copied, or transmitted to a third party without prior written
approval from RUSSELL MINERAL EQUIPMENT PTY. LTD.
DESIGN DD 24.11.16
Copyright Russell Mineral Equipment Pty. Ltd. 2016 Drawing Not to Scale DRAWN BP 28.11.16
CHECK DD 02.12.16
Russell Mineral Equipment P/L
149 Hursley Road
PO Box 100
TOQUEPALA PROJECT APP'D DD 02.12.16
Dwg Status: RELEASED
RUSSELL 7 MILL RELINING MACHINE
Toowoomba QLD
B0 As Built BP DD DD 17.05.17 AUSTRALIA 4350
P. +61 7 4698 9100 RME Drawing No. Rev
A0 Approved for Construction As per Approvals F. +61 7 4639 2116
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W. rmeGlobal.com BILL OF MATERIAL 1/3 TQAMRM384-ELE-25 B0
Rev Description DWN CHK APP'D DATE ABN 20 010 708 406
This drawing remains the property of RUSSELL MINERAL Client No. Approvals
EQUIPMENT PTY. LTD. and must not be manufactured from,
copied, or transmitted to a third party without prior written
approval from RUSSELL MINERAL EQUIPMENT PTY. LTD.
DESIGN DD 24.11.16
Copyright Russell Mineral Equipment Pty. Ltd. 2016 Drawing Not to Scale DRAWN BP 28.11.16
CHECK DD 02.12.16
Russell Mineral Equipment P/L
149 Hursley Road
PO Box 100
TOQUEPALA PROJECT APP'D DD 02.12.16
Dwg Status: RELEASED
RUSSELL 7 MILL RELINING MACHINE
Toowoomba QLD
B0 As Built BP DD DD 17.05.17 AUSTRALIA 4350
P. +61 7 4698 9100 RME Drawing No. Rev
A0 Approved for Construction As per Approvals F. +61 7 4639 2116
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Rev Description DWN CHK APP'D DATE ABN 20 010 708 406
This drawing remains the property of RUSSELL MINERAL Client No. Approvals
EQUIPMENT PTY. LTD. and must not be manufactured from,
copied, or transmitted to a third party without prior written
approval from RUSSELL MINERAL EQUIPMENT PTY. LTD.
DESIGN DD 24.11.16
Copyright Russell Mineral Equipment Pty. Ltd. 2016 Drawing Not to Scale DRAWN BP 28.11.16
CHECK DD 02.12.16
Russell Mineral Equipment P/L
149 Hursley Road
PO Box 100
TOQUEPALA PROJECT APP'D DD 02.12.16
Dwg Status: RELEASED
RUSSELL 7 MILL RELINING MACHINE
Toowoomba QLD
B0 As Built BP DD DD 17.05.17 AUSTRALIA 4350
P. +61 7 4698 9100 RME Drawing No. Rev
A0 Approved for Construction As per Approvals F. +61 7 4639 2116
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W. rmeGlobal.com BILL OF MATERIAL 3/3 TQAMRM384-ELE-27 B0
Rev Description DWN CHK APP'D DATE ABN 20 010 708 406
This drawing remains the property of RUSSELL MINERAL Client No. Approvals
EQUIPMENT PTY. LTD. and must not be manufactured from,
copied, or transmitted to a third party without prior written
approval from RUSSELL MINERAL EQUIPMENT PTY. LTD.
DESIGN DK 24.11.16
Copyright Russell Mineral Equipment Pty. Ltd. 2016 Drawing Not to Scale DRAWN BP 28.11.16
CHECK DD 02.12.16
Russell Mineral Equipment P/L
149 Hursley Road
PO Box 100
TOQUEPALA PROJECT APP'D DD 02.12.16
Dwg Status: RELEASED
RUSSELL 7 MILL RELINING MACHINE
Toowoomba QLD
B0 As Built BP DD DD 17.05.17 AUSTRALIA 4350
P. +61 7 4698 9100 RME Drawing No. Rev
A0 Approved for Construction As per Approvals F. +61 7 4639 2116
E. rme@rmeGlobal.com
W. rmeGlobal.com RME USER ERROR CODES TQAMRM384-ELE-28 B0
Rev Description DWN CHK APP'D DATE ABN 20 010 708 406
This drawing remains the property of RUSSELL MINERAL Client No. Approvals
EQUIPMENT PTY. LTD. and must not be manufactured from,
copied, or transmitted to a third party without prior written
approval from RUSSELL MINERAL EQUIPMENT PTY. LTD.
DESIGN DK 24.11.16
Copyright Russell Mineral Equipment Pty. Ltd. 2016 Drawing Not to Scale DRAWN BP 28.11.16
CHECK DD 02.12.16
Russell Mineral Equipment P/L
149 Hursley Road
PO Box 100
TOQUEPALA PROJECT APP'D DD 02.12.16
Dwg Status: RELEASED
RUSSELL 7 MILL RELINING MACHINE
Toowoomba QLD
B0 As Built BP DD DD 17.05.17 AUSTRALIA 4350
P. +61 7 4698 9100 RME Drawing No. Rev
A0 Approved for Construction As per Approvals F. +61 7 4639 2116
E. rme@rmeGlobal.com
W. rmeGlobal.com ABB ERROR CODES TQAMRM384-ELE-29 B0
Rev Description DWN CHK APP'D DATE ABN 20 010 708 406
No.:
Date: 01-NOV-2015
DATA SHEET
Three-phase induction motor - Squirrel cage rotor
Customer :
Product line : W22 Industrial Motor - High Efficiency E3
Frame : L90S
Output : 1.1 kW
Frequency : 60 Hz
Poles : 4
Full load speed : 1763
Slip : 2.06 %
Voltage : 460 V
Rated current : 2.09 A
Locked rotor current : 18.8 A
Locked rotor current (Il/In) : 9.0
No-load current : 1.21 A
Full load torque : 5.96 Nm
Locked rotor torque : 300 %
Breakdown torque : 420 %
Design : ---
Insulation class : H
Temperature rise : 80 K
Locked rotor time : 17 s (hot)
Service factor : 1.15
Duty cycle : S1
Ambient temperature : -20°C - +40°C
Altitude : 1000
Degree of Protection : IP66
Approximate weight : 23 kg
Moment of inertia : 0.00631 kgm²
Noise level : 51 dB(A)
Notes:
m10 w22
Performed by Checked
1 2 3 4 5 6 7 8
B
D1*
0Z1* 3/8"*
G
210 bar
D P T1 P P T2 P P
COT 1 COT 2 COT BSF 1 BSF 2
3/4"*
3/4"*
0C1* 3/4"*
3/4"*
B0 0P1*
kW CURVE
BAR L/MIN
50 180
60 179
70 178
80 177
90 165
100 151
110 137
120 125
130 112
3/4"*
140 99
150 88
160 76
170 70
180 66
190 60
200 54
210 48
OG1*
1780 RPM
37 kW
210 bar 44 cm³/rev
100 cm³/rev
145L
45 L 80 °C 45L
RANDO HD-32
3/8"*
3/4"*
1-1/4"S*
WLL 2500 kg 2"S* Item Identifier Quantity Part Number Catalogue Description
0C1 1 03B3242 COOLER - OIL/AIR OK-EL5S 380-415V/50Hz 440-480V/60Hz IP66 MOTOR
ELECTRIC MOTOR 0G2 1 12R3702 MANIFOLD GROUP - PRESSURE FILTER - MACHINE ENABLE
SPECIFICATIONS 0P1 1 12R4821 PUMP GROUP - HYP 364/5T - 100/44cc
415V, 3 PHASE, 60 HZ 0Z1 1 03B0186 GAUGE - HYDRAULIC PRESSURE Ø63 250 Bar
4 POLE, 1780 RPM, IP66 OG1 1 12R4588 TANK GROUP - HYP 167L RUSSELL 7
This drawing remains the property of RUSSELL DESIGN BDS 13/12/16 SOUTHERN PERU COPPER DRAWING STATUS
MINERAL EQUIPMENT PTY. LTD. and must not be RELEASED
DRAWN JMS 13/12/16 CORPORATION
manufactured from, copied, or transmitted to a third RME DRAWING NUMBER SIZE
party without prior written approval from RUSSELL CHECK SJF 16/01/16 TOQUEPALA
B0 UPDATED WITH AS-BUILT MARK-UPS SDL SP JMS 22/05/17 MINERAL EQUIPMENT PTY. LTD.
A1
A0 APPROVED FOR CONSTRUCTION AS PER APPROVALS APPD BDS 18/01/17 RUSSELL 7 MILL RELINE MACHINE TQAMRM384-HYD REV
Copyright Russell Mineral Equipment Pty. Ltd.
POWERPACK SCHEMATIC
Rev Description Drawn Check Appd Date TEMPLATE REVISION A0 SHEET 1 OF 3 B0
LINER CART DRIVE INNER BEAM OUTER BEAM REAR STEER FRONT STEER MACHINE DRIVE 6G2* FRONT JACKS
MOTOR
6G1* 6400 N.m 28:1
2Z1* 5A1* 5A2* 100 cm³/rev GB
DIRECTION 4A1* 6400 N.m 28:1
315 cm³/rev 11A1* 3 in
3.5 in 3.5 in GB 100 cm³/rev
1.75 in 1.75 in
6 in 5 in
254 mm 229 mm
4 in 1250 mm
MOTOR DIRECTION
4365 mm
GEARBOX TURNS OPPOSITE 7A1* 7A2*
1/2"*
1/2"*
TO MOTOR
3/4"* 3/4* 2.5 in 2.5 in
4 in 4 in
3/8"*
3/8"*
75 mm 75 mm
11B1* A01 B01 C1 C2
145 bar 4V1* 120 bar 4V2* D2 D1
3/8"*
3/8"*
3/8"*
3/8"*
180 bar 180 bar
CWEG LGN BR2 BR1
CBEG LJN 1/4"* A2 A1 1/4"*
3/8"* B2 B1 3/8"*
4B1* 3/8"* 3/8"* C2B C1B
C2 OMS315 C1
V1 V2
1/4" INTERFACE 1/4" T01
COFA XCN 210 bar 210 bar
BSPP 2 X 01-N214 BSPP
1/4"*
C2A C1A
165 bar 165 bar
1/3 TURN OPEN
145 bar
0.3 bar 0.3 bar
20 bar 20 bar 3/4"* CXED
XCN
1/3 TURN
2 bar
1.4 bar
1.4 bar
CBEG LJN
0.3 bar 0.3 bar
OPEN 7B1*
V2 V1
1-3/4 TURNS OPEN
V01 V02
3/4"*
3/4"*
2 bar 2 bar 6B1*
D B T A BR
V2 D V1
9/16" 9/16" 9/16" 2B1*
UNO UNO UNO
R2B A1 B1
TO SHEET 3* TO SHEET 3* TO SHEET 3*
R2A*
R1A*
3/8"
3/8"*
3/8"*
P03A*
3/8"
3/8"
3/8"
1/2"*
1/2"*
1/2"*
1/2"*
3/8"*
3/8"*
1V1* A B A B A B A B A B A B
80 bar 125 bar 140 bar 175 bar 175 bar 140 bar 210 bar 210 bar 160 bar 160 bar
215 bar
LINERCART BEAM EXTEND REAR STEER FRONT STEER MACHINE DRIVE FRONT JACKS
This drawing remains the property of RUSSELL DESIGN BDS 13/12/16 SOUTHERN PERU COPPER DRAWING STATUS
MINERAL EQUIPMENT PTY. LTD. and must not be RELEASED
DRAWN JMS 13/12/16 CORPORATION
manufactured from, copied, or transmitted to a third RME DRAWING NUMBER SIZE
party without prior written approval from RUSSELL CHECK SJF 16/01/16 TOQUEPALA
B0 UPDATED WITH AS-BUILT MARK-UPS SDL SP JMS 22/05/17 MINERAL EQUIPMENT PTY. LTD.
A1
A0 APPROVED FOR CONSTRUCTION AS PER APPROVALS APPD BDS 18/01/17 RUSSELL 7 MILL RELINE MACHINE TQAMRM384-HYD REV
Copyright Russell Mineral Equipment Pty. Ltd.
BASE HYDRAULIC SCHEMATICS
Rev Description Drawn Check Appd Date TEMPLATE REVISION A0 SHEET 2 OF 3 B0
BOOM SLEW BOOM RAISE/LOWER BOOM EXTEND/RETRACT
GRAPPLE TOOL LINER LIFT GRAPPLE SLEW GRAPPLE ROLL
9A1* GB 10A1* 10A2* 11A1* 5 in
6400 N.m 22:7:1 2.75 in 12A1* 13A1* 14A1* 15A1*
1 in
96 cm³/rev 1500 mm 1600 daN.m 1600 daN.m 1600 daN.m
2 in
H38 150 deg 150 deg 150 deg
6 in 6 in 150 mm
2.5 in 2.5 in 75 bar 75 bar 70 bar 70 bar 60 bar 60 bar
685 mm 185 bar 685 mm 185 bar
2 bar
H45
B0 B0 105 bar 145 bar
1/4"*
1/4"*
12B1*
1/2"* 1/2"*
3/8"* 1/4"*
3/8"*
03B4150 T03 M01 T02 A02 M02 M03 B02 A03 M04 T05
03b4163 LEFT VIEW OF TOP VIEW OF REAR VIEW OF
8B1 GRAPPLE SLEW GRAPPLE SLEW GRAPPLE ROLL
B0 M08 M08a
M08
130 bar 80 bar T01
V03
V08
V11
115 bar 80 bar V12
V04
1/4"*
V09
V05
V11
V06 V07
3/4 OPEN 2 TURNS
M09a
OPEN
2 bar
M09
M09
ABS BBS M07 A08 A01 A09 B01 A07 A06 A05 A04
3/8"*
3/8"*
1/4"*
1/2"*
3/8"*
1/2"*
1/2"*
1/4"*
1/4"*
3/8"*
1/4"*
1/4"*
1/4"*
1/4"*
A1 B1
TO SHEET 2 TO SHEET 2
7V1*
A B A B A B A B A B A B A B
80 bar 80 bar 80 bar 190 bar 100 bar 140 bar 140 bar 175 bar 190 bar 190 bar 190 bar 190 bar 190 bar 190 bar
40 lpm 100 lpm 65 lpm 100 lpm 5 lpm 25 lpm 10 lpm 10 lpm
1/4"*
1/4"*
3/4"*
1/4"*
PRESSURE
SWITCH
COT ENABLE
B0 215 bar
Motion Warning B0
R.U. B-PORT* B1 TO SHEET 2* 8B1 12R4829 1 MANIFOLD GROUP - MRM TTU SUPER W/ POS. SENSOR BOOM
9A1 02B2411 1 GEARBOX - TURNTABLE SLEW 22.7:1 6400N.m 310DS FLANGE W/MOTOR
3/4"* P03A* 10A1, 10A2 10R9544 2 CYLINDER GROUP - BMA 2 RAISE LOWER CLEVIS 685
11A1 10R9136 1 CYLINDER GROUP - BMA 2 EXTEND RETRACT 1500
3/4"* R2A* 12A1 10R8808 1 CYLINDER GROUP - GRAPPLE TOOL
R1A*
T01* R2B TO SHEET 2* 12B1 03B3699 1 MANIFOLD - GRAPPLE TOOL
13A1, 14A1, 15A1 03B1692 3 ROTARY ACTUATOR - 16000Nm 150°
INNER BEAM CABLEVEYOR
This drawing remains the property of RUSSELL DESIGN BDS 13/12/16 SOUTHERN PERU COPPER DRAWING STATUS
MINERAL EQUIPMENT PTY. LTD. and must not be RELEASED
DRAWN JMS 13/12/16 CORPORATION
manufactured from, copied, or transmitted to a third RME DRAWING NUMBER SIZE
party without prior written approval from RUSSELL CHECK SJF 16/01/16 TOQUEPALA
B0 UPDATED WITH AS-BUILT MARK-UPS SDL SP JMS 22/05/17 MINERAL EQUIPMENT PTY. LTD.
A1
A0 APPROVED FOR CONSTRUCTION AS PER APPROVALS APPD BDS 18/01/17 RUSSELL 7 MILL RELINE MACHINE TQAMRM384-HYD REV
Copyright Russell Mineral Equipment Pty. Ltd.
TURNTABLE HYDRAULIC SCHEMATIC
Rev Description Drawn Check Appd Date TEMPLATE REVISION A0 SHEET 3 OF 3 B0