Crowd system maintenance
Continued from page 5 .
When installing new belts, make sure that the
tensioning system is backed off far enough to allow
the belts to slide into place without being forced.
Never use a pry bar or lever to force the belts over the
“V” grooves. It is possible to damage the belts
causing short life.
It is a good idea to check motor alignment when
replacing belts. Simply place a straight edge or
stretch a string across the two sheaves. If the straight
edge is touching the two sheaves at four points, the
motor is aligned. As a general rule, sheave mis-
alignment should be less than 1/2-degree or 1/10-inch
per foot of drive center distance.
The crowd belt adjusting system on P&H shovels is
really quite simple. The motor is mounted on a table
that pivots (see Figure 2).
MANUAL CROWD BELT TENSIONING SYSTEMS
Originally, a threaded adjusting rod and adjusting nut
are mounted to the boom on the upper side of the
motor table. Turning the nut upwards tightens the
belts, and turning it downward loosens the belts.
The procedure
is to measure the
center-to-center
distance of the
sheaves, and then
turn the adjusting
nut in the belt-
tightening
direction until the
center-to-center
distance increases 1/8-inch. Continue to do this until
the belts will not slip when the operator crowds into
the bank. You then increase the center-to-center
distance another 1/8-inch.
HYDRAULIC CROWD BELT TENSIONING SYSTEMS
In later shovel models, P&H added a hydraulic
cylinder to assist in raising and lowering the table.
Proper belt tension is specified in terms of hydraulic
pressure. Remember that if a hydraulic cylinder is
replaced, it must be replaced with an identical
cylinder. If the replacement cylinder is not identical,
a different belt tension will result for a given
hydraulic pressure.
The same basic system — different components, but
same theory — is used on P&H Models 2100, 2300
and 2800. Remember that on these systems, higher
6 Minesite Insights
hydraulic pressure results in higher belt tension.
When P&H introduced the Model 4100 shovel, the
crowd belt tensioning system was changed. On the
4100 and 4100A, the belt tensioning system is located
at the bottom end of the motor table. In this system,
gravity acting on the motor table provides the belt
tension. The hydraulic cylinder and adjusting rod
limit the amount of belt tension caused by gravity. In
the 4100 system, higher hydraulic pressure results in
lower belt tension. Lower hydraulic pressure results
in higher belt tension.
MODEL 4100, 4100A AND 4100A/LR CROWD BELTS
The P&H part number for the new-style belts for
models 4100, 4100A and 4100A/LR is R17893D1.
This part number supplies one set of two belts that
are precision-matched in length.
Remember, these belts are not ordinary Kevlar
belts, and using these pressures with a Kevlar belt
other than R17893D_ can result in significantly
increased impact-loading to the gearing. Ordinary
Kevlar belts can grab and instantaneously transmit
many times the rated horsepower. Therefore, their
use is not recommended.
Because the new belts are so different, the
procedure for tensioning is also different. It is
important to follow the new tensioning procedures
with the new belts. These new procedures only apply
to the belts supplied by P&H under part number
R17893D1.
Also, make sure that the hydraulic cylinder in the
belt-tensioning system is the correct P&H part
number. The hydraulic cylinder should be 21Z1047.
If some other cylinder is used, the belt tension might
not be correct for a given hydraulic pressure.
Refer to Table A. P&H engineering has tabulated
all of the data required to properly tension the crowd
belt. Notice that the same part number belt is
specified for all three models of 4100 — the adjusting
pressures (and resulting belt tension) vary by model
and by crowd motor frame number.
The next line says “New Decal.” This is the part
number of a decal that can be applied over the
original plaque. The new decal has the revised
adjustment procedure and hydraulic pressures to be
used with the new-style belts.
The part number of the new decal is R29599D1. If
you would like copies of the decal, contact your
regional P&H MinePro Services office when you
place your order for the new belts. P&H stands ready
to provide you with this important information
reference tool at no charge. The next line on the
chart lists the P&H part number of the hydraulic
cylinder used in the adjusting system.
The bottom half of the table deals with actual
adjusting pressures. These pressures were determined
by P&H engineering and were confirmed by field
experience.
IMPORTANT: The INITIAL belt settings are
used when a new set of belts is installed and
tensioned for the first time. After the belts have
run for three (3) shifts, they are adjusted to the
RETENSION belt settings.
Both the Initial and Retension belt sections of the
table specify a PRETENSION and a TENSION
setting.
The Pretension setting results in a higher belt
tension to make sure that the belts are fully seated in
the sheave grooves. Once the Pretension setting is
accomplished, operate the hydraulic pump until the
tension pressure is reached.
Remember this about the relationship between
crowd-adjustment hydraulic pressure and belt tension
on P&H Model 4100s:
■ Lower hydraulic pressure = higher belt tension.
■ Higher hydraulic pressure = lower belt tension.
Check the adjustments of the belt after three shifts of
operation using the Retension Settings in Table A.
Check and retension the belts every 2,000 hours of
operation using the Retension settings.
ADJUSTING 4100, 4100A AND 4100A/LR CROWD BELTS
Before adjusting or replacing the crowd belts, read
the appropriate section in the shop manual to become
familiar with the procedures and cautions and
warnings. The illustrations in the shop manual will
show details of the adjusting mechanism more clearly
than is possible in this publication.
Remember that the crowd belts are adjusted by
means of a hydraulic pump and cylinder. Before any
adjustments are made, inspect all components for any
signs of wear or abuse. Do not use any hydraulic
components which appear damaged. Refer to Table B
in this publication for adjustment pressures. Also, see
Figure 2.
To retension the crowd belts, first remove the
smaller diameter pin from the upper clevis of the
holding rod assembly. Next, pump the hydraulic
pump until the motor base just starts to lift away from
the rod nut. Back-off the rod nut from the clevis
approximately 2 inches. Do not let the rod disengage
from the clevis. SLOWLY release the pressure (load)
in the hydraulic hand pump until the pressure gage
indicates the Pretension pressure shown in the
Retension section of Table A.
Now operate the manual pump until the pressure
gage indicated the Tension pressure shown in the
Retension section of Table A. Turn the adjusting rod
nut upward until it is against the upper clevis.
Continue turning the nut upward until the pressure on
the gage just begins to drop. Align the adjusting rod
to the nearest hole in the clevis and lock in place with
the pin and cotter pin. Release the hydraulic pressure
from the cylinder.
REMOVING AND INSTALLING 4100 CROWD BELTS
To remove and install new crowd belts, remove the
smaller diameter pin from the upper clevis of the
holding rod assembly. Then pump the hydraulic hand
pump until the motor base lifts approximately 2
inches away from the upper clevis. Tighten the rod
nut against the upper clevis. Continue to alternately
raise the motor base (2 inches) and tighten the rod nut
against the clevis until the crowd belts can be
removed and installed on the sheaves.
CAUTION! Due to motor weight when hydraulic
pressure is released, the motor base and motor
can pivot downward rapidly causing injury and
damage. To prevent this from happening, do not
allow the adjusting rod to disengage from the
clevis at any time. Make sure the adjusting rod
nut is tight against the upper clevis when motor
base has been raised to its final position to
remove or install crowd belts.
Next remove the old belts and install the new belts.
Back off the adjusting rod nut from the clevis approx-
imately two (2) inches. Bleed off hydraulic pressure
to lower the motor base. Alternately back off the nut
and release hydraulic pressure until the crowd belts
are tight. Then refer to Table A — INITIAL SETTINGS
(for P&H 4100, 4100A and 4100A/LR crowd belts)
and release the hydraulic pressure until the gage reads
the proper pretension pressure. Now pressurize the
hydraulic cylinder to the tension pressure — NEW
BELT SETTINGS.
Turn the adjusting rod nut against the upper clevis
until the pressure gage reading just starts to drop.
Align the adjusting rod to the nearest hole in the
clevis and lock in place with the pin and cotter pin.
Readjust the belts after three (3) shifts of operation
using the retension settings (Table A — Crowd Belt
Settings for 4100 and 4100A). Check and readjust
Please turn to page 8.
Minesite Insights 7
Crowd system maintenance
Continued from page 7.
the crowd belt tension every 2,000 hours.
MODEL 2800 MKII, 2800XPA, 2800XPB CROWD BELTS
Up until this time, the standard crowd belt on all 2800
models has been 7Z399D7. These belts have been
superseded by P&H engineering to new aramid cord
belts, P&H part number R17893D2. The new-style
belt requires different hydraulic adjusting pressures.
See Table B — Crowd Belt Settings for P&H Models
2100, 2300 and 2800 — for the new adjusting
pressures.
The actual adjusting procedure is the same as with
the old-style belts, but the adjusting pressures change.
See Table B for the new adjusting pressures. Also,
with the new belts, retension (readjust) them after
three (3) shifts of operation using the Retension
pressures listed in Table B. Check and retension the
belts every 2,000 hours of operation using the
retension pressures listed in Table B.
Instruction decals for the new-style belts installed
on 2800s will be available, free of charge, from your
local P&H MinePro Services office. Ask for decal
P&H part number R29605D1.
CROWD BELTS — 2100S AND 2300S
Polyester PowerBand belts are still standard for the
2100s and 2300s. However, because of research done
by engineering, we are recommending that using
different adjusting pressures will result in even better
belt life. Table B lists the new recommended
adjusting pressures. If you would like decals that list
the new recommendations, contact your local P&H
MinePro Services office and ask for decal R29602D1
for 2100s, or decal part number R29603D1 for 2300s.
The decals are free of charge.
New aramid belts for these machines are also
optionally available and would use the same pressure
setting in Table B. However, they only receive one
retensioning after three (3) shifts. ■
This article was researched and drafted by
Jim Wohlitz, Joe Colwell and Nate Rife.

Minesite Insights is published quarterly to provide information updates of interest to P&H Mining Equipment customers and the
P&H MinePro Services team. If you have ideas or suggestions for topics, or if you need extra copies of a back issue, please fax this
information to Mark Dietz in the P&H Mining Equipment Marketing Communication Department, (414) 671-7249.
IMPORTANT: If we need to revise or update the mailing list for better delivery to you, please fax us this information.

X - 1489

West Milwaukee, WI 53214

PERMIT NO. 463 P.O. Box 310
MILWAUKEE, WI 4400 West National Avenue
U.S. POSTAGE PAID P&H Mining Equipment
BULK RATE Minesite Insights
 Minesite Insights

Maintenance and Update Tips for P&H Mining Equipment

Electric Shovels, Drills, Draglines and Hydraulic Excavators August, 1997

How To Maximize The Life

And Performance Of The
P&H ‘PowerBand ’ Crowd Drive TM

Back in 1969, P&H introduced the PowerBandTM

crowd drive system to the mining world. No more
torque tubes or worm gears. No crowd ropes.
Instead, P&H shovel users now had an effective new
crowd delivery mechanism on their digging machines.
PowerBand is a simple, efficient and economical
power transmission system that was first used on the
P&H 2800MkI shovels built for Kaiser Resources in
British Columbia.
WHAT IS POWERBAND DRIVE?
PowerBand Drive is a V-belt drive that uses multiple
V-belts joined together by a high-strength tie band to P&H PowerBandTM crowd drive system.
provide lateral rigidity. V-belts offer a number of
POWERBAND BELT LIFE
advantages:
The life of PowerBand crowd drive belts depends on
◆ Efficient power transfer. a number of factors such as ...
◆ Simplified design — eliminating gears, ◆ Type and manufacturer of the belt
torque tubes, and so on.
◆ Operations
◆ Shock loading protection stemming from the ● Material ● Blasting ● Operator technique
elasticity of the belts.
◆ Maintenance
◆ Simplified motor alignment. ● Installation ● Adjustment
◆ Reduced maintenance requirements. ◆ High ambient temperatures
Over the last 28 years, the PowerBand crowd drive P&H uses belts selected for the application from
concept has proved itself during millions of hours of suppliers whose belts have shown superior
shovel operation all over the world under conditions performance under field conditions.
ranging from the heat of the Sahara Desert to the The material being excavated and the blasting can
extreme cold of Siberia. Because PowerBand belts
play a large part in belt life. Material that is blocky
are so reliable, they are often forgotten — until
and doesn’t fragment well must be “dug” rather than
problems, in particular, short belt life occur. Belt
maintenance will be discussed later in this article. loaded. Hard toe conditions and variations in
Please turn to page 2.
P&H ‘PowerBand’ Crowd Drive
Continued from page 1.
operator technique result in the high shock loads
mentioned above when the operator jams the dipper
into the toe or is forced to chip away at material.
Hard digging conditions are especially troublesome
during the belt break-in period when a sequence of
slip and re-tension can occur.
materials and belt construction, maintenance must
undergo change.
As an example, shovel operators have traditionally
been instructed to notify maintenance whenever they
hear crowd belts slip and squeal. The new belts do
not squeal when they slip, so periodic checking of
belt tension becomes more important. Belt tensioning
will be discussed later in this article.
REGULARLY SCHEDULED INSPECTIONS AND ADJUSTMENTS

In the end, because all of the above considerations Regular inspections of the crowd drive system doesn’t
must be dealt with by the maintenance team, proper have to be complicated. Start by listening, smelling,
looking, and touching.
installation and adjustment are probably the biggest
factors in determining crowd belt life. A thorough While the shovel is operating, listen for any unusual
understanding of the conditions and their conse- sounds that could indicate a problem. Especially on new
quences will prove invaluable in ensuring that the shovels, do not depend on the operators to alert you to
belts get through the break-in period and ultimately unusual noises. The newer operator cabs are better
provide acceptable life. A lot of patience helps, too. insulated and thus much quieter than on older machines.
Operator awareness of unusual sounds can also be
CROWD BELT PRODUCT KNOWLEDGE
impaired if the in-cab radio/stereo system is used.
The need for crowd belt product knowledge starts in
Any unusual smells — like burning rubber — are
the purchasing department. If the buyers are buying also an indication of belts that have been slipping.
belts strictly on price, belt life will be low.
When the shovel is shut down, remove the cover
Belts supplied by P&H are engineered to meet the from the belt case and visually inspect the belts and
requirements of the drive system on a particular the sheaves. Any signs of glazing or burning are
model shovel. Belts must be purchased as matched- signs of slipping belts. Also look for unusual accu-
length sets. mulations of debris in the belt case. This could be an
P&H will only supply PowerBand belts in matched indication of motor mis-alignment, or perhaps that the
belts are nearing the end of their useful life. If there
sets. It is important that the belts be stored in the
are any signs of cracking, fraying or unusual wear,
warehouse as sets and installed on the shovel as a set.
the belts should be replaced.
POWERBAND BELT IMPROVEMENTS
As P&H mining shovels have increased in size, and
with increasing load capacities, the construction of
belts specified by P&H have undergone changes.
As an example, the belts now specified on Model
4100s and 2800XPBs feature aramid tensile
(Kevlar™) cords for increased strength, durability,
and virtually zero stretch. Consequently, the need for
frequent re-tensioning during the break-in period is
eliminated. The rubber compound has been changed
to a chloroprene rubber compound for increased heat
resistance.
The new belts also feature a specially treated cover
which slips under impact-loading while withstanding
slip and shear forces at rated load without generating
excessive heat. The new belts are also precision-
matched to maximize power absorption and belt life. PowerBand crowd belt life depends on a number of
factors, including the material being excavated, blasting,
This new-type belt will be available for other P&H operator technique, high ambient temperatures and belt
models in the near future. Because of the new installation and adjustment.

2 Minesite Insights
 Touch test: Being very
careful, place your hand on the
TABLE A: Crowd Belt Settings for P&H 4100, 4100A and 4100A/LR
belts. If you cannot hold your Machine Type 4100 4100A 4100A/LR
hand on the belts for five (5) Crowd Motor K1010 K700 K700
seconds, the belts are running too P&H Belt R17893D1* R17893D1* R17893D1**
hot — and you must determine New Decal R29599D1 R29599D1 R29599D1
why. Quite often, excessive heat
Hydraulic Cylinder 21Z1047 21Z1047 21Z1047
is caused by frequent slipping of
the belts. In hot climates you
INITIAL SETTINGS
might consider cleaning the
outside of the belt case occasion- Pretension (psi) 200 0 0
ally. Oil and dirt buildup will act Tension (psi) 600 600 300
as an insulation and cause the RETENSION SETTINGS
belts to run hotter. Pretension (psi) 1300 800 800
The effect of temperature on Tension (psi) 1700 1200 1075
belt life is important. It is
estimated that a 36-degree Additional Notes: * Belt R17893D1 supersedes belt 7Z399D14.
**Belt R17893D1 supersedes belt 7Z430D5.
Fahrenheit rise in ambient Belt R17893D1 is not a standard Kevlar belt, and should not
temperature will reduce a belt’s be substituted with such.
life by 50%. Your hand can
tolerate about 140 degrees F,
which is the maximum FIGURE 1 - Belt-Tensioning System
temperature at which a belt for Models 4100 and 4100A.
should run, provided the ambient
PowerBand
temperature is under 110 Assembly
degrees F.
Excessive slippage due to loose
belt tension or very difficult, high-
impact digging can increase a belt’s
operating temperature.
Temperatures above 160 degrees F
Belt-Tensioning
will significantly shorten the life of
Assembly
the belt.
Belt tension should be checked
as part of the inspection
procedure. The procedure for
checking and adjusting belt
tension will vary depending on
the model of shovel, type of belt
used, and the type of crowd
motor on a particular shovel.
Details on this will follow.
DIAGNOSING BELT FAILURE
Frequently, in an attempt to
identify the cause of poor belt
life, especially after the failure of
a number of belts in quick
succession, attention is focused
on the belt sheaves, prompting

Please turn to page 4.

Minesite Insights 3
P&H ‘PowerBand’ Crowd Drive Belt failures are rarely, if ever, caused by a defect in
Continued from page 3.
the sheaves. However, mis-alignment of the sheaves
might be a contributor.
such questions as...
The appearance of a broken belt can provide a clue
◆ Are the grooves the correct depth? to the cause of the failure. Shredded belts are an
◆ Are they the correct angle? indication of high heat, most likely due to slipping.
Belts will slip if tensioned improperly, especially
◆ Is the sheave cutting the belt?
during the break-in period of a belt that is not made

Note that pressure / tension data for the original 7Z399D_ belts used earlier on 2800XPA / B and 4100s
is not included in Tables A and B. Field experience strongly indicates that application variables
(digging, operator techniques, belt stretch, maintenance practices, and so on) make the definition of a
specific practice impractical, and that the alternative is trial-and-error. For this reason, the original belt
has been superseded.
Usage of these new settings with the original-style belts will likely cause premature belt breakage
during the break-in period if difficult digging is encountered.

TABLE B: Crowd Belt Settings for P&H Models 2100, 2300 and 2800
Machine Type 2100BL/BLM 2100BLE, XP, 2300XP, 2300XPA*, 2300XPA**, 2800XP, 2800XPB
XPA, XPB MK-II, LR XP/LR, XPA/LR XPB XPA, MK-II

Crowd Motor CR-63C K300 K408/K489 K408 K408 K408 /K489 K489

P&H Belt 7Z399D5 7Z399D5 7Z399D3 7Z399D3 7Z399D3 R17893D2 R17893D2

New Decal R29602D1 R29602D1 R29603D1 R29603D1 R29603D1 R29605D1 R29605D1

Hydraulic 21Z767 21Z767 21Z767 21Z767 21Z767 21Z767 21Z767

Cylinder
Initial Tension 1400 1850 1600 1800 2000 2150 2250

Retension 500 1200 725 1050 1300 1250 1600

Additional Notes: * 2300XPA models with the 100J4416 boom configuration shown at lower left.
** 2300XPA models with the 100J5562 boom configuration shown at lower right.
***Belt number R17893D2 supersedes belt number 7Z399D7.

100J4416 BOOM CONFIGURATION

100J5562 BOOM CONFIGURATION

4 Minesite Insights
up of aramid tensile cords (Kevlar™).
Once a belt slips, it glazes and is more likely to slip
again. The result can be a destructive spiral of re-
tensioning a slipping belt to higher and higher
tension. Under these conditions, a belt could fail
either due to slip, or it could fail from over-
tensioning. Over-tensioning could also result in
reduced shaft and bearing life.
A clean break in a belt is an indication of over-
tensioning and overload. Overload can occur when a
properly tensioned belt is subjected to high shock
loads. Shock loads occur when a drive is quickly
stalled from high speed. Due to the rapid stopping of
the motion, the crowd reference is usually
maintained. Add to this the inertia of the drive
components, and the instantaneous torque seen at the
belt can be greater than 300% of stall torque,
resulting in a torque overload failure of the belt. It is
this type of failure that is addressed with the new
R17893D_ belts.
POWERBAND BELT MAINTENANCE
FIGURE 2 -
Belt-Tensioning System for Models 2100, 2300 and 2800.
An effective crowd belt
maintenance program consists of
several elements:
◆ Maintaining a safe working
environment.
crowd belt case is in good condition, and that
everything is tight.
Above all, when changing belts, make sure proper
lockout / tagout procedures are used.
PROPER BELT INSTALLATION PROCEDURES
When installing new belts, make sure both belts are
replaced with a matched set. If only one belt is
replaced, the new belt will carry the entire load and
will fail prematurely.
Make sure that the pulleys are in good condition.
Remove any burrs or sharp edges that may be present.
Check the pulleys for overall condition.
Make sure the sheave grooves are clean. If
necessary, use a non-flammable, non-petroleum
solvent to clean the grooves. Petroleum solvents may
leave a residue that could cause the belts to slip under
load. The use of belt dressing is specifically not
recommended.
Please turn to page 6.
Adjusting Nut
Adjusting Rod

◆ Belt product knowledge.

◆ Proper belt installation Jam Nut
procedures. Jam Nut & Cover

◆ Regularly scheduled Crowd Motor Hydraulic

inspections and Cylinder
adjustments.
◆ Troubleshooting. Pump
MAINTAINING A SAFE WORKING Assembly
ENVIRONMENT

Before working on the crowd

drive system, make sure the
shovel is parked on level ground
— with the dipper resting on the
ground — away from the working
face, with all of the brakes set.
Make sure that all walkways
and platforms are in good
condition and clear of
slipping and tripping hazards.
Make sure that proper tools are
available.
Check to make sure that the

Minesite Insights 5