YOUR CLIMBER HAS:

Manufacturing No.: Year: Part No. 9056 093 - 1 042001 - 05 - 07

If the bottom right corner of this book is cut, the book is only valid for illustrative use!

This manual is only applicable if the manufacturing number indicated below corresponds to the manufacturing number stamped on the identificationsign of the equipment. Where there is a conflict contact Your ALIMAK representative.

Operation & Maintenance Alimak

Raise Climber STH-5

Photographs and drawings are illustrative only and do not necessarily show thedesign of the products on the market at any given point in time. The products must beused in conformity with applicable practice and safety regulations. Specifications ofthe products and equipment presented herein are subject to change without notice.

FOREWORDThis product is designed and manufactured to meet strict qualityand safety standards. This manual is intended to provide adviceand instructions to the operator and qualified service personnelso that he can safely control the situations which can occur whenthe product is used, and can carry out the required service andmaintenance on the product.

This manual shall always be available in the box intended forthis purpose on the machine.

Potential risk for user or equipment are indicated in the followingway, in this book:

WARNING!

Information with these symbols and headings indicates the possibility of personal injury.

IMPORTANT: Information with these headings indicatethe possibility of damage to the equipment.

WARNING!

Misuse of this equipment could result in personalinjury or property damage.

The equipment should not be operated if operatorsManual is missing.

CONTENTS

AABBCDEFGGHHIIKKLLMM

TECHNICAL DESCRIPTION

TECHNICAL DATA

INSTRUCTIONS FOR USE

OPERATING INSTRUCTIONS

SERVICE AND MAINTENANCE

TROUBLESHOOTING

EXCAVATION FOR RAISE CLIMBER

GUIDE RAIL AND GUIDE RAIL CURVES

PREPARATIONS BEFORE INSTALLATION

INSTALLATION

DRIVING

TROUBLESHOOTING AND REPAIR

Section I: Technical Description: chapter A, B, G H and ISection II: Operation & Maintenance: chapter C, D, E and FSectionIII: Installation & Driving: chapter K and LSection IV: Troubleshooting & Repair: chapter M

ALIMAK AB IS ISO 9001 CERTIFIED This Certificate is valid for the following product or service ranges:

design, development, manufacture, rental and service of construction hoists, mast climbing work platforms,permanently installed lifts and equipment for shaft raising and enlarging

INSTRUCTIONS FOR THE USE

Instructions for the use of Alimak Raise Climbers ..............................

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C 1Instructions for the use of Alimak Raise ClimbersThe regulations below are drawn up only to advise and remindthe climber operator/keeper of the necessary control andprecautionary measures and must in no way be interpreted as –or preclude – national/local safety regulations andrecommendations.

1. The climber operator, i.e. the person allowed to operate theraise climber, must have the necessary knowledge ofthe design, condition and action of the climber.

2. He must be very familiar with operating the climberboth in normal conditions and in emergencies, andwith the instructions applying to the climber and itsequipment.

3. He must be very familiar with the use of the signaldevices and the safety climber. If the climber isnormally operated by more than one person, thestatements under 1 – 3 above apply to at least twoof these.

4. The climber must not be used with a higher load orspeed than the maximum established at the greatestdriving length. Nor must it be used, contrary toprohibitions laid down, for transporting personnel.The same applies to safety climbers.

5. Transport of materials must be done in such waythat the materials cannot injure the passengers,fall down, or get stuck in the climber path.Where required the materials should be securelybundled up and attached to the cage or workplatform.

6. In driving of raises with a raise climber, themethod of ignition should be such that it allowsigniting from a protected location. If electric

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detonators are used with an electrically powered raiseclimber, these shall have a higher safety factor, See theSwedish Industrial Safety Board rec. No. 14”Gruvhissanvisningar”, the 1973 issue recommendeddetonators type VA, ignition current min. 1.3 Amp.

Transporting explosives by raise climbers, as well as storingand handling such goods in the cage and on the platformmust be done in such way that no risk for explosion arisesthrough mechanical damage, fire or inadvertent initiation ofelectric detonators. Detonators must be stored separate fromexplosives in boxes intended for this purpose. Electricdetonators must not be remowed from their storage box ifthere is any risk of ignition, e.g. during electric operationbefore the current has been switched off.

During charging work on the platform storage boxes are notrequired, if only the equipment necessary for the charging ispresent on the platform and the explosives are kept thereonly during the actual charging work and then in theirfactoty packaging.

7. If electric ignition is used together with electric raiseclimber, the current must be switched off before the chargingwork commences.

8. Stepping in and out of the cage must only be done at a pro-tected location. During running, the passengers must stay inthe cage and the door to the work platform must be kept clo-sed. The hinged platform section should be raised.

9. During ascent after blasting, but at least once every working day, the guide rail with its attachment, especially expansionbolts, must be inspected and any damage rectified immedia-tely. If there is any severe damage to the guide tube, proceedwith caution with regard to poor ventilation in the upper partof the raise.

10. Setting up the guide rail and scaling must be done onlyunder the safety roof, if the raise is vertical or inclines 60°(67 gon) or more. If the raise inclines less than 60° and asafety roof is not used, scaling of walls and roof must bedone gradually during ascent, and the work must all the timebe carried out under the protection of a previously scaledhanging wall. When setting up a guide rail the workers mustbe under a safe hanging wall or safety roof.

11. During all work on the platform, a safety belt with a wireattached to the platform or safety roof must be used. Thehinged platform section should be let down only after thescaling is completed.

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12. On the bottom level the climber path should be fenced off sothat nobody can be hit by falling rocks or other objects orinjured by a moving cage. Such fencing can be constructed of loose trestles etc. A warning sign saying ”Work inprogress” or similar, should be placed on or adjacent to thefence.

Loading rock waste on the bottom level must be done from aprotected location, if work is in progress in the raise or if ithas not been scaled.

13. During each shift the attachments and resetting of the safetydevice must be checked, as well as the function of the signaldevices.

Theese regulations are in accordance with the regulations ofthe Swedish Industrial Safety Board No. 14, 1973, §292, §293.

Use of the equipment contrary the manufacturer’s instruc-tions is done at the user’s own risk.PIRATTILLVERKADE delar har medfört olyckstillbud medstigortshissen – i vissa fall med svåra personskador.Orsakerna har oftast varit felaktigt materialval.

Material med ytterst specifika egenskaper med avseende påbl.a elastisitet och nötningsbeständighet har använts istigortshissen. Tänk på det och välj därför alltid Alimak GenuinaReservdelar.

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OPERATING INSTRUCTIONS

Operating instructions ...................................Safety check before start................................Measures before start .....................................Air driven climbers ........................................Electric driven climbers .................................Diesel-hydraulic driven climbers .................Brakes ..............................................................Safety device....................................................Air and water central .....................................Air operated safety roof .................................Lubricator .......................................................High pressure water pump ............................Alimak Dupline system ..................................

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D 1D 1D 1D 2D 4D 11D 14D 14D 16D 17D 19D 21D 25

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D 1Operating instructionsPrior to any use of this climber perform safety proceduresbelow, as well as any required maintenance and lubricationspecified in this manual.

Safety check before driving– Before driving, check the counter roller and attachment of

the safety device. If the roller is not parallel to the guide rail,it must be replaced. Make sure that the safety device is reset – the white linestraight in front of the opening in the red field of the sightglass. Make sure that the four bolts which hold the brakedrum are tightened. The pinion must be properly aligned androll in the centre line of the pin rack.

– Check pinions, rollers, U-frame, brakes, bolt joints, telepho-ne equipment and its connection to the cable drum, tools,damages (repair if necessary)

– Make sure that the ventilation of the raise is satisfactory.

Measures before start– Pull out the plug from the outlet on the drum for the signal

wire and straighten out possible twists on the cable. Thenreinsert the plug.

Note: The electrically driven raise climbers have signalconductors included within the power supply cable. Ittherefore does not have this equipment.

– Disconnect and move the plug (A) for battery charging tothe outlet under the control panel in the cage – resp. underthe diesel-hydraulic power pack for climbers type STH-5Dor DD. Note that this connection is necessary for thefunction of the air and water central.

– Release the locking device on the air and water central.Valid for air and water central type AW-2 for non electric –NONEL – blasting system only!

AA

Air driven raise climber STH-5L & STH-5LL– Load the climber with necessary equipment.

Make sure that the climber is not overloaded.– Open the cook on the air and water central manifold to sup-

ply air to the hose reel and cock (B).

– Start the climber by pulling the lever on the control valve.When the lever is released the climber will stop.

– Check the guide rail during ascent and make sure that theclimber does not catch on the rock wall.

Make sure also during ascent that the air motors arereceiving oil – oil should emerge from the outlets of themotors! Refill oil is best done up in the raise. Refill byturn off cock (B), evacuate the control valve by driving theclimber and remove the refilling plug (C). After refilling,put back the refilling plug and open the cock.

– When descending, push the lever towards the control valve.In inclined raises where hose holders are used, a strict watchmust be kept over the hoses. If the hoses has fallen off ahose holder, the climber must be stopped and the hose putback in its holder before the descent is continued. The hosewill otherwise be damaged when the climber passes.

Descending after hose rupture etc.

To enable descent after interruption of air supply or otherbreakdowns, disengage the air motors by turning thedisengaging levers (D) through 180° so they point away fromthe motors. Release control brake (E) by hand and turn theflywheel (F) clockwise so that the climber starts moving. Thespeed will then be automatically limited by the centrifugalbrake. If the climber is to be stopped during descent, apply thecontrol brake.

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AC

B

Up

When engaging the air motors again, turn the disengaginglevers (D) in either direction until the levers point towards themotors or stop after turning them through 90°. To be able to fitthe coupling in the later case, turn the flywheel slowly with thehand lever while turning the disengaging lever quicklybackwards and forwards until it can be turned to point towardsthe motor.

Note! If the disengaging lever is turned to stop without theback-wards and forwards movement, the relative positions ofthe coupling halves will not change and they will not engage.

IMPORTANT: Do not drive the air motors or lower theclimber by gravity when adjusting the coupling.

Lowering the STH-5LL by gravity

A man with life line climbs down the ladder to the lower driveunit.Disengage the air motors, release the control brake whileturning the flywheels.

If only one man is to lower the climber, do as follows:

1. Find a 3/4” nut, or alternatively 2 U-washers or suchlike.

2. Put on a life line and climb down the ladder to the lowerdrive unit.

3. Disengage the air motor.

4. Release the control brake. Put the nut, or washers, betweenbrake lever and brake housing to keep the brake released.

5. Turn the flywheel so that the drive unit moves downwardsuntil it stops.

6. Climb up into the cage.

7. Disengage the air motor.

8. Release the control brake and turn the flywheel quickly. Theupper drive unit will then ”hit” the lower one and theclimber will start moving. To stop the climber duringdescent, release the upper control brake lever.

Note! After descending, remove the nut or the washersbetween brake lever and brake housing.

WARNING! Life line must always be usedoutside the cage.

Air driven service and safety climbers See operating instructions for raise climber

IMPORTANT: The staff on the raise climber must beinformed of the ascent with the safety climber.

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E

D

F

D

Electric driven raise climber STH-5E & STH-5EE– Load the climber with necessary equipment.

Make sure that the climber is not overloaded.

Operation Instruction STH5-E/EE, with contactor controland DUPLINE control system

Please use this instruction together with circuit diagram No.9080 459-001 page 1 – 6.

Check that all cables are connected in accordance with wiringdiagram 9080460-001 page 1.Check that the motors are connected for the right voltage.NOTE! The water pump motor shall always be connected for400V/50Hz or 460V/60Hz.

Please read the following before start of operation. This is howthe equipment shall be used:

General

If you turn off the switch Q64, in the climber, i.e. no supplymotors, all functions can be tested without driving the climberup or down. You then have a complete view of what ishappening, and you can follow the starting sequence withoutdriving the climber up and down.

The equipment in the STH-5 climber can only be started bymeans of a key switch pos S48, and in accordance with theinstruction sign on the cabin trap door in the base equipment.

The man going up with the climber shall start the equipment.First of all he shall test all functions (also the earth fault relay).Then, when going up with the climber, he shall bring the keyfor the switch S48.

After scraping/drilling, the man in the climber shall make theclimber out of current before commencing charging work. Thisis made by setting the switch ”power” in ”Off” position. The current circuits that are active (the signal system) arecurrent limited to 45 mA, which is a safe level for electricblasting caps.

Charging for blasting must be done in accordance with validinstructions and Authority Safety Regulations.

Noone but the operator in the climber should be able to energizethe climber, since the key is with the operator in the climber. In order to get down, after having finished the charging work,the climber is slid down.The above is for the STH-5 climber.

Trolley and Alicab, the life-saving climbers on the other hand,may be run without any conditions.

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The fundamental thing about the alarm function is that there is asignal from the climber to the base all the time. Each break,activated alarm button, empty battery or cable failure, starts thealarm equipment at the base.

The telephones shall always work, provided the cable iscomplete. However, the sound/light signals are dependent onvoltage. These are started by pressing the ”Call” buttons in thebase and the climber respectively.

Continue the commissioning.

Start instructions and safety test before operation

Four batteries are included with the equipment. The purpose isto change the batteries in the climber at every shift to a fullycharged. To achieve a continuous charging of the exchangebatteries, the main switch shall be in position ”Power On” andthere shall be power to the base station – also when theequipment is not in operation.

a) Connect fully charged batteries to the climberequipment. Then check that the green LED lamp, on the I/O cards U59and U60, in the climber, is lit up. This shows that there isvoltage for the cards. Switch the selector switches ”Power”and ”Air/Water” in the climber, to ”Off” position. Switch theselector switch S46, in the base equipment to ”Off” position.

NOTE! For the signal transfer batteries always have to beused, even if telephone equipment has not been installed.Connect the base equipment to the net, and switch on themain switch. Relay K41 shall be activated.The intention is that the main switch shall always be ”On”when the equipment is installed. This is to ensure that thespare batteries are always fully charged when available forexchange as a new shift starts.

b) Check that the green LED-lamp on the signal generator U52,is lit up, and that the green LED-lamps on the I/O-cards U31and U32 are lit up. This shows that there is voltage to thegenerator and the cards. The yellow LED-lamp on generatorand cards (the climber cards as well) shall now be lit up. Theyellow LED-lamps show that the cards communicate witheach other.

c) Check the voltage on terminals 115-116, it should be 230VAC. Check the output voltage to the climber (terminals104-106), should be 690 VAC. Check the output voltagefrom the net unit U26. Adjust with the potentiometer so thatthe output voltage is as close to 30 VDC as possible.

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d Check the DIP switches and the pot-settings on the earthfault relay K10, so that they are correct. See instruction oncircuit diagram, page 1.

Test the ground fault equipment with the test/reset button onthe electrical panel on the base station. The switch Q13 forSTH-5E/EE shall then trip out. The re-setting of the groundfault relay takes place automatically when the test button isreleased. In the event of a real ground fault, the relayremains in tripped-out position. The indication lamp remainslit until the test/reset button is pressed.

Opportunities are now provided for starting up the theequipment. The alarm relay K34 should now be ”ON”.Switch the selector switch S46 to ”On” position. If the alarmsignal is then activated, switch off by S47 ”Reset”.

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e) Connect the spare batteries for charging in thebase equipment.

f) Energize climber by switching on themaximal switch Q13. Then follow the sign instruction on thecabin.

NOTE! the selector switch ”Power” in theclimber has to be switched to ”On” posi-tion. Make a test of the ”Alarm button” in the clim-ber. This should start the alarm equipment. Check that relay K58 (external alarm) is acti-vated while the alarm button is pressed.Switch off the signal by ”Reset”.

g) Check the telephone communication in both directions. Atcall from the cage, use the ”Call Base” button. Theaudible/light signal at the base station is then activated.Before answering the telephone switch off the audible alarmby means of the ”Reset”-button on the electrical panel at base.

h) Switch the selector switch in the climber to ”Off” position.Q13 in the base should then trip out.

i) Energize climber again. Make a test from the climber thatair/water ON/OFF is working. Check that contactor K40works and that there is voltage for terminals 119 – 120 (115VAC) at the same time as K40 is ”On”. This should work,only when ”Power” (-Q13) is ”On”.

NOTE! The ”Remote controller” (-S50), has prioritycompared to the climber controller, and consequently, itmust be ”Off” during the air/water test from the climber.

k) The remote controller (-S50), is normally used to activatethe electric blasting caps. This is made by means of theair/water central, which then lets off compressed air whichstarts the charging. When that happens the water supply hasbeen cut off manually. This control unit can, however, beused to control air/water at the base.The maximal switchQ13 may then be in ”Off” position.Make a test of this control unit to see if it works, i.e. contac-tor K40 goes On/Off when you are operating the remotecontroller.

l) Relay K33, is a safety relay, which is normally never activa-ted. DUPLINE possesses a quality which makes a disturban-ce activate all outputs, and in order to minimize dangeroussituations, we have this safety relay which will stop all func-tions, in case it is activated.

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m) Test run up/down, with the Joystick.Check that the contactors change phase sequence.

– Put the switch Q64 in the cage to position ”On”.

– Turn the brake lever so that the control brake is released.

– Start the climber by moving the lever for desired direc-tion of travel.

When the lever is released the climber will stop.Immediately apply the control brake.

– Check the guide rail during ascent and make sure thatthe climber does not catch on the rock wall.

– When the drilling work is finished and the preparationfor the blasting with el. ignition is to be started, thepower supply of the climber shall be switched off, i e therotary switch in the climber is turned in position ”PowerOff”. The main circuit breaker at the base station is thentripped-out to Off-position. After the blasting preparationis finalized, the climber is to be slided downward to thebase station by means of gravity. As the key for the tra-velling is kept by the person in the climber, noone canreenergize the electric system, until this person has retur-ned back to the base station.

All functions of the STH5-E/EE have now been tested.

Start-up of Trolley/Alicab, with contactor control.

General: If you switch off the switch Q77, in TROLLEY, resp.Q92 in ALICAB, i.e. no supply for the motor, you can easilycontrol all functions without running the climberup and down.You then have a full survey of what is happening, and you canfollow the start-up without driving the climber.Switch the maximal-switch Q12 to ”On” position. The climberis now energized.

When testing the ALICAB: Check that the transformer in theclimber -T96 – is connected so that the brake gets correct voltage(230 VDC).

Test run up/down, with the joystick. Check that the contactorschange phase sequence.

IMPORTANT: The vibrations when detonating the roundmight cause relays and thermal relays to release. Reset theequipment by pushing all resetting buttons (also thermalrelay for the high pressure pump)

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Lowering the STH-5E & STH-5EE by gravity

The STH-5E/EE must be lowered by gravity since the powerhas been switched off (see above).

STH-5ETurn the brake lever to release the control brake. Turn theflywheel by hand to move the climber. The speed will then beautomatically limited. To stop the climber during descent, turnthe brake lever until the control brake is applied.

STH-5EEA man with life line climbs down the ladder to the lower driveunit. Release the control brake and turn the flywheels. If onlyone man is to lower the climber, do as follows:

WARNING! Life line must always be used outsidethe cage.

1. Put on a life line and climb down the ladder to the lowerdrive unit.

2. Release the control brake (on the lower drive unit).

3. Turn the flywheel so that the drive unit moves downwardsuntil it stops.

4. Climb up into the cage.

5. Release the control brake and turn the flywheel quickly. Theupper drive unit will then ”hit” the lower one and theclimber will start moving. The speed is then automaticallylimited. To stop the climber during descent, turn the brakelever to apply the control brakes.

If the climber is not to used, set the ALARM-SYSTEM and theSTH-5E/EE-switch in position ”Off”

IMPORTANT: If the safety climber is to be driven upwards,and the main power cannot be switched on, turn the mainswitch ”Climber STH-5E/EE” to off-position. The mainswitch ”Trolley/Cab” is turned to position on.

WARNING! Never leave the cage without havingapplied the control brake.

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In inclined raises where cable holders are used, a strict watchmust be kept over the cables. If the cable has fallen off acableholder, the climber must be stopped and the cable put backin its holder before the descent is continued. The cable willotherwise be damaged when the climber passes.

Electric driven service and safety climbers– Turn the switch ”Trolley/Cab” in the main electric box to

position ”On”. If the main current cannot be turned on, turnthe switch marked STH-5E/EE to position ”Off”.

IMPORTANT: While charging is going on, the current tothe safety climber should not be turned on. Naturally, if anaccident occurs during the charging operation, the currentmay be turned on to the safety climber. If possible, thecharge should be disconnected before the ascent.

The staff on the raise climber must be informed of theascent with the safety climber.

– The climber ascends by quickly turning the control lever tothe position for ascent. When the lever is released, theclimber stops.

During operation, keep a strict watch at all times over thecables and guide rail.

– For descent, the control lever is turned to the position fordescent. When the lever is released, the climber stops.

Lowering the Alitrolley 5E service climber by gravity

See operating instructions for the raise clinber.

Lowering the Alicab 5E safety climber by gravity

If the climber must descend under gravity, depress the pedal atthe bottom of the electric motor. Do not depress it to hard! At the same time turn the flywheel until the climber starts todescend. The speed is then automatically restricted by thecentrifugal brake. Release the brake pedal to stop the climber.

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Diesel-hydraulic driven raise climber STH-5D & DD– Fill up with fuel according to Deutz´recommendations,

Avoid driving the climber so that the tank is emptied – if so,the fuel system has to be ventilated. Check the hydraulic oillevel (if it is to low, the diesel engine will stop). Check theoil level in the diesel engine.

– Load the climber with necessary equipment.Make sure that the climber is not overloaded.

Start and stop of diesel engine– Check that the stop button is drawn out, The indication lamp

for the magnet is lit.

– Press the button for glowing and keep it pressed during –30 seconds if the engine is cold (warm engine shorter time).

– Then press the start button and keep it pressed until the indi-cation lamp for the generator lights up (the diesel engine hasstarted).

– To stop the engine – press the stop button.

IMPORTANT: The stop button shall always be in thelower ”pressed” position when the diesel engine is not inoperation. If the stop button is drawn out the stop magnetis actuated, which discharges the battery.

Driving of climber

– Start the diesel engine (see instruction above). Turn thebrake lever to release the control brake. Turn the operatinglever towards opsition ”Up”. The further the lever is turned,the faster the speed.

– Stop the climber by resetting the lever. Apply the controlbrake. Stop the diesel engine.

IMPORTANT: Never leave the cage without havingapplied the control brake.

Lowering the STH-5D & STH-5DD by gravitySTH-5D

Disengage the hydraulic motor by turning the disengaging leverthrough 180° (the lever should point away from the motor).Turn the brake lever to release the control brake. Turn theflywheel by hand until the climber starts moving. The speedwill then be automatically limited. To stop the climber turn thebrake lever to apply the control brake.

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STH-5DD

A man with a life line climbs down the ladder to the lower driveunit. Release the control brakes and turn the flywheelssimultaneously. If only one man is to lower the climber, procedeas follows:

IMPORTANT! Life line must always be used outside thecage.

1. Put on a life line.

2. Climb down to the lower drive unit.

3. Disengage the hydraulic motor.

4. Release the control brake (on the lower drive unit).

5. Turn the flywheel so that the drive unit moves downwardsuntil it stops.

6. Climb up into the cage.

7. Disengage the hydraulic motor.

8. Release the control brake (on the upper drive unit).

9. Turn the flywheel quickly. The upper drive unit will then”hit” the lower one and the climber will start moving. Thespeed is then automatically limited. To stop the climberduring descent, turn the brake lever to apply the controlbrakes.

If necessary, the climber can be driven downwards with thediesel engine. When the climber is driven backwards on thehorizontal part of the guide rail the speed will be comparativelylow. When engaging the hydraulic motor(s), turn the dis-engaging lever(s) to point towards the respective motors. Ifengagement is not obtained immediately, bring back the lever alittle, turn the flywheel a couple of degrees and turn the levertowards the motor again. Repeat if necessary. If the motor(s)must be engaged up in the raise, the control brake should not bereleased but the flywheel should be turned with the hand lever.

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Diesel-hydraulic driven service and safety climbersService climber Alitrolley 5D

See operating instructions for raise climber

IMPORTANT: The staff on the raise climber must beinformed of the ascent with the safety climber.

Safety climber Alicab 5D

Start and stop of diesel engine

Pull the strap with the black ball so that the large (not coloured)lamp lights up. The preheater plugs are then switched on. Afterabout 30 sec. pull the strap further to engage the starter. Whenthe engine has started, release the strap and the indication lampwill go out.

The engine is stopped by pulling the strap with the red ball untilthe engine stops.

Note! Do not pull the start strap while the engine is running.

Operating the climberStart the diesel engine. Turn the brake lever to release the stopbrake. Turn the operating lever to position ”Up”. The more thelever is turned, the greather the speed. Stop the climber byturning back the lever. Apply the brake. Stop the diesel engine.

During descent the climber can be driven down or lowered bygravity. Descent under gravity is done in the same way as forSTH-5D/DD.

IMPORTANT: There is no automatic device to stop thediesel engine if the oil level is to low in the engine orhydraulic oil reservoir, or if the V-belt of the cooling fansnaps. If the oil pressure indicator lights up the engine mustbe stopped immediately.

The staff on the raise climber must be informed of theascent with the safety climber.

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BrakesIf the control brake should be put out of operation, thedescending speed of the climber will be automatically limitedby the centrifugal brake. If both brakes should be defective, thesafety device will automatically stop the climber when thespeed has reached approx. 0.9 m/s (54 m/min.)

If the power transmission between drive unit and guide railshould fail – for instance in case of worm wheel breakage, shaftbreakage, pinion breakage or if the meshing between pinion andpin rack should be broken due to breakdown of counter-rollersin the U-frame and worn out stop cleats – the climber will falldown. The safety device will then stop the climber.

Safety deviceIf the maintenance of the climber is satisfactory, the risk oftripping due to breakdown of the drive unit is almostnonexistant. After tripping, drive unit and guide rail must bechecked before the climber is released. To release the climber,turn the flywheel(-s) counter-clockwise and the climber willmove upwards one or two centimetres (the air driven climberSTH-5L can be driven). If the climber moves up, an uninten-tional tripping has taken place and the climber can descend afterreleasing of the safety device.

Unintentional tripping is sometimes caused by exceptionalvibration due to, for instance, worn down guide rails, badlyfitted guide rail joints, incorrect tripping rotation speed etc.After tripping, check the tripping rotation speed (150 rpmtripping speed 0.9 m/s). Unintentional trippings can also becaused by worn out centrifugal brake linings, oil on the brakelinings or incorrect adjustment. The descent must then becarried out in steps while limiting the speed with the controlbrake to prevent another tripping.This is especially important if the safety device is installed ona heavy climber, since repeated tripping without resetting aftereach tripping can cause deformations.

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Resetting the safety device

After parking the climber on the horizontal bottom level of theguide rail, reset the safety device:

– Clean the safety device – especially the surfaces which shallbe divided/turned. Be careful so that dirt does not press inbetween the flange surfaces.

– Dismantle the four bolts (A).

– Turn the brake drum with the resetting lever in the directionof the arrows – until the white reflecting line is in the centreof the cross in the sight glass.

– Turn the drum in either direction until the holes for the boltsare in position.

– Put the bolts back and tighten. Tightening torque approx.75 Nm.

– Dismantle the cover of the safety device. Pull out the brakecone approx. 1 – 2 mm from the drum by means of platepart No. 9064 677-000 and 5 bolts M10 x 30. Tighten thebolts alternately. When the white reflecting line has movedapprox. 2 mm the brake cone is loose.

– When the cone is pulled out from the drum, dismantle thebolts and take off the plate. Reinstall the cover.

Exchange intervals, see sign on safety device.

IMPORTANT: From a safety point of view the safety devicemust never be dismantled more than is necessary to reset it.For this reason the safety device is sealed.

WARNING: Resetting of the safety device musttake place at the horizontal bottom level of theguide rail.

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D 15

Resetting lever

Bolt

Sight glass

Bolt M 10 x 30

Plate part No. 9064 677-000

Air and water central manifoldType LVL for air driven climber STH-5L & LLBefore ascending, open cock (10) – to enable remote control ofthe central manifold.

When cock (4) of the lubricator LB-2 has been turned off, thecentral manifold will open after about 1/2 – 2minutes. If cock(4) is opened the central manifold will turn off.

If there is a sizeable leakage in the guide rail tube, the pressurecannot be raised inside the rail and the central manifold will notopen. Connect a cock and a hose to the control valve – connectthe hose to cock (4). Air can now be blown into the rail to raisethe pressure enough to open the central manifold.

When ventilating the raise, turn off cock (10), and push lever(6) completely or partly forwards depending on the requiredamount of air and water. After the ventilation, open cock (10)and the central manifold will turn off.

Type LVE/D for STH-5E/EE and STH-5D/DDThe central manifold is turned off when cock (10) is open, andthe switch in the cage and the switch on the remote control arein position ”Off”.

Note: The air and water central manifold cannot be remotecontrolled if the main current supply is broken.

On the floor of the raise the operation of the air and watercentral manifold is done from the remote control. Beforeascending do not forget to reset the switch to position ”Off”. Ifthis is not done the central manifold cannot be turned off fromthe climber.

If only a small amount of air and water is required for theventilation, turn off cock (10) and put lever (6) in the requiredposition. To turn off the central manifold, open cock (10).

There is a cock on the central manifold for emptying the guiderail of water before blasting. If the rail is empty, the risk of O-ring damage when falling rock hits the guide rail is limited. Thisis especially the case when the height of the raise is more than300 m.

IMPORTANT: Never empty the rail of water withoutmaking sure that the cock on the lubricator (if mounted) atthe top of the guide rail is open. If it is closed, the vacuumwill change the positions of the O-rings, which will result inleakage.

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D 16

Open

106

Lubricator LB-2 or connection plate with 4 cocks

1

11

Turned off

23

4

Air operated safety roofAir driven climber STH-5LIf the roof is mounted on a air driven climber it can be operatedanywhere in the raise if the air supply to the climber is turnedon.

Electric or Diesel-hydraulic climber STH-5E/5DIf the roof is mounted on a electric or diesel-hydraulic drivenclimber, it cannot be operated when the climber is being driven.When the climber is in working position, the air for operatingthe roof is taken from the guide rail via lubricator or headerplate.

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D 17

Air operated safety roof

C

For STH-5E/EE& STH-5D/DD

Single-acting cylinderin support leg

Double-acting cylinder

For STH-5L/LL

C

A

WARNING!

This elbow has a restriction forreducing the lowering speed ofthe roof. The elbows mustconsequently not be replacedwith standard elbows. Not valid for safety roof withwelded inlet plug.

B

Operation

The roof is raised by opening cock (A) (– leave the cock open).The height can be adjusted by changing the lengths of thechains – they should be equally long for both legs. To lower theroof, turn off cock (A). The weight of the roof will then pressout the air through the outlet channel of the cock.

When driving the climber, make sure that the roof is in its upperposition.

Adjust of the angle of the roof is done with valve (B). Push orpull the valve lever to press the roof against the guide rail. Putpins (C) in the required holes. Put the valve lever in its otherposition. The roof then tilts over to the required position and thesupport legs are pressed against the pins.

During ascent or descent, make sure that the roof is in its topposition and that the legs are parallel with the centre line of theraise.

In many cases the space in the curve does not allow the safetyroof to pass without changing its angle. This can be done if ahose with cock and claw couplings is available in the curve andaccessible from the cage. Connect the hose of the safety roof tothis hose and you will now be able to operate the roof.

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D 18

LubricatorType LB-2Can be used with all types of raise climbers.

The lubricator is mounted with four bolts to the header plate.When it is connected it supplies oil/air mixture to two drills.Four O-rings seal the joint between guide rail and lubricator. Lubricator LB-2 is equipped with four cock connections, twofor oil/air mixture, one for water, and one for operating air- andwater central manifold LVL.

Oil reservoir, capacity: 3 litresOil quality: pneumatic tool oilMax. operating pressure: 1 MPaWeight: 23 kg (excl. oil)

1. Lubricated air 6. Bleed before topping up.2. Water cock 7. Pipe plug3. Pipe plug 8. Adjusting screw for oil su.4. Cable seal 9. Cock for operating air and water central 5. Filler plug manifold LVL.

Type LB-3Can be used with electric and diesel-hydraulic raise climbers.

The lubricator is mounted with four bolts to the header plate.When it is connected it supplies oil/air mixture to three drills.Four O-rings seal the joint between guide rail and lubricator. Lubricator LB-3 is equipped with four cock connections, threefor oil/air mixture, one for water.

The air and water central manifold is operated electrically withelectric and diesel-hydraulic powered climbers. Thus there is nocock for this purpose on LB-3.

Oil reservoir, capacity: 4.6 litresOil quality: pneumatic tool oilMax. operating pressure: 1 MPaWeight: 27 kg (excl. oil)

ALIMAK 30948 - 1/01

D 19

11

4

2

56

3

8

7

9

1

1

12

4

56

3

8

7

Adjusting the oil supply

Remove pipe plugs (7). The oil flow increases when theadjusting screw is turned counter-clockwise. The oil flow is cutoff completely when the adjusting screw is turned fullyclockwise. After adjusting, replace pipe plugs (7). Make surethey are tightened securely. Any leakage means that thelubricator cannot work satisfactorily.

Where the signal/ignition cable is placed inside the guide tube,remove pipe plug (3) and screw on the cable seal (supplied withthe telephone equipment).

Maintenance

In the event of failure, remove the filler plug, the gable endplug, the pipe plugs and the adjusting screws. Blow through allpassages and the pipe at the filler hole in the tank withcompressed air.

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D 20

High pressure water pumpType 50/3 E is powered by a 5.5 kW electric motor and type50/3 L by an Alimak K-14 air motor.

The pump is identical for both types. It has 3 cylinders withenamelled interiors. The pistons have cup-shaped replaceablepiston packings.

Capacity type 50/3 E type 50/3 L

Flow rate 40 – 60 l/min 40 – 60 l/min.Pressure (adjustable) 500 – 6000 kPa 0 – 6000 kPa

(5 – 60 bar) (0 – 60 bar)

Start-up and operationElectric driven pump type 50/3 E

Before start-up, check that there is oil in the pump crankcase.See ”Lubrication”.

To obtain an even pressure (flow), air can be pumped into thereservoir as outlined below. This should be done at the initialstart-up and then as required.

a) Drain off any water from the air reservoir.

b) Start the pump with the suction strainer below the watersurface and run it for about 1 minute to prevent the pistonsfrom running dry.

c) Drain off the water from the pump (loosen pressure line (6).

d) Start the pump with the suction strainer lifted. After about30 sec. lower the suction strainer into the water.

e) If there are air locks because air has been pumped too long,open the plug on the side of the pressure valves.

Required water pressure is set (from low to high pressure) asbelow:

1. Close valve (20).

2. Turn hexagon nipple (5) in counter-clockwise direction, tolower the pressure, or clockwise, to get a pressure of 2000– 2500 kPa (20 – 25 bar). Start the pump and check onmanometer.

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D 21

10

9

11

8

100 mm

3

4

ALIMAK 30951 - 1/01

D 22

3

1

46

4

7

2019

2

18

5

3. Open valve 20.

4. Pressure can now be set with the adjustment screwon theoverflow valve (19) between 500 kPa and the earlierpressure of 2000 – 2500 kPa.

5. To increase the pressure to more than 2000 – 2500 kPa,close the valve (20) and turn the hexagon nipple (5) clock-wise to required pressure.

1. Oil filler plug with dipstick 8. Suction strainer 15. Air regulator2. Pressure regulator 9. Water reservoir 16.3. Suction hose 10. Water line 17.4. Return hose 11. Float 18. Plug5. Nipple for adjustm. of water pressure 12. 19. Overflow valve6. Pressure line 13. 20. Valve7. Manometer 14.

Air driven pump type 50/3 L

a) Blow through air hoses and lines with compressed air befo-re connecting them to the pump.

b) Check before start-up that there is oil in the pump crankca-se and in the air motor lubricator. See ”Lubrication”.

c) Check that the suction strainer (8) is below the water surface.

d) Close cock (17) – handle horizontal!

e) Turn hand-wheel (14) counter-clockwise until the air regu-lator (15) is fully closed. Open cock (16).

f) Turn hand-wheel (14) clockwise until the pump starts torotate and the required pressure is obtained,

g) Screw the needle valve while the motor is running until therequired oil flow (approx. 1 drop/sec.) is obtained. Checkthrough the observation glass. More oil – screw counter-clockwise, less oil – screw clockwise.

At intervals check the number of drops through the obser-vation glass – if necessary adjust the setting.

h) To obtain an even pressure (flow), air can be pumped intothe air tank – see items c), d) and e) under headline”Electric driven pump type 50/3 E”.

Before blasting the pump is stopped by closing cock (16).When the pump is started, by opening cock (16), it should beopened slowly so that the air motor is prevented from racing. Do not rev the air motor, the max. speed is 1500 rpm.

Required water pressure is set by changing the air pressure tothe motor through air regulator (15). Turning the adjustinghand-wheel (14) clockwise increases the water pressure. Thepressure regulator (2) on pump type 50/3 L only functions as asafety valve. It is preset at the factory to open at 6000 kPa (60bar) and should normally require no alteration.

Avoid setting the water pressure so high that the pressureregulator (2) is forced to open, as this results in a pulsatingpressure and unnecessary wear of the pressure regulator (2).

Valve (17) contains a leak hole which lets through a small waterflow from the pressure line to the return line. Even if no water isconsumed the pump will thus rotate at low speed. The speedthen increases in proportion to the water consumption.

IMPORTANT: Check at first start-up that the pump issucking water. If this is not the case, lift up the suction hoseabove the pump and fill it with water. The pump must notbe allowed to run dry.

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D 23

ALIMAK 30953 - 1/01

D 24

1. Oil filler plug with dipstick 8. Suction strainer 15. Air regulator2. Pressure regulator 9. Water reservoir11. 16. Valve On/Off3. Suction hose 10. Water line 17. Valve4. Return hose 11. Float 18. Plug5. 12. Lubricator with oil reservoir6. Pressure line 13. Sight glass7. Manometer 14. Adjusting hand-wheel

6

12

4

2

16

18

3

1

17

7

1415

13

Alimak Dupline systemThis equipment is used for transmitting signals from raiseclimber to base station or vice versa.Signals from climber are: Alarm, Power ON/OFF, Air/WaterON/OFF, and Audio call signals.

Only Audio call signalling is used in the opposite direction,(from base station).

The system is powered by batteries in climber and a DC powerunit at the base.

Study the fenclosed description and circuit diagrams for moredetailed information.

Principal Function

Explanation of the 3-wire system (Dupline). Only three wiresconnected to all the inputs/outputs signals at the variouslocations in the Base panel and Main panel on top of the cage.These (non-shielded) wires of a standard installation cablehandle both, the signal communication and the supply of powerto any output load.

One Pulse generator is located in the Base panel, witchgenerates pulse trains and synchronizes the transmission signalsfor an entire of the I/O-unit (signal transmission units).

I/O-units (Signal transmission units) is located in the Base paneland the Main panel on the top of the cage. This I/O-unit usesthree wires for the communication with all other I/O-units. Eachunit has 4 inputs (NPN/contact) and 4 outputs (PNP). Everyinput and output is given its individual adress with theprogramming unit (GAP 1605). The On/Off-signal that isapplied to an inputs of any I/O-unit is associated to the adressgiven to that input. Any output of all I/O-unit that is given theidentical adress will now follow that input signal and switch itsoutput signal ON or OFF. This means that a signal that is aninput at one location (for examples as an output form the PLC)may be output wherever required and as many times asrequired. The input pulse is prolonged 0.5s to ensure transfer offast pushbutton activation.

Programming unit GAP1605

The GAP 1605 is a portable-programming unit used for readingor programming channel code(s) in the ASIC-based series ofDupline products.Once the battery is installed, the GAP 1605 is ready for use.Connect the cable between the programming unit and I/O-unit(signal transmission unit). 5 keys provide the means of operating the GAP 1605: two keysare used for reading and programming, two keys for changingGroups and channels and one key for selecting the desired Input/ Output.

ALIMAK 34213 - 1/03

D 25

ALIMAK 34214 - 1/04

4 x 8 LED’s display the current coding. The top row of theLED’s displays the selected input or output. The two middlerows display the current channel groups, while the bottom rowdisplay the current channel code.

<< In/Out >> - key

This key is used to scroll though the I/O’s of a module. If a newmodule is connected off consecutive channel codes areallocated to the I/O’s pressing the << In/Out >> key has noeffect since all Dupline modules are programmed to theirphysical number of inputs/outputs. This key is also used toswitch between consecutive and individual coding of the mode;keep << In/Out >> pressed for more than 2 seconds.

<< Group >> - key

Used to select the Group adress within the range A to P. theGroup LED will shift one position right for each key activation.

<< Channel >> - key

Used to select the channel(s) within the group. The ChannelLED will shift right one, two or four positions, depending onthe number of inputs/outputs. If consecutive channels areselected then pressing the << Channel >> key will have noeffect.

<< Read / On >> - key

Used to turn on the GAP 1605 and to read the channels codes ofthe connected module. When the reading is completed, thedisplay will show the channel code of the module: either 1, 2, 3or 8 inputs/outputs.2, 4 or 8 In/Out LED’s being ON indicates that consecutivechannel codes are allocated to the I/O’s e.g. input 1 coded to P1,input 2 to P2 … input 8 to P8.If only one In/Out LED is ON, and then the I/O’s are codedindividually, e.g. input 1 to C5 input 2 to D4 etc. A group LEDand channel LED indicate the code for each I/O.If the GAP 1605 is not connected to a dupline system, it willturn off within two seconds.

<< Prog >> - key

when the displayed I/O-coding corresponds to the desiredchannel configuration, the codes will be downloaded to theDupline module when pressing the << Prog >> key.After programming is executed, verification takes place. If thisverification fails, all activated LED’s in the display will flashtwo times, and programming unit will switch off.If such behavious occurs repeatedly on the same module, themodule may be faulty. If several modules fail to download, theGAP 1605 may be faulty.

ALIMAK 34215 - 1/03

D 27

Individual In/Out channel programming

The GAP 1605 features an additional mode of single channelediting. Pressing << In/Out >> key for more than 2 seconds willchange the operating mode to single point programming. The<< In/Out >> - key is now used to select one of the eightpossible inputs/output, thus making individual channel codingpossible. The In/Out-LED’s assigned the display channel codeto the corresponding physical input/output of the module.In single mode the << Channel >> key also has the ability todisable an In/Out-position. << Channel >> must simply bepressed past channel 8, whereby both the channel LED and theGroup LED will turn off. To reenable, just press << Channel >>again.It is possible to change all eight Inputs/outputs, even thoughsome Dupline modules are built for only 1, 2, or 4Inputs/Outputs.To exit single channel programming, just keep the << In/Out >>pressed for 2 seconds.

Output status setting

On receivers it is possible to configure the status of the outputsduring Dupline Failure. Normally, any output of a receiver willgo off during Dupline Failure. In some cases the invertedfunction is desirable (e.g. light applications – turn on light if theDupline is down)

To change output status, the GAP 1605 must be put intoconfiguration mode. This is done as follows:

– Remove any connected Dupline system.– Keep both << In/Out >> and << Group >> pressed, while

pressing << Read/On >>.

The first In/Out LED now turns on. Connect the DuplineSystem, and Press << Read/On >>. If output status is set, thenchannel LED 1 will illuminate. Pressing << Channel >> willtoggle the output status On/OFF.Press << Prog >> to store.If << Read/On >> is pressed when no Dupline system isconnection, the LED’s will flash to indicate a false condition.Only a successful reading will reset this condition.

ALIMAK 34216 - 1/03

D 28

Other Features

To code a Dupline module off-line, neither Dupline normalpower to supply the module is required. Simply connect themodule to the programmer and start coding

If On-line coding (module connected to an operation duplinesystem) is performed, the module automatically disconnect ifself form the Dupline and returns to normal operation after theprogrammer cable is disconnected.The GAP 1605 automatically turns off when no key has beenpressed within the last 30 seconds.

If the connection cable is removed from the Dupline module,the GAP 1605 will switch off within 2 seconds.

Low battery indication

When battery is low, the In/Out row of LED’s will rollcenterwards in an eye-catching manner.

Warning

When using the GAP 1605 you must connect the cable to theGAP 1605 before connecting the cable to any Dupline modulethat is to be coded. Even so, the cable must first be removedform the Dupline module before disconnecting it form the GAP1605.Without observing these precautions you may destroy the ASICinside the Dupline module though static discharges.

Caution

To ensure long battery life, always remember to remove thecable form the Dupline modules. The Dupline modules will bekept in an inactive state as long as the GAP 1605 in connected.

ALIMAK 34217 - 1/04

D 29

ALIMAK 34218 - 1/04

D 30

SERVICE AND MAINTENANCE

Service and maintenance ...............................Adjustment and wear limits ..........................Brake torque ...................................................Worm gear.......................................................Pinion ...............................................................U-frame............................................................Guide roller .....................................................Guide rail.........................................................Pin rack ...........................................................Lubrication diagram ......................................Hydraulic system ............................................

ALIMAK 30954 - 1/01

E 1E 4E 4 E 5E 6E 6E 7E 7E 7E 10E 13

E 0

Service and maintenance In order to avoid unnecessary breakdowns, those responsible forthe service and maintenance of this equipment must regularlyensure that all scheduled maintenance work according to themaintenance programme below is carried out at the recommen-ded intervals.

Adjustments and replacement as a result of checks, must becarried out by trained/authorized servicepersonnel. Only ALIMAK Genuine Spare Parts must be used.

WARNING! Care, lubrication, repair etc. must only be carried out on a protected site.

When carrying out work service, the mainswitch must be switched off, locked andprovided with a warning sign.

Service intervalsIntervals based on operating time shall be followed in the firstinstance. If the climber is used only periodically, the firstapplicable interval to be reached shall be followed.

ChecklistChecklist, with room for notes on maintenance executed, will befound at the end of this manual. Use them!

Service and maintenance scheduleSee the appendix at the end of this manual for tightening torques.

ALIMAK 30955 - 1/01

Interval Part Instructions

8 operating 1. Cleaning Flush away sludge, cuttings etc. from the climber and guide rail curve.hours or at least 2. Safety device Check that the mounting and counter-roller of the safety device are without.once a day defects.

3. Rollers in the U- Check that the rollers in the U-frame and in the roller assembly are free fromframe and rollers defects. Don´t forget the rolles inside the U-frame!in roller assy.

4. Telephone equip- Check the telephone equipment. For air- and diesel-hydraulic climbers a test ment cable must be connected between the climber and the main electric box.

5. Control brake Check function of the control brake. See also the special instructions forchecking brake torque with a spring balance.

6. Diesel fuel Refill fuel – valid for diesel-hydraulic climbers only!

7. Lubricating See the instructions in the ”Lubricating diagram”.

E 1

ALIMAK 30956 - 1/02

Interval Part Instructions

40 operating 10. Sign plates/ Check that all signs are in position and that they are legible. parts manual,hours or at least instruction that they are legible. Check also that the documentation according to theonce a week manuals documentation box is available.

11. Attachments Check all attachments: bolts, nuts, pins etc.

12. Guide rollers Check the guide rollers for wear, bearing play and operation acc. toinstructions later in this chapter No rollers must be missing.

13. U-frame Check U-frame according to instructions later in this chapter.

14. Pinions Check the wear of the pinions (incl. the safety device) later in this chapter.

15. Control brake Check brake torque acc. to instructions later in this chapter. Replace thelining when it is worn down to 3 mm.

16. Centrifugal brake Check the centrifugal brakes. The upper brake should be turned so that thecooling air intakes are turned downwards when the climber is on thehorizontal part of the guide rail. Repalce the linings when they are worndown to 3 mm.

17. Lubricating See the instructions in the ”Lubricating diagram”.

18. Function test – air driven climber:Check that the air motors receive oil. Disengage the motors and run them.Oil should then emerge from the motor outlets.

– electric driven climber:See headline ”Start instructions”.

– diesel-hydraulic climber:See instruction manual for diesel engine. Also check that there are no fuel oroil leaks.

19. Operating control Check that the operating control moves freely and that no bolts and nuts have– valid for diesel- worked loose. Also check that the mounting of the control arm on the hydraulichydraulic climber pump and that the ball joints moves freely.only

20. Electric wiring. Check all wires/hoses, sealing glands and connections. Especially the dieselincl. air- and power pack to see that the insulation is not chafed off anywhere.hydr. hoseswhere applicable

21. Diesel-hydr. Check that there are no fuel or oil leaks. Valid for diesel-hydraulic drivenpower pack climbers only.

22. High pressure Check crankcase oil with the dipstick on the filler plug. Clean the magnet onwater pump the dipstick.

125 operating 25. Safety device Check the operation of the safety device.hours or at least 26. Guide rail The guide rail should be checked and all nuts tightened. No pins must be misonce a month sing from the rack. The guide rail must be repaired or scrapped when the

pins of the rack are worn down to 16 mm, or when the rack flats are worndown to 2 mm above pins.

27. Worm gears Check worm gears according to instructions later in this chapter.

28. Insulator in Detach the high pressure hose from the guide rail bottom insulator and clean guide rail end the hole through the insulator.

29. Lubricating See the instructions in the ”Lubricating diagram”.

30. Signal equipment Check the function of the control device, alarm signal, lighting, and, where and lighting applicable, voice communication system.

E 2

ALIMAK 30957 - 1/01

Interval Part Instructions

31. Control valve for Clean air filter inside the valve with white spirit or suchlike and compressed air motor – valid air.for air drivenclimber only

32. Diesel engine – Routine maintenance according to munufacturer´s handbook.valid for diesel-hydr. drivenclimber only

250 operating 35. Diesel engine Routine maintenance according to munufacturer´s handbook.hours or at least 36. High pressure Check belt tension and adjust if necessary.every 3rd month pump

500 operating 40. Contactors – Check the condition of the contact points in the contactors.hours or at least valid for el. driventwice a year climber only

41. Shaft couplings Check.

42. Motor overload Check that the motor overload ptotector is set with the rated current on theprotection – data plate for the electric motor.protectionvalid for el. drivenclimber only

43. Corrosion, Inspect the equipment in its entirety for corrosion and wear on loadbearingdamage and and force-absorbing components with the aid of an ultrasonic thickness meawear suring instrument. This inspection any actions which may need to be

taken after the inspection must be performed by trained/authorized servicepersonnel.

A method for internal corossion protection of the guide rail tubes isavailable, please contact your ALIMAK representative.

44. Lubricating See the instructions in the ”Lubricating diagram”.

45. Diesel engine Routine maintenance according to munufacturer´s handbook.

1000 operating 50. Diesel engine Routine maintenance according to munufacturer´s handbook.hours or at leastonce a year

Annually 55. Complete hoist Have the complete hoist checked by a qualified technician.

Every 3.rd year 60. Safety device Replace the complete safety device.or acc. to sign onthe safety device

E 3

Adjustment and wear limitsBrake torqueMeasuring the brake torque is done with the climber in thehorizontal drift or the drive unit on the floor.

Disengage the motors on air- and diesel-hydraulic climbers

1. Apply the brake.

2. Fit the hand lever in one of the holes in the flywheel.Hook the spring balance onto the outer end of the lever.

3. Turn the flywheel by pulling the spring balance.Read max. force on the balance while turning the flywheel.Note: the angle between balance and lever – 90°.

4. Measure distance L.

5. F x L = the braking torque.

Example: F = 180 N L = 0.4 m

Braking torque = 180 x 0.4 = 72.0 Nm (or 7.2 kpm)

Minimum allowed braking torque = 40 Nm (or 4 kpm).

At workshop overhauling, it is recommendable to adjust thetorque to min. 60 Nm (or 6 kpm).

ALIMAK 30958 - 1/01

E 4

Brake curve

Cleat

Brake drum

Flywheel

Disengaged motor

Brake shoe

Cup spring

F

L

90°

Worm gear

Check if the worm gears are worn. This is done on the serviceguide rail with the rack section remowed.

One flat iron bar 60 x 6 length 450 mm is bolted onto thepinion.

Measure the distance between the flat end and the rack. Turn thebar upwards and measure the distance to the rack again. Thedifference between the dimensions must not exceed 3.9 mm.

When the worm wheel is replaced, the worm screw should alsobe replaced.

IMPORTANT: If the climber is exposed to abnormal load,e.g. a heavy rock fall, or there are other reasons to suspectthat the worm gears have been overloaded, e.g. runningagainst a mechanical stop which results in a sudden stop, thegears must be dismantled and checked.

ALIMAK 30961 - 1/01

E 5

Hole dia. 21 mm

< 3.9 mm

450 ± 5 mm

PinionCheck wear on pinion with gauge Part. No. 9046 516-000

U-frameCheck wear and deformation on U-frame with gauge Part. No.9046 516-000 according to the figure.

Stop cleats A

Check the stop cleats (4 pcs.) inside the U-frame. If the climberis driven with big breakdown rollers inside the U-frame, hard-facing deposit must be added up to the height of the originalsurface.

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E 6

Min. 15 mmNom. 17.5 mm

A A

Roller

Max. 170 mmNom. 168 mm

U-frame

Guide roller

Measure with sliding caliper.

Dimensions New roller Worn-out roller(mm) (mm)

D Ø 72 min. Ø 71D Ø 124 min. Ø 123

Note that the ”wearing” on the roller face must be equal – allaround.

Guide railCheck wear on guide rail with gauge Part No. 9046 516-000 ac-cording to the figures.

Pin rack

Check wear on pins with gauge Part. No. 9046 516-000

ALIMAK 30963 - 1/02

E 7

Min. 16 mmNom. 19 mm

Min. 43.5 mmNom. 48 mm

Min

. 2 m

m

Min. 165 mmNom. 167 mm

Guide rail

use the gauge (thickness 2 mm) Min. 33.5 mmNom. 38 mm

D

Directions for the safety check and repair of a used raise climber guide railCheck and repair in accordance with the list below, arerecommended as minimum measures and do not limit oreliminate the further responsibility of the end user. The repairsand check of the guide rail shall be made by persons, wellaware of the actual norms.

Cleaning

Each guide rail must be cleaned, so that welds and material canbe used for reliable tests. Preferrably, sand blasting should beused.

After cleaning

After cleaning, the guide rails shall be sorted out by aqualified and well informed person. A guide rail must not beused if any of the following faults can be found.

a) The thickness of the end plate with O-ring positions is lessthan 12.5 mm.

b) The thickness of the opposite end plate is less than 9.5 mm.

c) Big damages like compressions and bendings of the pipewhich is farthest away from the rack, in combination withother damages and general wear.

d) If the same pipe has been damaged by corrosion, which willjeopardize the strength of the pipe. The pipe must not at anypoint have a wall thickness of less than 3.5 mm. This ischecked by means of ultra-sonic sounding part No. 3001991-301

e) If the guide rail is otherwise deformed and worn out.

f) If crackings in welded joints and material can be regarded asserious and cannot be measured safely enough.

g) If the guide rail section has been worn more than the limitsprescribed.

ALIMAK 30964 - 1/01

E 8

Greasing control brake for the air motorThe coupling half inside the upper coupling housing is equippedwith a grease nipple. For lubrication, remove the plug on theupper brake housing.

Turn the flywheel by means of the hand lever until the greasenipple can be seen through the hole. Disengage the motor andgrease sparingly.

Note! If you use too much grease it might come into contactwith the brake linings.

ALIMAK 30965 - 1/01

E 9

Plug

Grease nipple

Lubrication diagramThe oil in the worm gears shall be changed after the first 25 operating hours. At the same time, change the hydraulic

oil filter if the hoist is a model with diesel-hydraulic machinery. Also change crankcase oil in the diesel engine, atsame time.

INTERVAL ITEM LUBRICATING POINT LUBRICANT VOLUME INSTRUCTIONS

8 operating hours 1 Control valve for air Shell Torcula 1,1 lit. Refill oil.or at least once a day driven climber. Oil 32

– Control valve for hose / Shell Torcula 1,1 lit. Refill oil.cable reel. Oil 32

– High pressure water pump Oil The regulators liftingspin-dle should be lubricatedwith oil once a day. Alsoinject a little oil into thelarge hole on th side ofthe regulator.

– Air driven high pressure Shell Torcula Refill oil in lubricator.water pump only. Oil 32

40 operating hours 2 Safety device with frame. Grease Grease nipples. 8 pcs. orat least once a week (12 pcs. for extra roller

assy. where applicable.

3 Upper coupling half and Grease Grease nipples.2 pcs.shaft for release lever. Dismantle the pipe plugValid for air driven on the brake housing andclimbers only! turn the flywheel until the

grease nipple can be seenthrough the hole. Disen-gage the motor. Greasesparingly!

4 Rollers on U-frame with Grease Grease nipples. 6 pcs.climbing machinery. (12 pcs. for climber with

two machineries).

5 Worm gears. Alioil HD Check level and refill – ifnecessary.

6 Lower coupling half and Grease Grease nipple. 2 pce.shaft for release lever. (4 pcs. for climber withValid for air and diesel- two machineries).hydraulic climbers only! Turn the flywheel until

the grease nipple can beseen through the hole (airdriven climbers only!)Disengage the motor.

7 Rollers on suspension frame Grease Grease nipples. 6 pcs.for diesel-hydraulic power pack. Valid for diesel-hydraulic climbers only!

8 Control brake. Valid for Grease Grease nipple. (1 pce. forelectric and diesel-hydraulic climber with twoclimbers. Also grease links machineries). Also greaseand guides for syncronising brake lever curve/-s. rod for climber with twomachineries.

– Cable -/Hose reel Oil Oil rollers, chains andlinks.

– Cable reel spooling device Grease Grease nipple. 1 pce.

– Air and water central Oil Oil links and moving parts.

ALIMAK 30966 - 1/02

E 10

INTERVAL ITEM LUBRICATING POINT LUBRICANT VOLUME INSTRUCTIONS

125 operating hours 12 Diesel engine See manufacturers 9.5 lit. Change crankcase oil.or at least four times handbooka year

250 operating hours 13 Diesel engine See manufacturers 9.5 lit. Change crankcase oilor at least four times handbooka year – High pressure pump Shell Omala 68 6.0 lit. Change crankcase oil

400 operating hours 15 Worm gears Alioil HD 3.0 lit. Change oilor at least twice a year

800 operating hours 16 Hydraulic oil Shell Tellus 40 lit. Change oilor at least once a year Oil TX 46

The lubricating oil grades indicated above have been used when the equipment is delivered from the factory. Only oilrecommended by ALIMAK shall be used. If for some reason this is not possible, please contact ALIMAK or ALIMAKRepresentative for advice.

ALIMAK 30967 - 1/01

E 11

4

5/15

6

7

1

8

121316

3

2

45/15

6

7

1

121316

3

2

4

5/15

6

8

8

ALIMAK 30968

E 12

Hydraulic system General information on service workA particle as small as 10 µm (1/100 mm or .000394”) can, causea pump or motor breakdown in the hydraulic system. Considerthe fact that the smallest particle which can be detected by thenaked eye is about 40 µm and you can imagine the requirementsfor cleanliness which apply when working in a hydraulic system.

– Always give top priority to cleanliness requirements. Haveplastic bags at hand for spare parts and plastic plugs forplugging hoses and pipelines.

– Never use cotton waste or other fluffy rags – always use aspecial drying cloth.

– Never use teflon tape to seal threads.

– Always make sure that hoses and other spare parts are care-fully cleaned.

– Remember, a coupling or connection which begins to leakcannot, as a rule, be tightened by force.

– Always change the insert in the hydraulic oil filter and thehydraulic oil, and flush the system thoroughly, when replac-ing the hydraulic pump or motor if a breakdown occurs.

IMPORTANT! Due to high oil pressure only ALIMAKGenuine Spare Parts may be used.

WARNING: Never use your hand or any otherpart of your body to locate a leak in a pressurizedhydraulic oil system.

ALIMAK 30969 - 1/01

E 13

Diesel-hydraulic power unit

Hydraulic oil tankThe tank is equipped with a sensor which indicates “insufficientoil level” in the hydraulic tank. The tank is also equipped with alevel glass. The level of the hydraulic oil must always be visiblein the glass.

Discharge condensate from the hydraulic oil tank regularly, once

a month or so, by removing the drain hose plug and permitting afew centilitres of fluid to run out, before tightening the plug.This must always be done after a lengthy period of down time– before the climber is put into operation.

The tank is filled with Shell Tellus TX 46 on delivery from thefactory. Be sure to use oil with the same specification since oilalways remains in the system, when changing oil.

Hydraulic oil filterThe hydraulic oil is filtered by a filter on the pressure side of theservo system. The filter is of intermediate pressure type and hasa filtration degree of nominal 10 µm.

Replacing oil in the hydraulic system1. Warm up the system to 20 – 30°C, (68 – 86°F).

2. Empty the tank into a suitable container, (approx. 40 litres )

3. Remove the spin on filter and mount a new one.

4. Fill up with new hydraulic oil. Use thoroughly cleaned con-tainers.

5. Start the motor and let it idle for about 10 minutes.

6. Check the oil level and refill if necessary.

ALIMAK 30970 - 1/01

E 14CONDENSATE

HYDRAULIC OIL

Inspection of hydraulic hosesInspect hoses for leakage and signs of deterioration.

Leakage

This refers to leakage in the hose itself or leakage between thehose and the hose coupling. If such leakage is detected, the hosemust be replaced. Incipient leakage can be characterised by:

– oil in the transition between the coupling and hose.

– a swelling at the rubber cover adjacent to the coupling or, inrare cases, along the hose.

Signs of hose deterioration

The first signs of hose deterioration are cracks in the rubbercover. Check hoses by bending them and looking for cracks.

Hoses with such symptoms should be replaced at the nextsuitable occasion. There is no immediate danger of rupture.

Other damage

Hoses should also be replaced when mechanical damage takesplace, such as puncturing of the rubber, kinking or crushing.

Operating temperatureA temperature of up to 80°C (176°F) can be regarded as normalfor the hydraulic oil.

A higher temperature will result as the hydraulic oil oxidizesforming products which impair the viscosity of the oil, which isa measure of its flow characteristics. Furthermore, water will bebound in the oil by condensate which always occurs when thetemperature fluctuates alternatively upwards and downwards.The larger the temperature difference, the greater the condensate.

One reliable sign that the oil contains too much water is, that itbecomes grey and cloudy.

The water can be drained off after a lengthy period of downtime. See previous pages. If no such down time period isavailable within the near future, the oil has to be changed.

ALIMAK 30971 - 1/01

E 15

TROUBLESHOOTING

Electric troubleshooting .................................

ALIMAK 30973 - 1/02

F 1

F 0

ALIMAK 30974 - 1/01

F 1Electric troubleshootingAdvice concerning procedures for troubleshootingAll forms of troubleshooting require adapting the procedure tothe function and structure of the equipment in question and toother conditions which may be local in nature. For example, themine, maintenance, previous operational disturbances, etc.

The main principles for all forms of troubleshooting in electricsystems are presented below. Troubleshooting is carried outwith the aid of a test lamp or voltmeter. We recommend avoltmeter – preferably a universal instrument – for rapid andreliable troubleshooting.

WARNING: Danger! High voltage. Work on theelectric equipment in the machinery may only becarried out by an authorized electrician orauthorized service personnel.

1. Use the circuit diagram. This shows how the electricequipment should function, and how it is built andconnected.

1a. Check that the stopping circuit is not broken, in other wordsthat thermal relays and phase failure relays have not beenactuated and that the control switches in the stopping circuitetc. have their contacts closed. Make sure that stop bottons,are not in the depressed position. When the stopping circuitis unbroken, the main contactor, if any, shall be in the ”On”position.

2. Connect the voltmeter/test lamp between the zero terminaland the terminal as indicated on the circuit diagram, andcheck that power is supplied where it should be supplied. Gothrough each terminal, one by one, and work methodicallyso that the circuits which function correctly can beeliminated and the fault can be localized.

3. Begin at the base station by checking that power issupplied on all three phases of the incoming main voltage.

4. Check that the outgoing power cable receives power whenthe main switch is switched on.

5. Now begin troubleshooting in the climber by checking thatthe power reaches the climber.

6. Check in the equipment cabinet to ensure that power occurson all three phases of the incoming cable from the basestation.

Mechanical, hydraulic- and pneumatic truouble-shooting – See Repair Manual.

8. Make a trial run and check that the coil on the contactor receives power and that it is actuated.

9. If the fault does not occur in the climber operating system but in its lighting or signal system,carry out fault-tracing in a manner similar to that described above, in other words check thecircuits methodically one by one until you have narrowed down the fault and localized it.

Experience shows that certain fault causes have symptoms which, in turn, may indicate the causeand the probable location of the fault:

Example:

Symptom Probable cause Probable fault location

a) Control fuses blow Short-circuit, equipment Damaged control cable, da-immediately. grounded. maged pushbutton,etc. locat-

ed ”outside”,

b) Fuse blows after a short Equipment partially grounded, Damp or water in switch, con-time. overload. nection box, etc due to dam-

age delectric installation.Improperly connected newequipment.

c) Hoist stops or cannot be Switch in stopping circuit Stop pushbutton depressed,started. has tripped/been actuated, thermal relay actuated due

blown fuse. to overload or careless opera-tion, power failure fromsupplying network. See alsoa) and b) above.

ALIMAK 30975 - 1/02

F 2

Tightening torqueRecommended torquesThe chart applies to galvanized screw and nut of strength class8.8 – dry surface.

Dimension Spanner size TorqueNm lbf x ft

ALIMAK 31176 - 1/01

Appendix

M 6M 8M 10M 12M 14M 16M 20M 24

1/4” UNC3/8” UNC1/2” UNC5/8” UNC3/4” UNC1” UNC1 1/4” UNC

10 mm13 mm17 or 16 mm19 or 18 mm22 mm24 mm 30 mm36 mm

7/16”9/16”3/4”

15/16”1 1/8”1 1/2”1 7/8”

718356095146285493

829691372415771142

10244781128198386668

1139941863277831549