AirScrubPro Maintenance Manual

P&H AirScrubPro Maintenance Manual Preface
Preface
This manual is provided as a guide to personnel involved with the operation, maintenance and repair of this mining
shovel. We recommend that such personnel review and become familiar with the general procedures and informa-
tion contained within this manual. In addition, we recommend that this manual be kept readily available for refer-
ence when repairs or maintenance are necessary.
Due to the complexities of mining equipment and the environment in which it operates, situations may arise which
are not directly discussed in detail in this manual. When such a situation arises, past experience, availability of
equipment, and common sense play a large part in what steps are to be taken. In addition, a P&H MinePro Ser-
vices Representative is available to answer your questions and assist you upon request.
Copyright
Copyright © 2006 P&H Mining, Inc. All rights reserved. All materials contained herein are protected by United
States copyright law and international treaties, and may not be reproduced, distributed, transmitted, displayed,
published or broadcast without the prior written permission of P&H Mining Inc. You may not alter or remove any
trademark, copyright or other notice from copies of the content. All rights in translations of these materials shall
remain exclusively with P&H Mining Inc.
Copyright © 2006 P&H Mining Equipment, Inc. Peak Services

Cat326Preface.fm -i- Preface, Version 00 - 03/06
Preface P&H AirScrubPro Maintenance Manual
Peak Services Copyright © 2006 P&H Mining Equipment, Inc.

Preface, Version 00 - 03/06 -ii- Cat326Preface.fm
P&H Air Scrub Pro Filtration SystemChange Record
Change Record
Changes to this manual are made by direction of the P&H Mining Equipment - Knowledge and Development
Department through recommendations of Instructors, Technical Writers, Engineers, Service Personnel, and results
of the manual review process. All changes shall ensure effective user comprehension and fulfillment of the topic
being described. Use the form below to enter all change information contained on the PDF enclosed on your man-
ual CD.
Number and Description of Change Entered By Date

Cat326ChangeRecord.fm -iii- Change Record, Version 00 - 03/06
Change RecordP&H Air Scrub Pro Filtration System

Change Record, Version 00 - 03/06 -iv- Cat326ChangeRecord.fm
P&H AirScrubPro Maintenance Manual Table of Contents
Table of Contents
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
Copyright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
Change Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v
List of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix
List of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi
SECTION 1, Safety
1.1 General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1
1.1.1 Safety Websites. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1
1.2 Safe Operating Practices for Users of P&H Mining Equipment. . . . . . . . . . . . . . . . . . . . . . . . 1.2
1.2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
1.2.2 Conduct of Operators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
1.2.3 Responsibilities of All Crew Members . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
1.3 Safety Decals and Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
1.3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
1.3.2 Hazard Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
SECTION 2, Introduction
2.1 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1
2.3 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2
2.3.1 High Efficiency Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2
2.3.2 Continuous Self Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2
2.3.3 Easily Maintained . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2
2.3.4 Air Flow Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
2.3.5 House Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4
2.3.6 Screw Conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4
2.3.7 Cold Weather Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4
2.4 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5
2.4.1 Overview of Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5
2.4.2 Specifics of Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5
2.4.3 Overview of Filter Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
2.4.4 Specifics of Screw Conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
2.4.5 GUI Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9
SECTION 3, Controls
3.1 Intelligent Interface Module (IIM). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1
3.1.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1
3.1.2 Mode Selector Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1
3.1.3 Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2
3.1.4 Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2
3.1.5 Micro Memory Card (MMC) Description and Operation . . . . . . . . . . . . . . . . . . . . . . . 3.4

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3.1.6 LED Lights Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6
3.1.7 Resetting the Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9
3.1.8 Terminal Assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11
3.2 Control Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11
3.2.1 Differential Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11
3.3 Control Junction Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12
SECTION 4, Maintenance Procedures

4.1 Air Filter Inspection and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1
4.1.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1
4.1.2 Filter Cartridge Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
4.2 Airlock Feeder Information (1037Z589). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
4.3 Screw Conveyor Inspection and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5
4.4 Blower Fan Inspection and Maintenance (R52632F1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6
4.4.1 Blade Adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6
4.5 Speed Switch Adjustment (1079Z8303) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11
4.6 Air Lock Inspection and Maintenance (1037Z589) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11
4.6.1 Lubrication Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11
4.6.2 Rotor Shaft Packing Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.12
4.6.3 End Plate Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.13
4.6.4 End Plate Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.14
SECTION 5, Fault Diagnostics

5.1.1 Graphic User Interface (GUI). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1
5.2 Panel Fault Indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2
5.2.1 Filtration System Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
5.2.2 Conveyer Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4
5.3 Fault Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5
5.3.1 Fault 2: New Filter Must Be Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5
5.3.2 Fault 3: Filters Are Getting Clogged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5
5.3.3 Fault 4: Filters Are Clogged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5
5.3.4 Fault 5: Screw Conveyor Overload Is Tripped . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6
5.3.5 Fault 7: The Zero Speed Switch Did Not Close . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7
APPENDIX A, Checklists
A.1 Air Lock Inspection and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A.1
A.2 Screw Conveyor Inspection and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A.2
APPENDIX B, Cold Weather Kit

B.1 Cold Weather Package Upgrade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B.1
B.1.1 Cold Weather Package Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B.1
B.1.2 Heat Trace Cable Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B.3

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Reader Comment Form

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P&H AirScrubPro Maintenance Manual List of Figures
List of Figures
SECTION 1, Safety
Figure 2-1: Air Filtration System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1
Figure 2-2: Cartridge Replacement from Machinery House Roof . . . . . . . . . . . . . . . . . . . . . . . . . 2.2
Figure 2-3: Air Flow Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
Figure 2-4: House Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4
Figure 2-5: Control Cabinet - Front Panel Closed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5
Figure 2-6: Trough and Auger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7
Figure 2-7: Air Lock and Dust Collector Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8
SECTION 3, Controls
Figure 3-1: Intelligent Interface Module (IIM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2
Figure 3-2: Interface Module Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2
Figure 3-3: Intelligent Interface Module Terminal Assignments . . . . . . . . . . . . . . . . . . . . . . . . . 3.11
Figure 3-4: Control Junction Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12

Figure 4-1: Diaphragm Air Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1
Figure 4-2: Filter Order of Pulse Cleaning - View Standing In Front Of Unit. . . . . . . . . . . . . . . . . 4.2
Figure 4-3: Air Filter Cartridge Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
Figure 4-4: Rotary Airlock Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4
Figure 4-5: Blower Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7
Figure 4-6: Checking Blade Setting/Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8
Figure 4-7: Speed Switch Sensor Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11
Figure 4-8: End Plate Set Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.13
Figure 4-9: Air Lock Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.15

Figure 5-1: Control Cabinet -- Front Panel Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2
Figure 5-2: I/O Module Cleaning System and Conveyor Fault Indication . . . . . . . . . . . . . . . . . . . 5.3
Figure 5-3: Auger Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6
Figure 5-4: Rotary Airlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7

Figure B-1: Components and Heat Trace Cable Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B.2
Figure B-2: Heat Trace Valve Wrapping Detail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B.3

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P&H AirScrubPro Maintenance Manual List of Tables
List of Tables
SECTION 1, Safety
Table 2-1: Cartridge Filter GUI Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9
SECTION 3, Controls
Table 3-1: Mode Selector Switch Positions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1
Table 3-2: Intelligent Interface Module LED Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7
Table 3-3: Intelligent Interface Module LED Configuration Indicators . . . . . . . . . . . . . . . . . . . . . . 3.8

Table 4-1: Fan Blade Setting Chart Guide for Cartridge-type Filtration . . . . . . . . . . . . . . . . . . . . 4.9
Table 4-2: Current Draw and Horsepower for Cartridge-type Filtration. . . . . . . . . . . . . . . . . . . . . 4.9
Table 4-3: Fan Blade Setting Chart Guide for Cartridge-type Filtration . . . . . . . . . . . . . . . . . . . 4.10
Table 4-4: Current Draw and Horsepower for Cartridge-type Filtration. . . . . . . . . . . . . . . . . . . . 4.10

Table 5-1: System Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
Table 5-2: Conveyor Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4
Table A-1: Airlock Installation and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A.1
Table A-2: Removal of Existing Filter System Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A.2

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P&H AirScrubPro Maintenance Manual Safety
Section 1
Safety
1.1 General Information

Since the earliest days of mining, the job of digging coal and other useful materials out of the earth has been con-
sidered one of the world's most dangerous occupations. Public concern about the toll of deaths, injuries and
destruction in mine accidents has prompted passage of much-needed safety legislation and intensified the search
for safer methods and improved training practices and technology. Growing cooperation among industry, labor and
government also has contributed to making mining safer and more healthful, especially in recent years.
Safety and health in the mining industry has improved greatly since the early 20th Century. Total mining fatalities
reached the lowest level in history in 2001. Listed below are Safety Information Websites that can assist in prevent-
ing mining accidents and injuries:
1.1.1 Safety Websites
www.msha.gov. The U.S. Department of Labor’s Mine Safety and Health Administration (MSHA) helps to reduce
deaths, injuries, and illnesses in the nation's mines with a variety of activities and programs. The agency develops
and enforces safety and health rules applying to all U.S. mines, helps mine operators who have special compliance
problems, and makes available technical, educational and other types of assistance. MSHA works cooperatively
with industry, labor, and other Federal and state agencies toward improving safety and health conditions for all
miners. MSHA's responsibilities are spelled out in the Federal Mine Safety and Health Act of 1977.
www.osha.gov. The U.S. Department of Labor’s Occupational Safety and Health Administration’s (OSHA) mis-
sion is “to assure, so far as possible, every working man and woman in the nation safe and healthful working con-
ditions.” By authorizing enforcement of the standards developed under the Occupational Safety and Health Act of
1970; by assisting and encouraging the States in their efforts to assure safe and healthful working conditions; by
providing for research, information, education, and training in the field of occupational safety and health; and for
other purposes.
www.cdc.gov/niosh. The National Institute for Occupational Safety and Health (NIOSH) is the Federal agency
responsible for conducting research and making recommendations for the prevention of work-related disease and
injury. The Institute is part of the Centers for Disease Control and Prevention (CDC).
NIOSH is responsible for conducting research on the full scope of occupational disease and injury ranging from
lung disease in miners to carpal tunnel syndrome in computer users.

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Safety P&H AirScrubPro Maintenance Manual
1.2 Safe Operating Practices for Users of P&H Mining Equipment
NOTICE
A review of many safety sources including MSHA, NIOSH, OSHA, ANSI, and various individual
mine safety policies was conducted to develop these safe operating practices recommenda-
tions. The purpose of these recommendations is to assist and support our customer in their
safety efforts in preventing accidents.
1.2.1 Introduction
P&H machines are carefully designed, manufactured, and tested. When used properly by qualified operators, they
will give safe, reliable service. There are P&H offices worldwide to answer any questions about P&H products or
their safe use. The World Sales and Service Headquarters for P&H Mining Equipment is:
P&H Mining Equipment

4400 West National Avenue
P.O. Box 310
Milwaukee, WI 53201 USA
Telephone: (414) 671-4400
Because mining machines are complex and massive pieces of equipment, they also have the potential for acci-
dents if safe operating practices are not followed. This section is intended to help prevent accidents which could
result in injury, death, or property damage. In all cases, general safe practices for working machinery must be fol-
lowed as well as safe operating practices. The following P&H Mining Equipment recommendations are provided to
supplement customer/owner, local or national safety codes, rules or procedures.
1.2.2 Conduct of Operators

Safety must always be the operator's primary concern. An operator must refuse to operate any
equipment in which a known unsafe condition exists. Consult your supervisor when safety is in
doubt.
1. The operator must read and understand the Operator's Manual and be familiar with all instructions and signs
on the equipment.
2. The operator must see that the equipment is in proper order before operating.
3. When physically or otherwise unfit, an operator must not engage in the operation of the equipment.
4. All controls must be tested by the operator before beginning a new shift. If any control does not operate prop-
erly, the operator must contact the appropriate maintenance department and have the controls repaired before
operating the equipment.
5. If adjustments or repairs are necessary, or any defects are known, the operator must promptly report the
defects to the appropriate maintenance department who will be responsible for the repair. The operator must
also notify the next operator of any remaining uncorrected defects upon changing shifts.

Section 1, Version 05 - 06/05 -1.2- Sec01Safety.fm
P&H AirScrubPro Maintenance Manual Safety
1.2.2.1 Operator’s Functional Checks
The operator must make a safety check before starting to work each shift to see that the shovel is in proper order.
Some things to check are:
NOTICE
Checklists for Pre-Start, Startup, and Shutdown are specified later in this Manual.
• Check for warning tags or lockout tags on the starting controls; do not operate the controls until the tag has
been removed by the person who placed it there, or by a qualified person. Consult your minesites specific
lockout-tagout procedures.
• Check with mine maintenance and operations management to see that periodic maintenance and inspec-
tions have been performed and all necessary repairs made.
• Check that all equipment guards are in place and all inspection and cover plates are closed and locked.
• Look inside, outside and underneath the equipment to make sure everything is clear before starting or ener-
gizing the machine.
• After starting the machine, check gauges and indicators for proper readings and operation.
• Test controls for proper operation and controlability before operating the equipment.
• During operation, be alert for unusual noises, vibrations or smells.
1.2.3 Responsibilities of All Crew Members
Any unsafe condition or practice must be reported to the job supervisor and shovel operator. Everyone who works
around the equipment, including support people and maintenance personnel, must obey all safety hazard signs
and watch out for their own safety and the safety of others in the area. Crew members setting up equipment or con-
ducting maintenance and repairs are expected to know and apply proper procedures, including lockout and tagout
practices.
Watch for hazards during operations and alert the operator of potential safety hazards such as the unexpected
presence of people or other equipment in the area.
1.3 Safety Decals and Signs
1.3.1 General
Hazard Indicators and Safety Hazard Decals and Signs identify potential safety hazards and prevent accidents by
displaying standard symbols, headers and pictograms or custom graphics. Headers, graphics, and layouts of indi-
cators, decals, and signs conform to current ANSI guidelines, and are consistent with the industry standards for
such devices commonly used for high voltage, personal protection, confined space, and bilingual applications.

Sec01Safety.fm -1.3- Section 1, Version 05 - 06/05
Safety P&H AirScrubPro Maintenance Manual
1.3.2 Hazard Indicators
DANGERS, WARNINGS, CAUTIONS, NOTICES, and SAFETY FIRSTS are used on signs and decals, and
throughout our manuals to emphasize important and critical instructions. In written documentation, DANGERS,
WARNINGS, CAUTIONS, and SAFETY FIRSTS will precede the paragraph or item to which they apply. NOTICES
will follow the paragraph or item to which they apply. DANGERS, WARNINGS, CAUTIONS, NOTICES and
SAFETY FIRSTS are identified and defined as follows:
! DANGER
Indicates an imminently hazardous situation which, if not avoided, will result in death or
serious injury. This signal word is limited to the most extreme situations.
! WARNING
Indicates a potentially hazardous situation which, if not avoided, could result in death or
serious injury.
! CAUTION
Indicates a potentially hazardous situation which, if not avoided, may result in minor or
major injury.
CAUTION
A Caution without a Safety Alert Symbol (Triangle and Exclamation Point) is used to
warn of hazards that result only in property damage.
NOTICE
Used to indicate a statement of company policy directly or indirectly related to the safety of per-
sonnel or protection of property. This signal word is not associated directly with a hazard or
hazardous situation and is not used in place of DANGER, WARNING, or CAUTION.

Used to indicate general instructions relative to safe working practices, remind of proper safety
procedures, and indicate the location of safety equipment.

Section 1, Version 05 - 06/05 -1.4- Sec01Safety.fm
P&H AirScrubPro Maintenance Manual Introduction
Section 2
Introduction
2.1 Scope
This catalog contains information related to the installation, operation and maintenance of P&H Cartridge-style Air
Filtration system. (Figure 1-1).
Figure 2-1: Air Filtration System
The P&H Air Filtration System is currently available for P&H mining shovels both as an upgrade to an existing
machine and as a new machine option.

Shovels deployed in fine-dust conditions must be able to more effectively filter smaller particulates. P&H Mining
Equipment, in association with a leading filter manufacturer, has developed an air filtration and house pressuriza-
tion system that uses replaceable cartridge type filters.
Information in this document are current as of the date of publication. Any changes to the air filtration system that
may not be included in this release will be included in later editions of this publication.
Questions regarding the shovel or this manual should be referred to your P&H MinePro Services representative.

Sec02Intro.fm -2.1- Section 2, Version 05 - 06/05
Introduction P&H AirScrubPro Maintenance Manual
2.3 Description
Cartridge type filtration systems are commonly installed at industrial or testing facilities that require hazardous dust
to be filtered out of the air for human comfort and safety. We have engineered our air filtration/pressurization sys-
tem to adapt these modular units designed for static factory applications to a dynamic mining shovel environment.
To insure that the unit holds up under a shovel’s dynamic loads we have incorporated “heavy duty” features in the
mounting, fabrication, and conveyor aspects of the unit. In addition we have added protection to the air inlet area to
significantly reduce ingestion of rain and snow.
2.3.1 High Efficiency Filters
The air filtration system is 99.9% efficient by weight at 0.3 micron and greater particulate.
2.3.2 Continuous Self Cleaning
Dirty air is trapped on the outside of the filter cartridges. Clean air flow continues through to the inside of the car-
tridges and then into the machinery house. There is a continuous cleaning cycle where cartridges are self cleaned
with periodic blasts of air blown into the center of each cartridge from the inside-out. Each blast consists of 1.5
cubic feet of air pulsed over a 0.1 second interval through each cartridge one cartridge at a time. Accumulated dust
and dirt on the outside of the cartridge is blown off and falls into a hopper below. A screw type conveyor carries the
dust off of the machine and onto the ground automatically. The cleaning pulses continue programmed to occur
every 20 seconds with subsequent filter openings in a programmed firing order until all openings one at a time are
purged from the inside out. The cycle then starts all over with the first cartridge 20 seconds later thereby exhibiting
a “continuous” self cleaning feature.
2.3.3 Easily Maintained
At some point the cartridges accumulate enough dirt in spite of the cleaning cycles and the operator is alerted to
this with a diagnostic message warning that the cartridges must be replaced. Cartridges are easily replaceable
from the machinery house roof as shown in Figure 2-2. Refer to Topic 4.1 for filter inspection and replacement.
Figure 2-2: Cartridge Replacement from Machinery House Roof
Cartridges in use for 18 months at an operating mine were removed after over 9,000 hours of operation. Subse-
quent inspection revealed that they were not yet dirty enough to require replacement.
The cartridge filtration system is somewhat taller than filtration and pressurization systems previously used on P&H
Mining Shovels, but otherwise fits comparably into the same area at the rear of the machine. Air inlet is from the

Section 2, Version 05 - 06/05 -2.2- Sec02Intro.fm
top of the unit rather than from in front of the unit. The air inlet on top is covered with an all encompassing rain/
snow hood.
All cartridge filtration units in the field are shipped with an entire new or rebuilt rear plenum assembly. This requires
complete replacement of the existing rear house assembly. The entire plenum is replaced to reduce downtime for
conversion.
2.3.4 Air Flow Description
Air inlet is located at top of unit protected by an expansive rain/snow hood, which prevents moisture and dust from
being sucked in. A large two-stage blower provides sufficient air flow even at 10,000 ft. and with dirty filters. This
prolongs life of individual cartridge filters before replacement is necessary.
Blowers are mounted vertically. With the rain hood and outlet duct removed, the blowers may be directly removed
straight up and out of the machine. Alternately, the entire filtration unit including blowers and outlet duct may be
removed as a unit.
Fan blade setting adjustments are achieved through an access door in the outlet duct for top blades, and through
the machinery house for bottom blades. Recommended fan blade settings for particular elevations from 0 to
15,000 ft are published in Table 4-1 through 4-4 of this document.
LEGEND:
01. Rear House Assembly 04
02. Cartridge Filter Unit
03. Air Flow
05
04. Inlet Hood 03
05. Outlet Duct
06. Two-Stage Blower
07. Discharge to 08
Machinery House
08. Hopper with Screw
09. Blower Silencer
02
01
06
front of shovel
ES03234c01
09 07
Figure 2-3: Air Flow Diagram
The relatively high intake prevents ingestion of accumulated dust and snow from the machinery house roof.
The rain hood prevents rain and snow from falling into the inlet area of the filter and acts as a plenum that reduces
capture velocity of the air entering the system, and the lower the capture velocity the more difficult it is for the air
stream to capture raindrops or snowflakes and suck them into the air flow. The hood inlet is lower than the actual
unit inlet on top of unit. This forces raindrops or snow to have to travel upward against gravity before they have a
chance at being ingested.

2.3.5 House Assembly
The rear house assembly is designed to support and cradle the new cartridge unit so as to support it in a dynamic
mining shovel environment.Rubber gaskets applied to all internal joints exposed to air flow protect against leaks
caused by vibration.
03
04
02
01
LEGEND
01. Outlet Duct
02. Bolted Access Door
03. Rain Hood
05 04. Rear House Assembly
05. Cartridge Filter Unit
06 06. Screw Conveyor
07 07. Air Lock Mechanism
Figure 2-4: House Assembly
The unit was shipped as shown above with the exception that the big inlet hood and supporting truss members are
shipped and mounted separately in the field. A flexible hose which leads down from the air lock mechanism to the
ground for dumping of dust is not shown.
The outlet duct is an air tight connection between the cartridge filter unit and the blower inlet. The outlet duct covers
and protects the blowers and the solenoid cleaning system in back of the unit from weather exposure.
Bolted access door on each side of the outlet duct allows access inside for upper-end blower blade setting and
solenoid valve replacement and inspection.
2.3.6 Screw Conveyor
The forward portion of the filter assembly features a screw conveyor which carries collected dust in an enclosed
trough to the right-hand side of machine. For a detailed description of conveyor operation, refer to Subtopic 2.4.4.
2.3.7 Cold Weather Kit
The cold weather upgrade kit is applicable to all Air Scrub Pro units. The purpose of this upgrade is to keep the air
solenoids and air solenoid valves warm and frost free as temperatures drop below 50° F. When the temperature
drops below 50° F, heat trace cable heats up the component it is wrapped around. There are three separate heat
trace cable runs, one for each filter sub unit. Refer to Appendix B for cold weather kit installation.

2.4 Operation
2.4.1 Overview of Normal Operation
Driven by an airstream generated by the house main blowers, contaminated dusty air enters the dust collector top
inlet area which is shielded by an immense rain hood. The rain hood itself acts to minimize rain, snow, and dust
ingestion by forcing these particulates to travel upward against gravity before entering the intake airstream. The
larger opening that the inlet hood provides further reduces the “capture velocity” responsible for drawing in these
contaminants.
Dust is collected on the outside surface of the filter cartridges. The clean, filtered air flows through the center of the
filter cartridges into the clean air outlet duct, past the house main blowers, through the blower silencers, and into
the machinery house. Clean machinery house air is used as a source of cooling air for numerous motor and electri-
cal cabinet blowers. A constant flow of clean air is needed in the machinery house to help purge the house of heat
buildup and to maintain a constant positive house pressure relative to the outside. The positive house pressure
helps to prevent dust from being drawn into the house through rope, door, and vent openings.
2.4.2 Specifics of Normal Operation
When the machine is started in the normal and customary manner from the operator’s cab, the filter control panel is
remotely initiated via a dry contact signal. The control panel is mounted in the rear of the machinery house near the
converter cabinets. See Figure 2-5.
01
04
Legend
01. Control Cabinet
03. Nameplate 03
04. Handle, Disconnect FILTER/SCREW CONVEYOR CABINET
05. Pilot Lights
13 SCREW CONVEYOR
CONTINUOUS AUTO
NEW FILTERS
INSTALLED RESET
07. Hour Meter

CLEANING CYCLE
ON
08. Display, Pressure Differential

FILTER CONDITION
EXCELLENT
FILTER CONDITION
09. Push Button, Red GOOD
10. Light, Screw Conveyor Off 12 SCREW CONVEYOR

ON
FILTER CONDITION
FAIR
REPLACE FILTERS
11. Light, Screw Conveyor On OFF
12. New Filters Installed Reset 11 MANUAL CLEAN

PRESSURE DIFFERENTIAL
13. Screw Conveyor Selection

07
OFF ON
Continuous/Auto
14. Manual Filter Clean Mode
10 HOURS
000000
Switch
14
09 08 05
Figure 2-5: Control Cabinet - Front Panel Closed

As long as the machine is empowered with main blowers operating, the control panel is active and the live air
stream is being filtered. There is an hour meter located on the control panel door that records total hours of car-
tridge filter unit operation. This timer should be used by maintenance personnel to help record pressure setting
changes and any maintenance done on the unit.
There are two main 40 hp two-stage blowers that provide the total pressure to pull air through the cartridge filter
system, pressurize the house, and purge cooling air. The blade setting of these blowers, i.e., the angular pitch of
the blades for sufficient air flow, is dependent on altitude and power source operating frequency (50 Hz or 60Hz).
Refer to Subtopic 4.4.1 for specific information.
The actual pressure drop reading across the filter cartridges will be digitally indicated on the pressure differential
display on the front of the control panel upon start up, see Figure 2-5. As the filters get dirty over their one to two
year expected lifetime, the pressure drop across the filters will rise even though they are constantly and automati-
cally cleaned with bursts of compressed air. The main blowers cannot create the necessary air flow to maintain
house pressure when the filter pressure drop exceeds maximum specified limits. When the specified pressure drop
limits are reached, the cartridge filters must be replaced.
2.4.3 Overview of Filter Cleaning
Filter cartridges are cleaned automatically and sequentially. As long as the main blowers are running, filter purging
will occur every 20 seconds according to the firing order shown in Figure 4-2.
During the filter purge, a solenoid valve is energized, causing the corresponding diaphragm valve to send a 0.1
second pulse of 1.5 cubic feet of compressed air (regulated at 90 psi) through the filter from the inside outward,
blowing the collected contaminants from the outside surfaces of the filter. These pulses are programmed to occur
every 20 seconds on subsequent cartridges determined by a solid state control timer until the machine is shut
down.
When the machine is shut down, the cleaning cycle is programmed to remain on for 10 more minutes. This allows
for each cartridge to get an additional burst of purging air without the main blowers operating at the same time. The
benefit is that the purged dust will not get sucked back into the cartridges but will fall directly into the trough below.
Further manual cleaning without the blower on can be achieved with the manual filter clean selector switch on the
control panel shown in Figure 2-5.
The dislodged contaminants are allowed to fall into a trough underneath the filter unit and are automatically carried
off the machine by an auger type screw conveyor that lies inside of the bottom of the trough.
2.4.4 Specifics of Screw Conveyor
Most of the dust falling from the cartridge filters from the blasts of pulsed air will fall into a trough at the bottom of
the filter unit. Inside this trough is a 6” diameter screw type auger that turns and conveys the collected dust to the
rear of the right hand side of the machine. See Figure 2-6.
The screw conveyor system has two modes, Auto and Continuous. A selector switch on the front of the filter control
panel selects the mode. In addition there are two lights, on the front door of the filter control, which will indicate
whether the screw conveyor is ON or OFF.
Auto Mode
When in Auto mode the screw conveyor will turn on for a set amount of time when the fans are running. The con-
veyor will wait 50 minutes and then turn on for 10 minutes. The cycle will repeat as long as the filter “Auto-Continu-
ous” switch is in Auto and the house fans are running and there are no faults in the system.

Continuous Mode
When in Continuous mode the conveyor will turn on continuously whenever the switch is placed in the Continuous
position and there are no conveyor faults in the system.
01 02 03 04
LEGEND
01. Conveyor Motor 03. Trough
02. Conveyor Drive 04. Auger
Figure 2-6: Trough and Auger
An air lock device mounted at the end of the trough ensures dust is carried off the machine, see Figure 2-6. From
here, a 5” diameter hose will channel dust to the bottom of the machine at grade level. The rotary auger is con-
trolled by a timer in the PLC, and can be programmed to operate for a portion of every hour. Constant operation of
the auger is not necessary and the timed feature keeps wear and tear on the screw conveyor to a minimum.

01
LEGEND
01. Trough with Auger 02
02. Air Lock
Drive Chain
03. Air Lock
03
04. Zero Speed Switch
05. Hose
04
05
ES03119a01
Figure 2-7: Air Lock and Dust Collector Hose
A zero speed switch incorporated into the screw conveyor assembly, mounted at the end of the rotary air lock
device, provides a signal to the PLC indicating whether or not the screw conveyor is turning. If the screw is sup-
posed to be turning but the zero speed switch indicates otherwise, a fault message will appear on the operator’s
touch screen, “The Zero Speed Switch Did Not Close When The Conveyor Should Be Moving.” An alarm will sound
warning of a 30-second delayed shutdown of the shovel.
If there is abnormal drag on the auger motor, motor speed reducer, screw conveyor, and/or rotary air lock, an over-
load relay will trip and the operator will receive the fault message, “Screw Conveyor Overload Is Tripped.” An alarm
will sound warning of a 30-second delayed shutdown of the shovel.

2.4.5 GUI Messages
Table 2-3 on 18 describes fault diagnostic messages displayed on the operator’s GUI related to the P&H Cartridge-
type Air Filtration and Pressurization System.
GUI Display Diagnostic Explanation
House Filter Control System Is Not Active
No Pressure Sensor Input The system has detected that the differential pres-
sure signal is missing.
New Filter Must Be Set The system has detected that the pressure differen-
tial has decreased substantially more than it had
been, which indicates that the filters may have been
changed.
Filters Are Getting Clogged The pressure differential across the cartridge filters
indicates that the filters are approaching a clogged
filter condition. At this point it is advisable to order
new filters.
Filters Are Clogged The pressure differential across the cartridge filters
has exceeded the highest allowable pressure differ-
ential as set by the pressure differential switch, the
filters are clogged and must be replaced.
Screw Conveyor Overload Is Tripped There is an abnormal drag on the screw conveyor
motor, the speed reducer, the rotary air lock, or the
conveyor itself. A 30-second delayed shutdown will
occur.
The Zero Speed Switch Closed When The The speed switch is indicating that the screw con-
Conveyor Should Be Stopped veyor is moving when it should not be. A 30-second
delayed shutdown will occur.
The Zero Speed Switch Did Not Close When Screw is supposed to be turning, but zero speed
The Conveyor Should Be Moving switch indicates that it is stopped. A 30-second
delayed shutdown will occur.
The Conveyor Contactor Auxiliary Is Closed The screw conveyor contactor auxiliary contact is
closed when the contactor should be open.
The Conveyor Contact Auxiliary Is Not The screw conveyor contactor auxiliary contact did
Closed When The Contact Should Be Ener- not close when the contactor should have been
gized closed.
Differential Pressure Sensor Is Not At The The junction box housing the differential pressure
Proper Temperature sensor in the house filter plenum is too cold.
Table 2-1: Cartridge Filter GUI Messages


P&H AirScrubPro Maintenance Manual Controls
Section 3
Controls
3.1 Intelligent Interface Module (IIM)
3.1.1 General Information
The Intelligent Interface Module (IIM) controls the operation of the air filtration unit. It is a component of the Remote
I/O System. The Intelligent Interface Module is an Intelligent Pre-Processing Unit, or I-Slave. It enables you to
decentralize control tasks.
A Remote I/O System with an Intelligent Interface Module can exercise full independent control over a process
related functional unit and can be used as a stand-alone CPU. The use of the Intelligent Interface Module leads to
modularization and standardization of process-related functional units.
3.1.2 Mode Selector Switch
The positions of the mode selector are located on the front of the Intelligent Interface Module. Refer to Figure 1-1
for switch positions.
Position Function Description
Run Run Mode The CPU executes the user program.
Stop Stop Mode The CPU does not execute the user program.
Programs can:
• Be downloaded from the Interface Module using a Laptop PC.
• Be transferred to the Interface Module using a Laptop PC.

MRES Memory Momentary-contact position of the mode selector for resetting the
Reset Interface Module memory.
NOTICE
You must adhere to a specific sequence when reset-
ting the Interface Module memory using the Mode
Selector Switch.
Table 3-1: Mode Selector Switch Positions

Sec03Controls.fm -3.1- Section 3, Version 05 - 06/05
Controls P&H AirScrubPro Maintenance Manual
3.1.3 Display
Several LED’s are located on the front of the Intelligent Interface

Module. The Run, Stop, On, BF, SF, and FRCE LED’s display
important information on the states of the Module to the user.
The Intelligent Interface Module has the following 6 LED’s. See
Topic 1.1.6.
• SF LED (system fault) - Indicates the

presence of a fault in the Remote I/O
System.
• BF LED (Bus Fault) - Indicates the pres-

ence of faults on the Profibus DP-V1.
• On LED - Indicates that the Remote I/O

System is connected to a power supply.
• FRCE LED - Indicates that a force

request is active.
• Run LED - Indicates that the CPU com-

ponent of the Intelligent Interface Module
is in the Run mode.
Stop LED - Indicates that the CPU com-

ponent of the Intelligent Interface Module
is in the Stop mode.
Figure 3-1: Intelligent Interface Module (IIM)
3.1.4 Memory
The memory of the Interface Module can be divided into three area.
Figure 3-2: Interface Module Memory

Section 3, Version 05 - 06/05 -3.2- Sec03Controls.fm
3.1.4.1 Load Memory
The load memory is installed on the Micro Memory Card, or MMC. The Load Memory is used to record code and
data blocks as well as system data (configuration, module parameters, etc.).
Blocks which are designated as non-processing-related are recorded in the load memory.
The complete configuration data for a project can also be stored on the MMC.
The program in the MMC is always retentive. When downloaded, it is stored on the MMC such that it is unaffected
by power failures and is not erased by memory resets.
NOTICE
The Intelligent Interface Module can only be operated with the MMC inserted.
3.1.4.2 Working Memory
The working memory is integrated on the Interface Module and cannot be expanded. It is used to process the
codes and data of the user program. Program processing is only performed at the working memory and system
memory.
The working memory of the Interface Module is retentive if the MMC is inserted. The data in the working memory is
saved on the MMC if the power supply is interrupted.
3.1.4.3 System Memory
The system memory is integrated on the Interface Module and cannot be expanded. It contains:
• The address areas “memory Markers”, “timers”, and “counters”.
• The process images of the inputs and outputs.
• The local data.
For memory markers, timers and counters, you can configure (Properties of the CPU, Retentive tab) which parts
are to be retentive and which parts are to be initialized with “0” when a complete restart (warm restart) is per-
formed.
The diagnostic buffer, transmission rate, as well as the run-time meter are generally stored in the retentive memory
on the CPU. Retentivity of the transmission rate ensures that your CPU is still able to communicate following a
power failure, a memory reset or the loss of communication parameters (by removing the MMC or erasing the com-
munication parameters.
3.1.4.4 Retentivity
The Interface Module has a retentive memory. The retentivity is provided on the MMC and Interface Module. The
retentivity means that the content of the retentive memory is retained even following power off and a restart (warm
restart).

3.1.5 Micro Memory Card (MMC) Description and Operation
3.1.5.1 General Information
A 64K Micro Memory Card (MMC) is used as a memory module for the Intelligent Interface Module. The MMC can
be used as a load memory and portable data carrier. It is an essential requirement for operating the Interface Mod-
ule. The following data is stored on the MMC:
• User program (all blocks)
• Archives and recipes
• Configuration data
• Data for an operating system update, operating system backup
! CAUTION
The module content of a MMC can be corrupted if the card is removed while a write oper-
ation is being performed. If this happens, the MMC must be erased or formatted in the
Interface Module. Never remove the MMC in Run Mode. It should only be removed when
the Interface Module is in the power off or Stop Mode and only if the Laptop PC is not
currently performing a write access operation. If in the Stop Mode you are not sure
whether or not the Laptop PC is performing a write access operation (e.g. loading/eras-
ing a block), unplug the communication connections beforehand.
The service life of an MMC mainly depends on the following factors:
• The number of erasing and programming operations.
• External influences such as ambient temperature.
At the ambient temperature of up to 60° C, the service life of an MMC with a maximum 100,000 erase/write opera-
tions is 10 years.
! CAUTION
To prevent data loss, do not exceed the maximum number of erase/write operations.
3.1.5.2 Removing and Inserting the MMC
The Interface Module cannot run if there is no MMC inserted. Practical operation is only possible if an MMC has
been inserted and a memory reset has been performed.
Removal and insertion of an MMC is detected by the Interface Module in all operating modes. To remove the
MMC, proceed as follows:

NOTICE
The module content of an MMC can be corrupted if the card is removed while a write operation
is being performed. If this happens, the MMC must be erased or formatted in the Interface Mod-
ule. Never remove the MMC in Run Mode. It should only be removed when the Interface Mod-
ule is in the power off or Stop Mode and only if the Laptop PC is not currently performing a write
access operation. If in the Stop Mode you are not sure whether the or not the Laptop PC is per-
forming a write access operation, unplug the communication connections beforehand.
Step 1: Place the Interface Module in the Stop mode.
Step 2: There is an eject button on the memory card slot to enable you to remove the card easily. To eject the
card, press the button with a small screwdriver or a ballpoint pen.
Step 3: When the MMC is removed, the Interface Module requests a memory reset.
To insert the MMC with the appropriate user program, proceed as follows:
! CAUTION
Make sure the MMC to be inserted contains the user program appropriate for the Inter-
face Module and Remote I/O System. An incorrect user program can have serious effects
on the processing and shovel motion and/or characteristics. This may cause personal
injury or property damage.
Step 1: Insert he MMC into the proper slot on the Interface Module.
Step 2: The Interface Module will request a memory reset. If the Interface Module requests a memory reset
again, this probably means that an incorrect MC or an MC with a firmware update has been inserted.
Step 3: Start the Interface Module.
3.1.5.3 Backing Up the Operating System on the MMC
To back up the operating system, proceed as follows:
Step 1: Insert a 4MB MMC into the Interface Module slot. The Interface Module will request a memory reset.
Step 2: Press and hold the Mode Selector Switch in the MRES position.
NOTICE
When placing the Mode Selector switch in the MRES position, it is spring returned to the Stop
position. You will have to hold the switch in the MRES position to accomplish this procedure.
Step 3: While holding the Mode Selector Switch in the MRES position, switch the power off then on. The Stop,
Run and FRCE LED’s will start flashing.
Step 4: Allow the Mode Selector Switch to return to the Stop position.

Step 5: Briefly, press the Mode Selector Switch to the MRES position and immediately allow it to snap back to the
Stop position.
The Interface Module starts to back up the operating system on the MMC.
All of the Interface Module LED’s illuminate during backup.
The Stop LED flashes after the backup has been completed. In this way, the Interface Module requests a
memory reset.
Step 6: Remove the MMC card for safe storage.
NOTICE
Install a MMC before restarting the system. The Interface Module cannot run if there is no MMC
inserted.
3.1.5.4 Formatting the MMC Prior to a Memory Reset
In certain exceptional cases, the MMC will have to be formatted. Refer to Step 1.1.7.2 for the formatting procedure.
• The module type is not a user module.
• The MMC has not yet been formatted, is faulty, or the data is corrupted.
• The content of the MMC has been designated as invalid.
• The Load User Program operation has been interrupted by power off.
• The Programming operation has been interrupted by power off.
• A fault has occurred during evaluation of the module content prior to a memory reset.
• A fault has occurred during formatting, or formatting could not be performed.
If one of the above-described faults has occurred, the Interface Module also requests another memory reset after a
memory reset has been performed. The content of the MMC is retained until the special measure has been com-
pleted, unless the Load User Program or Programming operations are interrupted by power off.
3.1.6 LED Lights Description
For the CPU component of the Intelligent Interface Module there are two separate LED’s that indicate the operat-
ing modes of the CPU:
• RUN
• STOP
You can obtain additional information on the Power Supply of the CPU, on force requests and on general errors via
three additional LED’s:

• On, FRCE, and SF
When the On LED is off, either no supply voltage or insufficient supply voltage is being applied to the electronic
components/sensors of the Remote I/O System. The cause is likely to be a defective fuse or inadequate or nonex-
istent system voltage.
LED Description Function
On Comes on when the supply voltage is applied to the Intel-

Power On ligent Interface Module.
(green)
Run Lights up continuously when the Intelligent Interface

Run Mode Module component is processing the user program.
(green) Flashes at 2 Hz during the startup of the Intelligent Inter-

face Module component:
• For at least 3 seconds, but the startup of the Intelli-

gent Interface Module component can also be
shorter.
• During the startup of the Intelligent Interface Module

component, the Stop LED also lights up; when the
Stop LED goes off, the outputs are enabled.
Flashes at 0.5 Hz when the Intelligent Interface Module
has reached a breakpoint you have set. At the same time
the Stop LED comes on.
Stop Lights up when the Intelligent Interface Module compo-

Stop Mode nent:
(yellow)
• Is not processing a user program.
• Has reached a break point you have set at the same

time the Run LED flashes at 0.5 Hz.
Flashes at 0.5 Hz, when the Intelligent Interface Module
component requests a memory reset.
FRCE Lights up when a force request is active.

Force Request
Active
(yellow)
Table 3-2: Intelligent Interface Module LED Indicators

LED Description Function
SF Lights up in the event of:

Group Error
• Programming errors.
(red)
• Parameter assignment errors.
• Calculation errors.
• Timing errors.
• Remote I/O errors.
• Hardware errors.
• Firmware errors.
Table 3-2: Intelligent Interface Module LED Indicators
If the BF and SF LED’s light up or flash, the Remote I/O System is not configured correctly. The table below shows
the possible error indications together with their meanings and necessary action. It also shows the LED states for
Profibus DP-V1 slave operation.
BF LED SF Description Cause Error Handling

LED
On On No connection • The Intelligent Interface Module is in Check that the connector

to the DP-V1 the active node = Bus short-circuit. for the Profibus DP-V1 is
Master. inserted correctly.
• The Intelligent Interface Module is in Check whether the bus
the passive node = Transmission cable to the DP-V1 Mas-
rate detection No active node at bus, ter is defective.
DP-V1 Master does not exist or is
switched off, or bus connection dis-
rupted.
SF is on due to station failure
Table 3-3: Intelligent Interface Module LED Configuration Indicators

BF LED SF Description Cause Error Handling

LED
Flashing On Parameter • Slave not configures or incorrectly Check the hardware of

assignment configures. the Remote I/O System.
error; there is Check the configuration
no data and parameterization of
• Incorrect but permissible station
exchange. the Remote I/O System.
address configured.
Check the settings for
• Configured address areas of the the configured address
actual configuration not identical to areas for the DP-V1 Mas-
the target configuration. ter.
• Station failure of a configured sender

in direct data communications.
• DP-V1 Master does not exist or is

switched off.
Off On Fault in slave: DP-V1 Master in Stop. Switch the DP-V1 Mas-
Diagnostic ter to Run mode.
Interrupt.
Off Off Data exchange The target configuration and actual config- This is the normal condi-
taking place. uration of the Remote I/O System match. tion, no action is
required.
Table 3-3: Intelligent Interface Module LED Configuration Indicators
3.1.7 Resetting the Memory
The memory of the Intelligent Interface Module must be reset under the following conditions:
• To erase retentive areas (memory markers, timers, counters).
• If the Intelligent Interface Module requests a memory reset by flashing the Stop LED.
The following are possible reasons why the Intelligent Interface Module requests the memory reset function:
• The Remote I/O is starting up for the first time.
• Inconsistent memory areas.
• The MMC has been replaced.
When the Interface Module requests a memory reset (the Stop LED flashes slowly), format it by operating the
Mode Selector switch.
3.1.7.1 Memory Reset Procedure
To reset the Memory of the Intelligent Interface Module with the Mode Selector switch, perform the following steps:
Step 1: Place the Mode Selector Switch in the Stop position.

Step 2: Press down and hold the Mode Selector Switch in the MRES (Memory Reset) position. Hold down the
Mode Selector switch in this position until the Stop LED illuminates for the second time (3 seconds).
NOTICE
Step 3: Allow the mode Selector Switch to return to the Stop position.
Step 4: Within 3 seconds, press and hold the Mode Selector Switch back to the MRES position until the Stop LED
flashes rapidly, (at 2Hz). When the Intelligent Interface Module has completed the memory reset function,
the Stop LED will cease flashing and remains illuminated.
3.1.7.2 Formatting the MMC
To format the MMC with the Mode Selector switch, perform the following steps:
NOTICE
Make sure the steps are performed in the specific times given, otherwise the MMC will not be
formatted and will reassume the Memory Reset status.
The MMC is only formatted if a formatting condition exists and not when a memory reset is
requested after a module is changed. In this case, switching to MRES only results in a standard
memory reset whereby the content of the module remains valid.
Step 1: Place the Mode Selector Switch in the Stop position.
NOTICE
Step 2: Press down and hold the Mode Selector Switch in the MRES (Memory Reset) position for approximately
9 seconds or until the Stop LED stops flashing.
Step 3: Within 3 seconds after the Stop LED stops flashing, release the Mode Selector switch then immediately
move it back to the MRES position. The Stop LED flashes during the formatting procedure.

3.1.8 Terminal Assignment
Table 1-3 below details the terminal assignments of the Intelligent Interface Module for the RS485, Profibus DP-V1
with fiber-optic cable interface, and 24 VDC.
Figure 3-3: Intelligent Interface Module Terminal Assignments
3.2 Control Monitor
3.2.1 Differential Pressure Sensor
When the pressure drop across the filters first reaches the maximum pressure switch setting, there will be a diag-
nostic warning message to the operator: “Filters are getting clogged; time to order new filters.” This message will
stay displayed on the operator GUI screen even if the filters have been cleaned and pressure has dropped.

When pressure drop across the filters reaches an additional 0.25” wg, another diagnostic warning message is dis-
played to the operator, “Filters are Clogged; Replace Filters”. This message should be heeded immediately (see
Caution below). This message will stay on until the filters are replaced.
If the diagnostic “Filters Are Clogged” is active, the system is indicating that the filters are clogged and they must
be replaced. That is, the pressure drop across the filters have reached or exceeded the Max Pressure Drop limits
of Tables 4-1 and 4-3, they cannot get clean to reduce that pressure drop, and their useful life has ended. If the fil-
ters are not replaced within 48 hours, a machine shut down will occur.
! CAUTION
Failure to replace the cartridge filters at this time will result in low machinery house
pressure, dust ingestion into machinery house, heat buildup, and possible overheating
of electrical components, including the motion motors and main blowers.
3.3 Control Junction Box

The control junction box is located either in the air filtration plenum (older models) or mounted outside the plenum
(newer models) and contains the pulse jet sequencer board, pressure transducer, valve terminal strips, and a ther-
mostat and heater.
02 03
01
04
Legend
01. Pressure Trans-
ducer
02. Thermostat
03. Heater, 100W
04. Board, Pulse Jet
Sequencer
Figure 3-4: Control Junction Box

P&H AirScrubPro Maintenance Manual Maintenance Procedures
Section 4
Maintenance Procedures
4.1 Air Filter Inspection and Maintenance
4.1.1 General Information
The cartridge filter cleaning cycle is programmed to be on constantly when the main fans are running. The filter
cartridges are self cleaned from blasts of air which happen every 20 seconds. Every 20 seconds 1.5 cubic feet of
compressed air (regulated to 90 psi) is blasted over a 0.1 second interval outward through each cartridge, one at a
time, in a sequential order.
Figure 4-1: Diaphragm Air Valves
The pulses of air come from the diaphragm valves shown above. These valves are pilot operated. The pilot air is
supplied by normally closed solenoid valves that are controlled by the control system.

Sec04Maint.fm -4.1- Section 4, Version 05 - 06/05
Maintenance Procedures P&H AirScrubPro Maintenance Manual
Figure 4-2: Filter Order of Pulse Cleaning - View Standing In Front Of Unit
The pulses are sequenced, starting with the top filters and working down. This pattern helps to direct the dust
downward as blown off dust tends to gather on cartridges below it. Dust eventually falls into the hopper below
within which the screw conveyor operates.
Note that the filters are divided into three subunits, and that the cleaning occurs in one subunit at a time. When the
machine shuts down the cleaning pulses continue for another 10 minutes and will then stop. The cleaning cycle,
therefore, stops somewhere in the middle of its pattern, and will start up there for the next cycle which may not be
at cartridge number 1.
It is possible to manually turn the cleaning cycle on even if the machine is shut down by using the selector switch
on the outside of the control panel in the machinery house.
If the diagnostic “Filters Getting Clogged” is active, the system is indicating that the filter pressure drop HIGH limit
has been reached. This HIGH limit was factory programmed per the expected altitude and operating frequency as
shown in Tables 4-1 and 4-3 under “MAX Filter Pressure Drop Indicating Need to Replace Filters.” When this diag-
nostic is active, it is time to order new filters as soon as possible if spare filters are not available.
If the diagnostic “Filters Are Clogged” is active, the system is indicating that the filters are clogged and they must
be replaced. That is, the pressure drop across the filters have reached or exceeded the Max Pressure Drop limits
of Tables 4-1 and 4-3, they cannot get clean to reduce that pressure drop, and their useful life has ended. If the fil-
ters are not replaced within 48 hours, a machine shut down will occur.
CAUTION
Failure to replace the filter cartridges at this time will result in low machinery hose pres-
sure, dust ingestion into machinery house, heat buildup, and possible overheating of
electrical components including the motion motors and main blowers.

Section 4, Version 05 - 06/05 -4.2- Sec04Maint.fm
4.1.2 Filter Cartridge Replacement
The filters are mounted such that they can be easily accessed from the shovel roof. They are held in place with
access covers and knobs. They are not heavy enough to require lifting equipment.
Filter maintenance is limited to replacement. Replacement takes place when the system is no longer able to clean
the filters any more. A short time before the filters need to be replaced, the system produces an alarm saying “Fil-
ters Getting Clogged”. At this point it is advisable to order new filters.
All filters must be replaced at the same time. If only a few filters are replaced, most of the incoming air will follow
the path of least resistance and flow through the new filters and not the dirty ones. This will drastically reduce the
life of the few new filters.
Figure 4-3: Air Filter Cartridge Replacement
NOTICE
When the filters can not be cleaned by the system an alarm saying “Filters Are Clogged” will be
produced and a system shut down will be initiated within 48 hours.
4.2 Airlock Feeder Information (1037Z589)
! DANGER
Keep chain guard in place and keep both inlet and outlet covered when the feeder is con-
nected to a power source.
! CAUTION
DO NOT TRY TO FORCE THE ROTOR TO TURN WITH YOUR HANDS. After disconnecting
power to the airlock feeder, use a board between the blades or use a pipe wrench on the
non-drive end of the rotor shaft in order to turn the airlock rotor by hand. If the rotor
does not turn relatively easy, look for the cause of the problem. Remember an airlock is
a precision piece of equipment and can be easily damaged if not handled properly by

personnel trained to work on precision equipment. There are numerous reasons why the
airlock rotor could be binding. If you are unable to find the problem yourself, consult
your MinePro representative.

Watch what you are doing. Use common sense. Do not attempt to operate Airlock Feeder with-
out the chain guard in place and without inlet and outlet covers in place.
Figure 4-4: Rotary Airlock Feeder
An airlock feeder is a precision piece of equipment operating with small internal clearances. Any distortion in the
housing will cause the rotor to rub against the housing and thus cause premature failure of the airlock.
Check the interior of the airlock for any foreign materials that might cause the airlock to bind while in operation.
CAUTION
BEFORE OPERATION, the user is responsible for checking to see that the gear motor
has oil to the proper level.
Most gear motors (but not all) are shipped with a sufficient quantity of lubricant for operation. It is the user’s respon-
sibility to ensure proper oil level in the gear motor.
Most gear motors are provided with three pipe plugs at different levels. The top (breather) plug is where oil is put in
the gear head with breather plug removed. The center plug when removed is used to indicate when the proper
amount of oil is in the gear head. When oil starts flowing out of the center plug (with plug removed), sufficient oil is
in the gear head and both the top (breather) plug and center plug can be replaced. The purpose of the bottom
(magnetic) plug is to be able to remove the oil from the gear head. It should be in place except to drain oil out of the
gear head. Maintenance technician should check and make sure the breather plug is the highest of three plugs and
the magnetic plug is the lowest of the three plugs.
Before operating the airlock, the motor should be bumped to determine the proper direction of rotation.

4.3 Screw Conveyor Inspection and Maintenance
Screw Conveyor Maintenance Issues
! WARNING
Always Lockout and Tagout power before removing any covers, guards, or access pan-
els on the screw conveyor equipment. Failure to adhere to instruction could result in
loss of life or severe personal injury.
To inspect remove top trough cover and note if bearing is equally spaced within the pipe opening. If bearing has
dropped excessively from a concentric location within the pipe, bearing must be replaced.
• The screw conveyor bearing on the airlock end needs grease (one fitting) every 3 to 6 months.
• The screw conveyor hanger bearing has impregnated graphite lubricant so no lubrication is required. How-
ever, it must be inspected every 3 to 6 months for excessive wear.
• The screw conveyor bearing on the driven end is lubricated by the drive gear box oil.
Gear drive box should have oil changed every 2 years.
Rotary air lock is sealed and lubricated for life; no maintenance needed unless it gets clogged up.
NOTICE
In case of clogging, screw conveyor can be opened from bottom access panels on the air filtra-
tion unit. Also, conveyor has 3 access panels on the run from air filtration unit to the rotary air
lock. These access panels are bolted every 16” and panels are gasketed; no need to replace
gaskets.
Periodic inspection should be made of conveyor components as follows:
1. All internal and external bearings should be inspected for excessive wear of bearing or shaft.
2. Bearings in hangers should have the bearing hangers and housings inspected for excessive wear, apparent
lack of lubrication, and for out-of-round condition.
3. The flight (forward) edge of the auger should be inspected for appropriate thickness and for wear or damage.
4. Coupling bolts at drive shaft should be inspected. Remove and inspect bolt and hole for wear.
5. All coupling bolts and nuts should be inspected for external wear or loss.
6. Inspect all seals for leakage.
7. Bearing, flange and cover bolts should be checked, looking for loose, damaged or missing bolts and nuts.
8. Check all gasket joints for leaking.

Several types of bearings may be used on screw conveyors, some of which require periodic lubrication. Frequency
of lubrication varies depending upon material being conveyed, temperature, speed and operating time.
9. Ball bearings in hangers, or at tail end or discharge end are furnished with grease fittings (for periodic lubrica-
tion).
10. Roller bearings, when used on conveyor ends for drive or thrust loads, should be routinely lubricated. Over-
greasing may cause seal damage and early failure.
11. The gear drive box should have oil changed every 2 years.
12. The rotary air lock is sealed and lubricated for life. No maintenance is required unless it gets clogged. In case
it gets clogged, the screw conveyor can be opened from the bottom access panels on the Air Scrub Pro.
4.4 Blower Fan Inspection and Maintenance (R52632F1)

Access to make fan blade setting adjustments is achieved through an access door in outlet duct for top blades, and
through machinery house for bottom blades. Inspect the ventilation system every 250 hours as follows.
! WARNING
Moving fans can cut and/or crush causing personal injury or death to personnel in the
fan housing. Disconnect and lockout the power to the fans before performing fan inspec-
tion, cleaning or service procedures.
• Check to insure air inlet screens are free of large debris which might reduce air flow.
• Check blower mounting for security.
• Check to make sure fan blades are tight and are all set at the same angle.
• Check the blades for dirt accumulations and debris. A light coating of dust on the blades is normal and will
not impair the operation or efficiency of the fans. In some installations the blades may accumulate a thicker
deposit of surface dirt due to the sticky character of an unusual dust, or due to the presence of oil mist or
similar vapors in the air. When the accumulated deposit reaches a thickness of 1/8 inch (3.2mm), the blades
should be cleaned.
At least twice a year or more, a detailed inspection of the system should be made. The fan blades should be
checked to make sure they are clean and that the blades are set at the proper pitch. See Subtopic 4.4.1.
4.4.1 Blade Adjustments
The amount of air supplied to the machinery house is highly dependent upon the pitch setting of the blower fan
blades. The blower blades are preadjusted to a setting of 14 by the manufacturer. However, this setting is adjusted
during shovel manufacture to the setting(s) shown in Table 4-1 through Table 4-4 as a function of altitude and
operating frequency. The settings should be checked when the blowers are installed, and whenever the filters are
serviced. To adjust the blower fan blades, refer to

NOTICE
Adjustment made to the blower can affect the filter’s capabilities to remove dust particles from
the incoming air. Improper blower adjustment could cause higher amounts of dust contamina-
tion to pass through the filters into the machinery house.
06 05
02
01
03
04
05
F
l 06
o
w 07
08
Legend
01. Nose ES04282b01
02. Screen Guards 02
03. Fan Blades
04. Housing
05. Electrical Junction Box
06. Lubrication Fittings
07. Fan Blades
08. Motor
Figure 4-5: Blower Components
1. Remove the inlet cover from the fan housing.
2. Remove the nose from the fan rotor, see Figure 4-5.
3. Check the setting of each blade as indicated by the blade position index stamped on the hub next to each indi-
vidually adjusted blade, see Figure 4-6. Refer to Table 4-1 or Table 4-3 for the correct blade settings.

NOTICE
All blades must be set to the same set point or the fan will be unbalanced and vibration will
result.
4. If a blade setting is incorrect, adjust the settings as follows:
A. Loosen the blade locknut for blade to be adjusted.
B. Set the blade index mark at the required blade setting and tighten the locknut.
NOTICE
Setting the blade angles to a higher number than recommended can overload the motor, result-
ing in shovel shutdown.
0
8
16
01
Legend
01. Index Mark
02. Blade Lock Nut
02
ES04278a01
Figure 4-6: Checking Blade Setting/Adjustment

60 Hz Applications
Altitude Blade Setting Per-Fan Flow House Pressure MAX Filter

Recommended Expected (ACFM) Expected Pressure Drop
(“wg) Indicating
Need To
Feet Meters Clean Fil- Dirty Fil- Clean Dirty Fil- Replace Filters
ters ters Filters ters (“wg)
0 0 14 24,300 18,750 0.50 0.12 8.00
5,000 1,524 14 24,300 18,750 0.42 0.10 7.00
10,000 3,048 13 27,500 21,700 0.58 0.20 6.00
15,000 4,572 13 27,500 21,700 0.48 0.17 5.00
Table 4-1: Fan Blade Setting Chart Guide for Cartridge-type Filtration
60 Hz Applications
Altitude Current Draw Fan Brake Current Draw Fan Brake

per Fan Horse- per Fan Horse-
@460V* power** @460V* power**
(Amps) (BHP) (Amps) (BHP)
Feet Meters Clean Dirty Clean Dirty Clean Dirty Clean Dirty
Fil- Filters Filters Fil- Filters Filters Filters Filters
ters ters
0 0 44.9 48.7 42.0 45.5 44.9 48.7 42.0 45.5
5,000 1,524 37.4 40.9 35.0 8.3 37.4 40.9 35.0 8.3
10,000 3,048 37.4 39.6 35.0 37.0 37.4 39.6 35.0 37.0
15,000 4,572 30.6 33.9 28.6 31.7 30.6 33.9 28.6 31.7
* Motor Ratings @ 460V, 3Ø, 60Hz; 48.3 Full Load Amps; 59.0 Airover Amps.
** Fan Horsepower is rated at 40 hp; can be taken up to 50 hp “air over” MAX rating.
Table 4-2: Current Draw and Horsepower for Cartridge-type Filtration

50 Hz Applications
Altitude Blade Setting Per-Fan Flow House Pressure MAX Filter

Recommended Expected (ACFM) Expected Pressure Drop
(“wg) Indicating
Need To
Feet Meters Clean Fil- Dirty Fil- Clean Dirty Fil- Replace Filters
ters ters Filters ters (“wg)
0 0 11 25,300 19,300 0.60 0.15 8.00
5,000 1,524 11 25,300 19,300 0.50 0.12 7.00
10,000 3,048 10 26,900 20,700 0.53 0.16 6.00
15,000 4,572 10 26,900 20,700 0.44 0.13 5.00
Table 4-3: Fan Blade Setting Chart Guide for Cartridge-type Filtration
50 Hz Applications
Altitude Current Draw per Fan Fan Brake Horse-

(Amps) power** (BHP)
Clean Filters Dirty Filters
Feet Meters 380V 415V 380V 415V Clean Dirty Filters

Filters
0 0 54.4 49.8 54.4 49.8 42.0 42.0
5,000 1,524 45.7 41.9 45.2 41.4 35.3 34.9
10,000 3,048 42.7 39.1 43.4 39.7 33.0 33.5
15,000 4,572 35.1 32.1 35.3 32.4 27.1 27.3
* Motor Ratings @ 380V, 3Ø, 50 Hz: 57.5 Full Load Amps; 72.0 Airover Amps
Motor Ratings @ 415V, 3Ø, 50 Hz: 54.4 Full Load Amps; 66.4 Airover Amps
** Fan Horsepower is rated at 40 hp; can be taken up to 50 hp “air over” MAX rating.
NOTES:
1. There are two sets of fan blades per fan, one set on each end of the fan motor
2. Access one set of blades from inside the filter plenum; access the other set from
inside the rear of the machinery house.
3. All blades must be set at the same blade number setting.
Table 4-4: Current Draw and Horsepower for Cartridge-type Filtration

4.5 Speed Switch Adjustment (1079Z8303)

The speed switch monitors auger rotation by sensing the pulser wrap rotating in front of the sensor. The speed
switch produces a control signal which is sent to the conveyor control.
The speed switch must be adjusted to provide correct gap between the speed switch and the sensor wrap. Refer to
Figure 4-7 for proper gap distance.
01
A A
02 01
03
ES04276a02
Legend
01. Speed Switch
02. Pulser Wrap
03. Auger Shaft
Dimension 1/16 - 1/4 inch

“A”
Figure 4-7: Speed Switch Sensor Gap
4.6 Air Lock Inspection and Maintenance (1037Z589)

The airlock is a precision piece of equipment operating with small internal clearances. Any distortion in the housing
will cause the rotor to rub against the housing and thus cause premature failure to the airlock.
4.6.1 Lubrication Instructions
A shaft bearing and three seals are provided in each end plate. Each bearing is equipped with two grease retention
seals and is factory lubricated. These bearings do not require re-lubrication for the lifetime of the bearing.

4.6.2 Rotor Shaft Packing Rings
! WARNING
els on the screw conveyor equipment.
! CAUTION
Do not try to force the rotor to turn with your hands. After disconnecting power to the
airlock feeder, use a board between the blades or use a pipe wrench on the non-drive
end of the rotor shaft in order to turn the airlock rotor by hand. If the rotor does not turn
relatively easy, look for the cause of the problem. Remember an airlock is a precision
piece of equipment and can be easily damaged if not handled properly by personnel
trained to work on precision equipment. There are numerous reasons why the airlock
rotor could be binding. If you are unable to find the problem yourself, consult your
MinePro representative.
1. U-cup packing rings are endless. U-cups are self energizing and need very little compression in order to be an
effective shaft seal. Too much compression will damage them.
2. Installation of new U-cup packing rings:
A. Remove end plates. See Subtopic 4.6.3.
B. Before installing, dip new U-cup packing rings in a light oil. Press three rings into each end plate with lips
toward the inside. Install the gland plate screws with an allen wrench until very light resistance can be felt,
then lock the screws in place with the jam nuts against the bearing housing.
C. After both housing end plates have been installed per Subtopic 4.6.4, check the U-cup packing rings to
make sure they have only a slight amount of compression. Back off the two gland plate screws enough to be
sure the U-cups are not being compressed and then retighten the gland plate screws and their gland nuts.
Do not compress the U-cup packing rings. The gland plate screws should be tightened only enough to snug
the U-cup packing rings down against the packing seat. With the roller chain removed and the airlock feeder
NOT connected to the power source, the rotor should rotate with some resistance caused by the lightly com-
pressed U-cup packing rings when pulling on the rotor vanes using an approximately 3 foot long 2 by 4
between the vanes. As a safety precaution, do not pull on the rotor vanes with your fingers.

4.6.3 End Plate Disassembly
! WARNING
els on the screw conveyor equipment.
! CAUTION
Do not rotate or pull on airlock rotor by hand. Always use a suitable tool.
1. Before either end plate is disassembled, the drive assembly must be removed.
2. Remove air purge hardware from both end plates if so equipped.
Figure 4-8: End Plate Set Screws
3. Loosen the packing gland plate and bearing set screws on both end plates.
4. Remove the hex bolts which fasten the non-drive end plate to the cylinder housing.
5. Pull the non-drive end plate off the rotor shaft. Do not attempt to remove the end plate by forcing a wedge
between the plate and housing. This could mar the machined surfaces of the housing and end plate. Do not
hammer on the end of the rotor shaft with a steel hammer as this will deform the shaft. If force is required, use
a gear puller or use a wood block on the end of the rotor shaft to hammer on. Be careful not to damage the
center in the end of the rotor shaft. Note the number of shims on the non-drive end so the same number can be
re-installed.
6. Extract the rotor from the cylinder housing. If force is necessary to remove the rotor, use a block of wood on the
rotor shaft to hammer on or a gear puller. Avoid setting the removed rotor on concrete or other hard surfaces,
as the machined rotor blade tips might be damaged.
7. Upon completion of steps 4, 5, and 6, remove the hex bolts which fasten the drive end plate to the cylinder.
The drive end plate should then be separated from the housing. Use a 2 by 4 of the proper length to pound on

interior of end plate if force is required. Note the number of shims on the drive end of the cylinder housing, so
the same number can be re-installed.
8. If replacement of bearings is necessary, remove the shaft bearing from the end plate by use of a soft metal or
fiber drift. Do not mar or dent any machined surfaces.
4.6.4 End Plate Assembly
1. Insert a shaft bearing in each end plate. The bearing should be a light press fit. Be sure the bearing is pressed
down against the bearing snap ring.
2. For installation of shaft seals, see Subtopic 4.6.2.
3. For easier installation of the end plates, leave the packing gland plates loose.
4. Before installing the drive end plate, polish the sealing surfaces and the bearing journals with a fine (100 grit or
finer) emery cloth. Be sure there is no foreign matter on the machined mating surfaces.
5. Install the drive end plate and tighten the hex bolts to fasten the drive end plate to the cylinder housing. Move
from bolt to bolt (not adjacent bolts) and tighten each down gradually.
6. Install the rotor assembly. Be sure not to scratch or mar the machined surfaces of the housing.
7. Repeat steps 4 and 5 for the non-drive end plate assembly.
8. Tighten down the packing gland plate screws. See Subtopic 4.6.2 for information for the proper compression of
the packing rings.
9. Check the axial clearances between the rotor and the end plate. To increase the total axial clearance, a shim
or shims must be added. To decrease the total axial clearance, a shim or shims must be removed. Each shim
is 0.003 inch thick. An end plate assembly must be removed in order to add or remove end plate shims.

01 02
03 04 05 06
A
07
08
09
A
10
11
12
ES04277a02
B B 13
Legend
01. Cylinder 08. Bearing
02. Rotor Assembly 09. Shaft Packing
03. End Plate 10. Bolt
04. Gland Plate 11. Lock Washer
05. Flat Washer 12. 0.003 Spacer Shim
06. Lock Nut 13. Gasket
07. Gland Plate Screw
Location Clearance
Rotor and Housing “A” 0.005 inch
Rotor and End Plate “B” 0.010 inch
Figure 4-9: Air Lock Clearances


P&H AirScrubPro Maintenance Manual Fault Diagnostics
Section 5
Fault Diagnostics

Help Screens are designed to assist the operator and maintenance technician in identifying and isolating malfunc-
tions with systems used on a P&H Mining Shovel.
The following information is provided in case of a Graphic User Interface (GUI) or Panelview fault message for the
P&H Air Scrub Pro Filtration System.
5.1.1 Graphic User Interface (GUI)
The cleaning system and conveyor faults will be shown as a Graphic User Interface (GUI) or Panelview fault mes-
sage. The fault descriptions are:
HOUSE FILTER CONTROL SYSTEM IS NOT ACTIVE
FILTER SYSTEM FAULT: NO PRESSURE SENSOR INPUT
FILTER SYSTEM FAULT: NEW FILTER MUST BE SET
FILTER SYSTEM FAULT: FILTERS ARE GETTING CLOGGED.
FILTER SYSTEM FAULT: FILTERS ARE CLOGGED.
CONVEYOR SYSTEM FAULT: SCREW CONVEYOR OVERLOAD IS TRIPPED.
CONVEYOR SYSTEM FAULT: THE ZERO SPEED SWITCH IS CLOSED WHEN THE CONVEYOR SYSTEM
SHOULD BE STOPPED.
CONVEYOR SYSTEM FAULT: THE ZERO SPEED SWITCH DID NOT CLOSE WHEN THE CONVEYOR
SHOULD BE MOVING.
CONVEYOR SYSTEM FAULT: THE CONVEYOR CONTACT AUXILIARY IS CLOSED. THE CONTACTOR
SHOULD BE OPEN.
CONVEYOR SYSTEM FAULT: THE CONVEYOR CONTACT AUXILIARY IS NOT CLOSED WHEN THE CON-
TACTOR SHOULD BE ENERGIZED.
TEMPERATURE FAULT: DIFFERENTIAL PRESSURE SENSOR IS NOT AT THE PROPER TEMPERATURE.

Sec05Fault.fm -5.1- Section 5, Version 05 - 06/05
Fault Diagnostics P&H AirScrubPro Maintenance Manual
5.2 Panel Fault Indication

The cleaning system and conveyor faults will be shown on a 4 Digital Output 24VDC Module located in the filter
control system enclosure. The seventh module from the left-hand side will sequentially display the system faults.
The lights will flash the fault for 5 seconds then flash the next fault for 5 seconds, etc.
01
FILTER/SCREW CONVEYOR CABINET

SCREW CONVEYOR NEW FILTERS
CONTINUOUS AUTO INSTALLED RESET
CLEANING CYCLE
ON
FILTER CONDITION
EXCELLENT
FILTER CONDITION
GOOD
SCREW CONVEYOR FILTER CONDITION
ON FAIR
REPLACE FILTERS
OFF
MANUAL CLEAN
PRESSURE DIFFERENTIAL
OFF ON
HOURS
000000
02 03
04
05
09
Legend
01. Control Cabinet 06
02. Power Supply
03. Transformer
04. Switch, Disconnect
05. Fuse Block
06. Contactor
07. Heater, 100W
08. Terminal Blocks
09. I/O Module, Fault Display
08 07
Figure 5-1: Control Cabinet -- Front Panel Open

Section 5, Version 05 - 06/05 -5.2- Sec05Fault.fm
Fault Light Light Light Light

# 1 2 5 6
1 ON
2 ON
3 ON ON
4 ON
5 ON ON
6 ON ON
7 ON ON ON
8 ON
9 ON ON
10 ON ON
Figure 5-2: I/O Module Cleaning System and Conveyor Fault Indication
5.2.1 Filtration System Faults
Fault Number Description

1 No Pressure Sensor Input. The system has detected that the differential pressure
signal is missing. The differential pressure sensor is located in a junction box
enclosure located in the blower plenum. Check the pressure display on the front of
the filter enclosure. check the pressure sensor and wiring.
2 New Filter Must Be Set. The system has detected that the pressure differential has
decreased substantially more than it had been, which indicates that the filters may
have been changed. If the filters have been changed then the “New Filters
Installed Reset” button on the control panel must be used to reset the system. If
new filters have not been installed then some of the filters may have broken
through and are no longer filtering the air.
3 Filters Are Getting Clogged. The system has detected that the filters are approach-
ing a clogged filter condition. At this point it is advisable to order new filters.
4 Filters Are Clogged. The system is indicating that the filters are clogged and must
be replaced. The programmed logic allows 48 hours before the machine shuts
down. If the problem is not corrected, the machine will shut down every 48 hours
on this fault.
10 Differential Pressure Sensor Is Not At The Proper Temperature. The system has
detected that the junction box housing the Differential Pressure sensor in the
house filter plenum is too cold. Check to see if the enclosure heater is operational.
Table 5-1: System Faults

5.2.2 Conveyer Faults
The filter screw conveyor system has two modes, Auto and Manual. A selector switch on the front of the filter con-
trol panel selects the mode. In addition there are two lights, on the front door of the filter control, which indicate
whether the screw conveyor is ON or OFF.
Auto Mode: When in auto mode the screw conveyor will turn on for a set amount of time when the house fans are
running. The conveyor will wait 50 minutes and then turn on for 10 minutes. The cycle will repeat as long as the fil-
ter control “Auto-Manual” switch is in Auto and the house fans are running and there are no faults in the system.
Manual Mode: When in Manual mode the conveyor will turn on continuously whenever the switch is placed in the
Manual position if there are no conveyor faults in the system.
The following screw conveyor faults can stop the operation of the screw conveyor.
Fault Number Description

5 Screw Conveyor Overload Is Tripped. The system has indicated that the screw
conveyor motor overload has tripped. The overload must be manually reset in
the filter control enclosure. Check to see if the screw conveyor is rotating freely
and not jammed.
6 The Zero Speed Switch Is Closed When The Conveyor Should Be Moving. The
system has detected that the zero speed switch is indicating that the screw
conveyor is moving when it should not be moving.
7 The Zero Speed Switch Did Not Close When The Conveyor Should Be Moving.
The system has detected that the screw conveyor is not turning. Visually check
to see if the screw conveyor is jammed or the speed sensor is out of position.
8 The Conveyor Contactor Auxiliary Is Closed. The Contactor Should Be Open.
The system has detected that the screw conveyor contactor auxiliary contact is
closed when the contactor should be open.
9 The Conveyor Contact Auxiliary Is Not Closed When The Contactor Should Be
Energized. The system has detected that the screw conveyor contactor auxil-
iary contact did not close when the contactor should have been closed.
Table 5-2: Conveyor Faults

5.3 Fault Diagnosis
5.3.1 Fault 2: New Filter Must Be Set
The system has detected that the pressure differential has decreased substantially more than it had been, which
indicates that the filters may have been changed. If the filters have been changed then the “New Filters Installed
Reset” button on the control panel must be used to reset the system.
NOTICE
If new filters have not been installed then some of the filters may have broken through and are
no longer filtering the air. Refer to Topic 1.1 for air filter inspection and maintenance.
5.3.2 Fault 3: Filters Are Getting Clogged
Order new filters.
• The pressure differential across the cartridge filters has temporarily exceeded the highest pressure
differential that the main blowers can handle.
• This is an indication that the cartridge filters are clogged to the extent that their useful life is nearing
an end. There will be lower machinery house pressure and possible rise in machinery house tem-
perature, because the main blower fans will not deliver as much air flow.
NOTICE
It is highly recommended to order new filters at this time.
5.3.3 Fault 4: Filters Are Clogged
Replace Filters.
• The pressure differential across the cartridge filters has exceeded the highest pressure differential
(the maximum filter pressure drop) that the main blowers can handle.
• The filter cleaning can no longer clean the filters to achieve a lower pressure differential.
• The main blower fans can no longer provide the air flow needed to pressurize the machinery house.
CAUTION
Failure to replace the cartridge filters at this time will result in low machinery house
pressure, dust ingestion into machinery house, heat buildup, and possible overheating
of electrical components.

5.3.4 Fault 5: Screw Conveyor Overload Is Tripped
The auger motor overload relay has tripped due to abnormal drag on one or more of the following components in
the auger system:
• Auger motor
• Motor speed reducer
• Screw conveyor
• Rotary air lock
! WARNING
Do not reach into screw conveyor while screw is turning or while there is residual poten-
tial rotational load present once obstacle is removed.
! WARNING
Lock out power before removing cover or guard. Do not step on cover or guard.
! CAUTION
Guards, access doors and covers must be securely fastened before operating this
equipment. Lockout power before removing guards, access doors and covers. Failure to
follow this instructions may result in personal injury or property damage.
Step 1: Check to see if there is an obstacle caught in either the screw conveyor or rotary airlock.
Figure 5-3: Auger Motor

Figure 5-4: Rotary Airlock
• Visual access to the air lock can be achieved by removing access cover over the auger trough fur-
thest to outboard side of auger discharge.
• Access panels are removable on top of auger extension over entire length of filter unit.
• Three access panels to screw conveyor directly below filter unit are located facing front of machine.
Step 2: Remove access panels to inspect screw conveyor.
• Once panel is removed from filter base, another panel (with handles) must be removed for direct
access to screw conveyor.
• A fourth access panel is located on auger motor end facing the back of the machine.
• Screw conveyor can be manually rotated
Step 3: Remove obstacles from trough and screw conveyor.
5.3.5 Fault 7: The Zero Speed Switch Did Not Close
! WARNING
Do not reach into screw conveyor while screw is turning or while there is residual poten-
tial rotational load present once obstacle is removed.
! WARNING
Lock out power before removing cover or guard. Do not step on cover or guard.

! CAUTION
Guards, access doors and covers must be securely fastened before operating this
equipment. Lockout power before removing guards, access doors and covers. Failure to
follow this instructions may result in personal injury or property damage.
Screw conveyor should be rotating but is not. Auger motor driving screw conveyor is not overloaded and is rotating.
There is a break in one or more of the following components in the auger system:
• Screw conveyor
• Screw conveyor shear bolt connection (just outside filter unit in trough)
• Auger motor drive shaft
• Rotary air lock chain drive
• Zero speed switch
Inspect the rotary air lock chain.

Keep hands and fingers out of the screw conveyor trough while rotating screw.
• Screw conveyor can be manually rotated with a wrench from auger motor end to help troubleshoot-
ing efforts.

AirScrubPro Maintenance Manual Checklists
Appendix A
Checklists
A.1 Air Lock Inspection and Maintenance
Check Box Step
! DANGER
Keep chain guard in place and keep both inlet and outlet cov-
ered when the feeder is connected to a power source. Always
Lockout and Tagout power before removing chain guard or inlet
and outlet covers. Failure to adhere to instruction could result
in loss of life or severe personal injury.
! WARNING
When installing the airlock feeder DO NOT connect the power
source until chain guard is in place and the airlock inlet and out-
let are covered so that there is no chance for fingers and hands
to get close to rotating blades.
CAUTION
Do not try to force the rotor to turn with your hands. After dis-
connecting power to the airlock feeder, use a board between
the blades or use a pipe wrench on the non-drive end of the
rotor shaft in order to turn the airlock rotor by hand. If the rotor
does not turn relatively easy, look for the cause of the problem.
Remember an airlock is a precision piece of equipment and can
be easily damaged if not handled properly by personnel trained
to work on precision equipment. There are numerous reasons
why the airlock rotor could be binding. If you are unable to find
the problem yourself, consult your MinePro representative.

Watch what you are doing. Use common sense. Do not attempt to
operate Airlock Feeder without the chain guard in place and without
inlet and outlet covers in place.
Step 1: Check the interior of the conveyor trough for foreign objects that could cause
the airlock to bind.
Step 2: Check oil level and verify positions of the drain plugs.
Table A-1: Airlock Installation and Operation

AppA.fm -A.1- Appendix A, Version 05 - 06/05
Checklists AirScrubPro Maintenance Manual
A.2 Screw Conveyor Inspection and Maintenance
Check Box Inspection
! WARNING
Always Lockout and Tagout power before removing covers or
guards on the screw conveyor equipment. Failure to adhere to
instruction could result in loss of life or severe personal injury.
Inspect all internal and external bearings for wear of bearing or shaft.
Inspect the flight (forward) edge of the auger for thickness, wear or damage.
Remove drive shaft coupling bolts and inspect bolts and holes for wear.
Inspect all coupling bolts and nuts for external wear or loss.
Inspect seals for leakage.
Inspect bearing, flange and cover bolts for looseness, damage, or missing nuts.
Inspect gasket joints for leaks.
Inspect ball bearings and roller bearings in hangers and at shaft ends; lubricate as nec-
essary. The bearing on the airlock end needs grease every 3 to 6 months.
Re-install all covers and guards, then remove locks and/or tags.
Change gearcase oil every 2 years.
Table A-2: Removal of Existing Filter System Assembly

Appendix A, Version 05 - 06/05 -A.2- AppA.fm
AirScrubPro Maintenance Manual Cold Weather Kit
Appendix B
Cold Weather Kit
B.1 Cold Weather Package Upgrade

The cold weather kit is applicable to all Air Scrub Pro units. Some units, however, have the main control in the
machinery house which requires additional lengths of wire runs.
The purpose of this kit is to keep the air solenoids and air solenoid valves warm and frost free as temperatures
drop below 50° F.
Installation involves adding junction boxes to connect heat trace cable that wraps around the solenoid valves and
solenoid enclosure boxes. Insulation is then wrapped around the heat trace. When the temperature drops below
50° F, the heat trace cable gets warm and heats up the component it is wrapped around. There are three separate
heat trace cable runs, one for each filter sub unit.
B.1.1 Cold Weather Package Instructions
! WARNING
els on equipment. Failure to adhere to instruction could result in loss of life or severe
personal injury.

AppB.fm -B.1- Appendix B, Version 05 - 06/05
Cold Weather Kit AirScrubPro Maintenance Manual
Legend
01. Air Manifolds
02. Junction Box Enclosures
03. Solenoid Enclosures
04. Main Control Box
05. Conduit Connections
Figure B-1: Components and Heat Trace Cable Routing
1. Drill (three) additional holes in the sidewall of main control box for 1/2-inch conduit connections vertically in line
and above connections that are already there.
2. The three junction box enclosures must be drilled to accommodate two connections each:
• The 1/2-inch conduit connection and
• The heat trace cable connector.
3. Locate and mount junction box enclosures, in three locations on vertical mounting stiffeners as shown.
4. Mount additional terminal strip provided in kit into main control box. The strip will be used for connection of
three junction boxes to power source.
5. Make wire and conduit connections from main control box to three junction box enclosure. Power connections
inside control box to be made to open terminal strip installed in Step 4.
6. Use EZHEATTM instructions provided by the vendor to connect each of the three heat trace cables from junc-
tion boxes to each solenoid valve in a path suggested in Figure B-1. Be sure to use heat trace cable to wrap
around solenoid enclosures and air manifolds as well. Use installation instructions in section B.1.2 for details
on how to wrap solenoid valves.
7. To power heat trace cables, use#12 AWG 5-conductor cable (in kit) to provide 120V connection to terminal
strip in main control box from appropriate breaker (in control room) that feeds the filter system. Total power
consumed by heat trace is 1080 watts.

Appendix B, Version 05 - 06/05 -B.2- AppB.fm
AirScrubPro Maintenance Manual Cold Weather Kit
B.1.2 Heat Trace Cable Installation
CAUTION
Do not over tighten hose clamps on heat trace cable.
Figure B-2: Heat Trace Valve Wrapping Detail
1. Double wrap heat trace cable between round coupling and round valve cover, and around the valve as shown
above. Pull cable tight.
2. Apply a 4-inch hose clamp or cable tie around the “double-wrapped” heat trace cable and secure tightly.
3. Wrap the vinyl-foam pipe insulation tape around each valve/heat cable assembly. Wrap the entire valve with
pipe insulation, double wrapping over the hose-clamped heat trace cable. Secure with cable ties (not shown).

AppB.fm -B.3- Appendix B, Version 05 - 06/05
Cold Weather Kit AirScrubPro Maintenance Manual

Appendix B, Version 05 - 06/05 -B.4- AppB.fm
P&H AirScrubPro Filtration System Reader
Comment
Maintenance Manual Form
To assist us in providing you with the most useful publications, we ask that you use this form to express your views
concerning this publication, its organization or subject matter, with the understanding that P&H Mining Equipment
may use or distribute whatever information you supply in any way it believes appropriate without any obligation to
you. All comments and suggestions are both welcome and appreciated.
To report machine problems or to request additional publications, do not use this form; rather, contact the nearest
P&H MinePro Office. P&H MinePro Services will forward your information or requests to the appropriate division at
P&H Mining Equipment.
Does the publication meet your needs? YES NO
Comment: _________________________________________________________________________________
__________________________________________________________________________________________
Is the information accurate and complete? YES NO Is it easy to read and understand? YES NO
Comment: _________________________________________________________________________________
__________________________________________________________________________________________
Is the information organized for convenient use? YES NO Is it well-illustrated? YES NO
Comment: _________________________________________________________________________________
__________________________________________________________________________________________
Is the information written to an appropriate technical level? YES NO
Comment: _________________________________________________________________________________
__________________________________________________________________________________________
Please use the space below to identify errors, suggest changes, or to provide additional comments. Include
drawings, photographs, or other graphics as appropriate. For comments regarding the manual, please refer to
page numbers and/or paragraph numbers. If necessary, use additional sheets and mail in an envelope.
Fold and Tape Please Do Not Staple Fold and Tape
PLACE
STAMP
HERE

P.O. Box 310
Milwaukee, WI 53201-0310
Attn.: Technical Communications Department

P&H AirScrubPro Filtration System Reader
Comment
Maintenance Manual Form
To assist us in providing you with the most useful publications, we ask that you use this form to express your views
concerning this publication, its organization or subject matter, with the understanding that P&H Mining Equipment
may use or distribute whatever information you supply in any way it believes appropriate without any obligation to
you. All comments and suggestions are both welcome and appreciated.
To report machine problems or to request additional publications, do not use this form; rather, contact the nearest
P&H MinePro Office. P&H MinePro Services will forward your information or requests to the appropriate division at
P&H Mining Equipment.
Does the publication meet your needs? YES NO
Comment: _________________________________________________________________________________
__________________________________________________________________________________________
Is the information accurate and complete? YES NO Is it easy to read and understand? YES NO
Comment: _________________________________________________________________________________
__________________________________________________________________________________________
Is the information organized for convenient use? YES NO Is it well-illustrated? YES NO
Comment: _________________________________________________________________________________
__________________________________________________________________________________________
Is the information written to an appropriate technical level? YES NO
Comment: _________________________________________________________________________________
__________________________________________________________________________________________
Please use the space below to identify errors, suggest changes, or to provide additional comments. Include
drawings, photographs, or other graphics as appropriate. For comments regarding the manual, please refer to
page numbers and/or paragraph numbers. If necessary, use additional sheets and mail in an envelope.
PLACE
STAMP
HERE

P.O. Box 310
Milwaukee, WI 53201-0310
Attn.: Technical Communications Department

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P&H AirScrubPro Maintenance Manual Preface

Copyright © 2006 P&H Mining Equipment, Inc. Peak Services

Peak Services Copyright © 2006 P&H Mining Equipment, Inc.

Number and Description of Change Entered By Date

Copyright © 2006 P&H Mining Equipment, Inc. Peak Services

Peak Services Copyright © 2006 P&H Mining Equipment, Inc.

Copyright © 2006 P&H Mining Equipment, Inc. Peak Services

Table of Contents (Continued)

SECTION 4, Maintenance Procedures

SECTION 5, Fault Diagnostics

APPENDIX B, Cold Weather Kit

Peak Services Copyright © 2006 P&H Mining Equipment, Inc.

Table of Contents (Continued)

Copyright © 2006 P&H Mining Equipment, Inc. Peak Services

Table of Contents (Continued)

Peak Services Copyright © 2006 P&H Mining Equipment, Inc.

SECTION 4, Maintenance Procedures

SECTION 5, Fault Diagnostics

APPENDIX B, Cold Weather Kit

Copyright © 2006 P&H Mining Equipment, Inc. Peak Services

List of Figures (Continued)

Peak Services Copyright © 2006 P&H Mining Equipment, Inc.

SECTION 4, Maintenance Procedures

SECTION 5, Fault Diagnostics

APPENDIX B, Cold Weather Kit

Copyright © 2006 P&H Mining Equipment, Inc. Peak Services

List of Tables (Continued)

Peak Services Copyright © 2006 P&H Mining Equipment, Inc.

1.1 General Information

1.1.1 Safety Websites

Copyright © 2006 P&H Mining Equipment, Inc. Peak Services

1.2 Safe Operating Practices for Users of P&H Mining Equipment

P&H Mining Equipment

1.2.2 Conduct of Operators

Peak Services Copyright © 2006 P&H Mining Equipment, Inc.

1.2.2.1 Operator’s Functional Checks

• During operation, be alert for unusual noises, vibrations or smells.

1.2.3 Responsibilities of All Crew Members

1.3 Safety Decals and Signs

Copyright © 2006 P&H Mining Equipment, Inc. Peak Services

1.3.2 Hazard Indicators

Peak Services Copyright © 2006 P&H Mining Equipment, Inc.

Figure 2-1: Air Filtration System

2.2 General Information

Copyright © 2006 P&H Mining Equipment, Inc. Peak Services

2.3.1 High Efficiency Filters

2.3.2 Continuous Self Cleaning

2.3.3 Easily Maintained

Figure 2-2: Cartridge Replacement from Machinery House Roof

Peak Services Copyright © 2006 P&H Mining Equipment, Inc.

2.3.4 Air Flow Description

Figure 2-3: Air Flow Diagram

Copyright © 2006 P&H Mining Equipment, Inc. Peak Services

2.3.5 House Assembly

Figure 2-4: House Assembly

2.3.6 Screw Conveyor

2.3.7 Cold Weather Kit

Peak Services Copyright © 2006 P&H Mining Equipment, Inc.

2.4.1 Overview of Normal Operation

2.4.2 Specifics of Normal Operation