TN295 M No. 9212 Sciw=5?~- l l^ iE, ?€fflK ■■■' WiUJMS E §H HlllI ;■-■ '■ Masfe m ■• v.. ■ ■ ' - .. .:■'.':■■'■•■' s ffl S S g -■■HEP2* ■■■■■ a as BEB m«l SBiili liBiHe .*-.-..- ...■■'■ .^ ■ ^'- ate** . , jj'M js ^^ imi ^ss ss x m^f^^ k ■ THWWP hBS _■■■"■■ BnBBBBHr WSKm mi n9 n K9 iimw MB" ffl B MiMUM ottsfc o • c«5^s-k - O • ** v \ --W /\ -w- ** v \ '-jSr' s\ "-w--" A : W : A : . > ^ v ^°^ .. •-•' ^ • o. iV** 77^ ^ \°'"-^i^^ \+^& % \#* \j^^\s* \y* » o »oV* .<»» BUREAU OF MINES INFORMATION CIRCUU\R/1989 C36.5 c973 Material Handling Devices for Underground Mines By Ernest J. Conway and Richard L. Unger UNITED STATES DEPARTMENT OF THE INTERIOR J S Ojit*. QXJU^ WW; Information Circular 9212 Material Handling Devices for Underground Mines By Ernest J. Conway and Richard L. linger UNITED STATES DEPARTMENT OF THE INTERIOR Manuel J. Lujan, Jr., Secretary BUREAU OF MINES T S Ary, Director • a MAR 1 6 »»»» ,0* n& Library of Congress Cataloging in Publication Data: Conway, Ernest J. Material handling devices for underground mines. (Information circular / United States Dept. of the Interior, Bureau of Mines; 9212) Supt. of Docs, no.: I 28.27:9212. 1. Coal mining machinery. I. Unger, Richard L. II. Title. III. Series: Information circular (United States. Bureau of Mines); 9212. TN295.U4 [TN813] 622 s [622' .6] 88-600243 CONTENTS Page Abstract 1 Introduction 2 Summary of design rationale 3 Mine and equipment maintenance 3 Mechanization requirements 4 Prototype material handling devices 4 Scoop-mounted lift boom 4 Swing-arm boom 5 Heavy-component lift-transport 6 Mine mud cart 7 Container-workstation vehicle 7 Timber car 9 Conclusions and recommendations 12 Appendix A.-Scoop-mounted lift boom 13 Appendix B.-Swing-arm boom 18 Appendix C.-Heavy-component lift-transport 20 Appendix D.-Mine mud cart 29 Appendix E -Container-workstation vehicle -p 36 Appendix F.-Timber car 42 ILLUSTRATIONS 1. Manual material handling in underground coal mine 2 2. Testing the scoop-mounted lift boom 5 3. Scoop-mounted lift boom during surface tests 5 4. Swing-arm boom during underground tests 6 5. Boom being mounted in removable base 7 6. Heavy-component lift-transport during testing with 1,500-lb concrete block 8 7. Tire-changing attachment to eliminate manual handling of heavy wheels during replacement 8 8. Mine mud cart 9 9. Container-workstation vehicle 10 10. Container removed from frame of vehicle 10 11. Timber car during underground tests at Bureau's Safety Research Coal Mine 11 12. Miners using timber car to raise 85-lb rail for roof support in eastern Ohio coal mine 11 A-l. Scoop-mounted lift boom 14 A-2. Roller, pin, and plate joint used in lift boom 15 A-3. Rib bar, plate filler, and angle 15 A-4. Tubing 16 A-5. Mount and clevis plates 16 A-6. Hoist plate 17 A-7. Upper and lower beams 17 B-l. Swing-arm boom 19 B-2. Bar and plate used in swing-arm boom, with assembly details 19 B-3. Plates and assembly details 19 C-l. Heavy-component lift-transport 21 C-2. Channel and plates used in heavy-component lift-transport 21 C-3. Bar, mounting block, and pipe 22 C-4. Pipe, gusset, and mounting plate 22 C-5. Main frame assembly for heavy-component lift-transport 23 C-6. Wheel frame assembly 24 C-7. Axle and spacer and retractable foot assembly 25 C-8. Crank jack assembly 26 C-9. Legs 27 ILLUSTRATIONS-Continued A-l B-l C-l D-l E-l F-l Page C-10. Floor jack leg assembly 28 D-l. Mine mud cart 30 D-2. Mount 31 D-3. Pivot and yoke 31 D-4. Coupling assembly 32 D-5. Pull bar and pivot 33 D-6. Shaft and axle assembly 33 D-7. No. 1 cart assembly 34 D-8. No. 2 cart assembly 35 E-l. Container-workstation 37 E-2. Runner, link, track end plate, and stop assembly for container-workstation 38 E-3. Main frame assembly 39 E-4. Axle shaft, lug and subframe assembly 40 E-5. Container assembly 41 F-l. Timber car ' 43 F-2. Extension details 44 F-3. Mounting block and mounting block cam follower assembly 45 F-4. Jackhead assembly 46 F-5. Jack leveler head assembly 47 F-6. Pin 48 TABLES Scoop-mounted lift boom parts list 13 Swing-arm boom parts list 18 Heavy-component lift-transport parts list 20 Mine mud cart parts list 29 Container-workstation vehicle parts list 36 Timber car parts list 42 UNIT OF MEASURE ABBREVIATIONS USED IN THIS REPORT in inch min minute lb pound psi pound per square inch lb/ft pound per foot MATERIAL HANDLING DEVICES FOR UNDERGROUND MINES By Ernest J. Conway 1 and Richard L linger 2 ABSTRACT This report presents engineering drawings for six material handling devices for underground coal mines. The devices were designed under a U.S. Bureau of Mines program to reduce injuries from material handling during mine and equipment maintenance. The six devices are (1) scoop-mounted lift boom, (2) swing-arm boom, (3) heavy-component lift-transport, (4) mine mud cart, (5) container- workstation vehicle, and (6) timber car. Each device is described briefly, and recommendations are made concerning the design of new devices. Principal investigator, Monterey Technologies, Inc. (Now with Vreuls Research, Inc.), Los Angeles, CA. 2 Civil engineer, Pittsburgh Research Center, U.S. Bureau of Mines, Pittsburgh, PA. INTRODUCTION Manual material handling represents a critical and per- sistent source of personnel injuries in underground coal mining operations. On an annual basis, such injuries represent the largest category of nonfatal, lost-time injuries, accounting for 35% of all lost-time injuries in 1983 and 1984, according to U.S. Mine Safety and Health Administration data. Approximately 26% of all injuries related to manual material handling are associated with the performance of mine maintenance or equipment maintenance tasks (fig. 1). As part of its program to improve health and safety conditions in mines, the Bureau of Mines recently com- pleted a research program that addressed the material handling problems of mine maintenance and equipment maintenance. Under contract H0113018 with Monterey Technologies, Inc., a detailed analysis of mine- and machine-related tasks was completed and sources of injuries were identified. Concepts for simple material handling devices that could replace manual handling were then developed and evaluated. Six of these devices were fabricated and delivered to operational underground coal mines for testing and evaluation. This report presents a brief discussion of the six devices, along with associated engineering drawings. The report is intended for mine operators who wish to make use of the design concepts to manufacture similar devices for use in their mines. Figure 1.— Manual material handling In underground coal mine. Manual material handling is the leading cause of injuries year after year. SUMMARY OF DESIGN RATIONALE This project specifically addressed material handling tasks related to mine maintenance and equipment maintenance performed in underground coal mines. Sur- face material handling tasks and the transporting of sup- plies or materials from the surface to the operating section were outside the scope of this effort. MINE AND EQUIPMENT MAINTENANCE Representative mine maintenance tasks included 1. Installation or removal of ventilation, electrical, communications, or compressed-air systems. 2. Installation of timbers, cribbing, and other supplemental materials used in roof or rib control. 3. Track installation, repair, and retrieval. 4. Rock dusting, installation of air control screens, electrical wiring, installation of warning or other systems. Typical machine maintenance tasks falling within the scope of this project included 1. Removal or replacement of belt drives, heads, pumps, drive motors, and other major machine parts on stationary equipment. 2. Assembly, installation, and repair of mine equipment, including mobile face equipment. 3. Routine servicing of mining equipment. All underground coal mine seam heights were included in this study. However, emphasis was placed on mid to lower scam coal mines (under 58-in seam height), because preliminary data suggested that the highest risks of manual material handling injuries were to be found in those seam heights. The study included a review of relevant material handling literature and past Bureau programs, visits to six operating coal mines, and an extensive analysis of the Mine Safety and Health Administration's accident data base. The mine maintenance and equipment maintenance tasks investigated involved, by their very nature, the manual handling of supplies and equipment components. Individual modules of the items handled might range in weight from a few to several thousand pounds. Because of the operational constraints in underground coal mines, these materials and components often have to be manhan- dled from the supply dropoff point to the place where they will actually be used or installed. Components used in equipment maintenance are typi- cally hoisted onto a railroad car, scoop bucket, or main- tenance jeep on the surface. They are then transported to the section where the disabled machine is located. At that point, they are manually lifted off the rail car or jeep or ejected out of the scoop bucket and manually carried to the installation position. Occasionally, hoists or come- alongs are attached to roof bolts in order to aid in this process. Replaced components are then manually loaded into the transport vehicle for shipment to the surface. Mine maintenance materials (e.g., timbers, rock dust bags, roof bolts, etc.) are typically loaded in bales or via pallets onto railcars or into scoop buckets for shipment to or near the working section. At the end of the rail line, the bales or pallets are broken down for manual loading into scoops or onto other transport vehicles for delivery to work locations. (One mine visited had rubber-tire- equipped railcars that could be detached at the end of the rail line and towed by battery-powered vehicle to the work locations or section supply area.) Once the materials are dumped near the work locations, miners manually carry them to the maintenance point for use. These mainte- nance personnel may lift materials weighing 50 to 100 lb continually on a daily basis. They handle materials weighing 1,000 lb or more (sections of rail or steel arches) on a monthly or more frequent basis. Analyses of material handling injuries in the six mines visited indicated that 1. 39% of all mine maintenance and 32% of all machine maintenance injuries involved the lower back, 2. 45% of all mine and 39% of all machine maintenance accidents were the result of overexertion, and 3. 68% of mine maintenance injuries involved the handling of timbers, posts, caps, and cribbing materials, while 32% of the machine-related accidents involved the handling of metal machine components. MECHANIZATION REQUIREMENTS The design implications of these and other findings revealed during studies of material handling tasks related to mine and equipment maintenance can be summarized by the following mechanization needs: 1. Devices to lift or lower and rotate machine components weighing up to 3,000 lb, for removal from and replacement on mining equipment. 2. Devices to lift or lower components of up to 500 lb in and out of scoops, off railcars and on or off other mobile vehicles. 3. Carts or other devices to transport small quantities of materials weighing up to 500 lb from storage areas or railheads to working sections. 4. A device to raise and support crossbeams for temporary roof support while permanent roof supports are installed. Six material handling devices were developed to fulfill these needs. Particular attention was focused on making the designs practical, low cost, and easily fabricated so as to be broadly applicable in underground operations. Where possible, the designs were simplified and off-the- shelf components used to permit fabrication of the devices by mine personnel on-site. 3 The devices discussed in this report are not intended to be final designs. Rather, they are working prototypes that have been field evaluated and are presented herein in the hopes of stimulating other innovative designs on the part of mine personnel. The six devices include 1. Scoop-mounted lift boom. 2. Swing-arm boom. 3. Heavy-component lift-transport. 4. Mine mud car. 5. Container-workstation vehicle. 6. Timber car. Functions performed by, and design specifications for each of these devices are discussed in the following section. PROTOTYPE MATERIAL HANDLING DEVICES SCOOP-MOUNTED LIFT BOOM One of the major identified needs was for a simple boom device to lift and transport components weighing up to 3,000 lb in the underground environment. The device had to be mounted on a powered mobile machine and had to be installed and removed quickly to minimize produc- tion downtime for the machine. This tool would be used for transporting and maneuvering heavy machine compo- nents such as a continuous miner head. A quick mount-dismount lift boom device was developed for installation on the front of a small scoop with its bucket removed (figs. 2-3). The design features of the scoop-mounted lift boom include 1. A 3,000-lb lift capacity. 2. Manual or powered lift capability. 3. Installation and removal in 5 min or less. 4. Ready storage in working sections or on mobile machinery. Four attachment points secure the lift boom to the scoop lift mechanism by means of four pins. The pins correspond in size and location to the pins used to secure the scoop bucket. The overhead design of the lift boom permits lifting or lowering of components being handled. The bucket tilt mechanism provides up and down maneuvering of the components, while the scoop's normal steering permits lateral and forward and reverse maneuvering. Appendix A provides details on the fabrication of the lift boom device, including a summary of the materials and components needed. 3 Specific products are identified in the appendixes as the materials used in fabricating the prototypes; however, comparable materials may also be used. Reference to specific products docs not imply endorse- ment by the Bureau of Mines. Figure 2.— Testing the scoop-mounted lift boom. SWING-ARM BOOM Accident and biomechanical analyses suggested the need for a simple swivel crane or boom device to lift components on and off transport vehicles and to assist in maneuvering heavy machine components in confined spaces. To address these requirements, a lightweight, removable, stowable lift boom was designed (figs. 4-5). This boom can be installed at various locations on maintenance carts or on mining machines themselves. The height of the boom can be varied by quickly changing the boom leg. The inexpensive mounts can be permanently welded at various locations on the machine frame and are designed to resist damage during normal machine operation. Two or more quick mounts can be installed on the same machine to permit access to all machine locations. Design features of the swing-arm boom include 1. Load capacity of 500 lb. 2. Boom height range from 24 to 68 in, depending on leg length. 3. Arm radius of 24 to 48 in. 4. Mounting and stowing without tools. 5. Light weight for carrying by one person. .■*>. ■1 1 v Figure 3.— Scoop-mounted lift boom during surface tests. »■.»;,,-' "' ' ■];> > yj i pjjp up I « m Figure 4.— Swing-arm boom during underground tests. Appendix B provides detailed drawings of the boom and the materials required for its fabrication. Several commer- cially available swing-arm cranes could be readily adapted for the same purpose. HEAVY-COMPONENT LIFT-TRANSPORT Another identified need was for a floor-type main- tenance jack that could be used to lift heavy machine components from the bottom, transport them over short distances, and lift them into position for installation. Saddles on the lift point could be designed to permit additional maneuvering of the component during actual installation. This type of device could be used, for example, to install drive motors under the nonremovable fenders in shuttle cars. This prototype is shown in figures 6 and 7. The device utilizes a standard hydraulic floor jack to provide the lift mechanism. The jackhead itself is tillable and rotatable to permit close-in maneuvering. The jack mechanism travels along the device frame by means of a sump drive mech- anism. This motion permits forward-backward movement of handled components and balancing of components over the lift-transport device wheels during travel. The long handle permits the user leverage by which to maneuver loads up and down or sideways, as required. Dual tires or oversized balloon tires increase the device's stability and permit easy movement over uneven floors. Figure 5.— Boom being mounted in removable base. The design features of the heavy-component lift- transport include 1. Up to 1,000 lb lift capacity. 2. Balloon tires for ease of transporting manually. 3. A standard automotive floor jack for the lift mechanism. 4. Ability to lift and maneuver a heavy component as it is being removed or replaced on a mining machine. 5. Jackhcad that can be trammed forward or back on the frame for close-in maneuvering or for load balancing. Appendix C presents detailed drawings of the lift- transport mechanism and lists materials and components required for its fabrication. Note that single balloon tires could be substituted for the tandem tires illustrated in these drawings. MINE MUD CART One of the basic problems faced by all miners is that of moving machine components or supplies such as concrete blocks from the supply storage area to the point of use. If a powered vehicle is not available, the task must be accomplished manually. The intent of this concept was to design a small, manually pulled cart that could transport up to 900 lb of materials over a short distance. The mine mud cart has the following design features: 1. Narrow width to permit passage by a parked mining machine. 2. Tandem design to prevent tipover if one unit is loaded and the second is empty. 3. Balloon tires for transit through mud or water and over mine floors. 4. Handle designed for pulling by one or two people. Figure 8 illustrates a tandem cart concept using eight wheels. The vehicle can also be fabricated as a single cart. Appendix D provides design details for a tandem cart with four wheels and its major components and materials. CONTAINER-WORKSTATION VEHICLE Tools and supplies required for many maintenance tasks performed in a section can be mounted on a transportable container. This concept is for a device that allows a single, manually powered mechanism to lift and transport such containers (figs. 9-10). There are many uses for the containers themselves, such as tool station, lubrication module, rock dust unit, fire and safety equipment storage, repair workstation, cable-splicing module, etc. To move the container around the working section, the transporter is positioned around the container and a lift mechanism raises it off the floor and positions the load slightly ahead of the axle. The load is carried by the wheels while the operator controls motion by pulling, steering, and balancing the unit on its axle. Figure 6— Heavy-component lift-transport during testing with 1 ,500-lb concrete block. Figure 7.-Tire-changing attachment to eliminate manual handling of heavy wheels during replacement Figure 8.— Mine mud cart. Design features of the container-workstation include 1. Rapidly interchangeable containers that can be picked up or dropped off as required. 2. Containers that can be used as secured storage units when dismounted from the vehicle. 3. Up to 1,000-lb load capacity. 4. Adjustable ground clearance. 5. Balloon-type tires for easy transporting on unimproved mine floor. 6. A towbar that can be adapted for towing behind utility vehicles. Detailed drawings and a list of materials and components for the device are provided in appendix E. TIMBER CAR One of the most hazardous material handling tasks in underground mining is that of installing crossbeams for roof support. A need was identified for a mechanism to lift beams weighing up to 500 lb to the roof, where they could be held in place until permanent supports could be installed (figs. 11-12). The device shown utilizes a modified hydraulic floor jack to provide the lift. The jack mechanism is moved manually along a track down the center of the car. This forward-backward movement permits easy positioning of the load. In addition, the jackhead rotates to ease positioning of extra-long members. Design features of the timber car include 1. Up to 500-lb lift capacity with a 60-in lift height (suitable for low- to medium-seam mines). 10 Figure 9.— Container-workstation vehicle. Figure 10.-Contalner removed from frame of vehicle. Containers with specialized functions may be attached. 11 Figure 11.— Timber car during underground tests at Bureau's Safety Research Coal Mine. Figure 12.— Miners using timber car to raise 85-lb rail for roof support in eastern Ohio coal mine. 12 2. Mounting on a low-profile flatcar, which serves double duty as a 40-ton-capacity supply car. 3. A modified automotive floor jack for the lift mechanism. 4. Jack that can be maneuvered forward or back in its track for close-in maneuvering. Appendix F presents detailed drawings of the track and jack assemblies for the timber car. Note that the components could be mounted on any suitable flatcar rather than be built as part of the car. CONCLUSIONS AND RECOMMENDATIONS On-site visits, task analyses, and interviews suggest that the majority of the risk exposure associated with material handling in underground coal mines results from the lack of properly designed and easily accessible material handling tools, devices, and vehicles. Mine personnel tra- ditionally rely on a "couple of extra hands" or on crowbars, come-alongs, and other makeshift tools to manhandle even the largest components of mining machinery. Similarly, lacking appropriate tools, carts, and other handling devices, mine personnel manually move timbers, posts, beams, and other heavy materials on a continual basis. In most instances, tools are simply not available for these heavy lifting, transporting, and positioning tasks. These investigations also revealed that what is needed is not another complex, powered vehicle designed to per- form any and all maintenance jobs. Rather, what is required is a series of simple, task-specific tools, aids, and devices to be housed and used in the working sections and maintenance areas. Mine personnel tend not to wait 30 to 60 min while a special vehicle or tool is brought in from another area of the mine. The material handling hardware should be relatively easy to fabricate and should, where possible, utilize off-the-shelf components. It should be relatively inexpensive and designed for fabrication in mine shops. The prototypes of six such devices that were devel- oped and tested by the Bureau are described in this report. There appears to be a sincere interest on the part of mine management and safety and production personnel in reducing injuries related to material handling. There is also a need for exposure to new ideas, products, and material handling mechanization concepts to assist mine personnel in identifying their own unique handling require- ments and in coming up with appropriate mechanical solu- tions to these problems. The concepts presented here were designed to stimulate the development of other mechanization concepts to address mine-specific material handling problems. Three major recommendations are suggested with respect to development of material handling devices: 1. Systems Approach to Material Handling . Many larger mines have developed so-called systems for moving huge quantities of supplies and materials from surface storage areas to in-mine drop points or supply depots. These systems, however, have many missing elements and built-in problems. For example, pallets are utilized to load quantities of 90-lb cement blocks or 100-lb bags of rock dust from the storage onto the supply train. Forklifts or hoists may be used to offload the pallets at the dropoff points. However, personnel must manually load these supplies onto battery-powered vehicles or physically lug them to the point of use. This systems-approach thinking has failed to account for the fact that the blocks still weigh 90 lb and the bags 100 lb apiece when they get into the mine. These loads are too heavy for personnel working in confined workspaces and on unimproved mine floors. If a systems approach is to be used, it should start with the end user or task and work backward from there. 2. Task-Specific Tools . As in any industry, the design of special tools to perform specific tasks is often over- looked. In underground mining, few if any tools or devices have been developed to cope with specific material han- dling tasks. Exposure to high-risk tasks could be substan- tially reduced if appropriate task-specific tools were available. For example, the transporting of materials through a 3- by 3-ft man door requires the miner to lift a 50- to 100-lb (or heavier) object, rotate his or her body, and heave the object through the man door opening. Exposure to overexertion-type injuries is very high. If a simple slide or materials conveyor were available, the miner could simply pass the material through the opening. Similar aids and mechanical tools are required for han- dling rail sections, timbers, posts, cribbing materials, etc. 3. New Technologies . The search for new technologies is an ongoing process in any industry. In underground mining, however, it is even more important since so little completely new technology has been introduced to this sector. With respect to material handling, this search should focus on new, low-cost, reduced-weight materials for mine maintenance and safety applications. It should address improved designs and packaging for manual handling in operational environments. It should cover improved methods of installation and maintenance of the mine and the mining equipment. It should focus on ways of reducing mine maintenance (e.g., cleaning up along belt lines) and machine maintenance (e.g., autolubing systems). It should attempt to replace muscle power (particularly back muscles) with mechanical or hydraulic power. 13 APPENDIX A.-SCOOP-MOUNTED LIFT BOOM The scoop-mounted lift boom is illustrated in fig- ure A-l. Table A-l lists the parts and their specifications. Details of individual parts and assemblies are shown in figures A-2 through A-7. The italic letters on the drawings correspond to the letters used in table A-l. All dimen- sions shown in the drawings are in inches. TABLE A-1. - Scoop-mounted lift boom parts list Description Material Roller Bar, round, AISI Type 1035, 2-in diam. Pin Shafting, AISI Type 1025, 0.5-in diam (0.499 - 0.501) Plate joint Plate, ASTM A36, 0.5 in thick. Bar, rib Cold-forged bar, AISI Type 1018, 0.75 by 2 by 18 in. Plate, filler Plate, ASTM A36, 2.5 by 6.75 by 0.25 in. Angle Steel, M1020, 3 by 2 by 0.25 in. Tube Square pipe, hot-rolled steel, 2 by 2 by 0.145 in. . . do Do. . . do Do. . . do Do. Plate, mount Plate, ASTM A36, 5.5 by 20 by 0.75 in. Plate, clevis Plate, ASTM A36, 1 in thick. Plate, hoist Do. Beam, upper .... Rolled steel, ASTM A500B, 5 by 2 by 1/4 in. Beam, lower Rolled steel, ASTM A500B, 3 by 2 by 3/16 in. Washer, flat Steel, 1/2-in ID, 0.109 in thick. Cotter pin Steel, 1/8 by 2 in. Cover Channel, ASTM A36, 3 by 5 by 6 in. Item Quantity A . B . C . D . E . F . G . H . J . K . L . M . N . O . P . Q . R . S . 14 Detail A-A ©- ~V~ ,Top lube 3 places)-; TOP VIEW NOTE: Line drill holes within 0016 diam after weldment, 4 places typical VIEW B-B, front view ~1 /*— 2.75 4 tubes / j/y ^— — f- T7 — < 4 places -[7 < 4 places VIEW D-D 4 -J7 (Full length, 4 places b dlam 2 hales, n line within _:_!_.,_ OOlOdlam mnimum 3 Sides) rpr 5 sides^ lower tubes ' K 2.62 SIDE VIEW Figure A-1 .—Scoop-mounted lift boom. See figures A-2 through A-7 for details of parts and assemblies. 15 *- 2.00*1 0.501- to 0.5ll-diam hole -• -0.491 to 0.511 I I > 2 00 ( j> ._- =; diam 1 \0/ ) " i 4 V T \ s — Full radius L 0.745 t d 0.761 diam 4 Roller 1 - 0.75 i ' t 1 o 0.38 0.50 nominal diam 5.00- 4.25 -0.38 1 \0.06 by 45° chamfer typical 0.125 to 0.156 diam, 2 holes B Pin D Bar, rib E Plate, filler 0.25 1.25 5.50 3.00 I 4 8.75- p.o 0-* U^\ 0.50 3.00 -0.25 by 45° chamfer typical 0.25 radius -0 25 by 45°chamfer C Plate joint Figure A-2.-Roller, pin, and plate joint used in lift boom. *- 3.00 — • 1 3.C ' ( }0 0.2 5 1 *- 2.00-* F Angle Figure A-3.-Rib bar, plate filler, and angle. 16 0.12 by 45° chamfer, 5 sides r-ai45 r "_""""] [J 1 1.00 r 0.72 -J -59.12 Jr -4.25 "1 0.35 Xo. i z -\ 2.00 25 -0.12 by 45° chamfer, 4 sides r~j> 0.145 -59.62 0.28- // 0.69— H 2.00 2.00 0.12 by 45° chamfer, 5 sides 0.145 } CZ3 J 0.72 X 2.00 2.00 "0.12 by 45° chamfer, 4 sides 0.69 -J !•- K Figure A-4.— Tubing. 0.75—^ h- L Plate, mount 1.62 radius 1.516 1.00- 20.25 reference l»- 5.00— H reference M Plate , clevis Figure A-5.— Mount and clevis plates. 17 5.19 -«1 diam hole 0.56 minimum Figure A-6.— Hoist plate. 2.00 1.00 radius ■1.00 typical r- 1.00 typical 7~ZI U-3.00 L 2.00— I— -J O Beam, upper 0.25-dlam hole both sides — \ | oo typical 5fc r - i 41.12 1.50 Ar- T 6.00 I I.OOtypical P Beam, lower Figure A-7.— Upper and lower beams. 18 APPENDIX B.-SWING-ARM BOOM The swing-arm boom is illustrated in figure B-l. Table B-l lists the parts and their specifications. Details of individual parts and assemblies are shown in figures B-2 and B-3. The italic letters on the drawings correspond to the letters used in table B-l. All dimensions shown in the drawings are in inches. TABLE B-1. - Swing-arm boom parts list Item Quantity Description Material A B C . D . F , 4 1 1 1 1 Bar Plate . . do . . do Swivel base Steel, M1020, 1.5 by 1 in. Steel, AISI Type 1010, 0.5 in thick. Steel, ASTM A36, 0.5 in thick. Do. M/C 3276T16, winch crane. 1 ! M/C = McMaster Carr catalog No. 88. 19 PI X 1 Swivel crane -Crane leg Swivel base (removable ) Mount welded to machine frame Figure B-1 -Swing-arm boom. See figures B-2 and B-3 for details of parts and assemblies. 6.I2 - 4.62 \~^ See detail A SIDE VIEW Stompor emboss- -0.50 / 0.53 to 0.59 ^-0.06 radius , maximum 5 1 0.53 to 0.59 Detail A „l ' — 2. 25 typical 6.50 < 4 P |ac -- \_ V N No weld past X TOP VIEW Figure B-2— Bar and plate used in swing-arm boom, with assembly details. 2.00 ♦ -6.00- ^v ' 0.38 radius REAR VIEW -(See note 4 r Note I > - [> 0.75 4 ~1 4.50 6.00 Mounting plate Swivel mount supplied by vendor X (See note 4) 3.00 Note 2 TOP VIEW NOTES: 1. Protect tube from heat distortion when welding. 2. Cut flange to this dimension. 3. Break sharp edges, 4. No weld on X areas. SIDE VIEW Figure B-3.— Plates and assembly details. 20 APPENDIX C.-HEAVY-COMPONENT LIFT-TRANSPORT The heavy-component lift-transport is illustrated in figure C-l. Table C-l lists the parts and their specifi- cations. Details of individual parts and assemblies are shown in figures C-2 through C-10. The italic letters on the drawings correspond to the letters used in table C-l. All dimensions shown in the drawings are in inches. TABLE C-1. - Heavy-component lift-transport parts list Item Quantity Description Material A B C D E F G H J K L M N O P Q R S T . U . W X . Y . Z . AA AB AC AD AE AF AG AH AJ AK AL AM 2 2 1 1 2 2 1 1 1 4 12 2 4 2 4 4 2 8 1 1 1 4 4 2 2 8 Side channel . . Plate . . do End plate Bar Mounting block Pipe . . do Nut Capscrew Lockwasher . . . Gusset Mounting plate Axle Plate . . .do . .do Spacer Pipe Plate . . do Washer, flat . . . Cotter pin .... Capscrew .... Lockwasher . . . Capscrew .... . . do . . do Nut, self-locking Plate Leg Leg Leg Screwjack .... Floor jack .... Wheel ASTM A36. ASTM A36, 0.25 by 2.5 by 10.25 in. ASTM A36, 0.25 by 1 by 10.25 in. ASTM A36, 0.25 by 1.5 by 13.25 in. Steel, 0.25 by 0.375 by 2.5 in. Steel, 0.5 by 1.25 by 2.5 in. Schedule 40, 1-1/4 by 2.5 in. Schedule 40, 1-1/4 in. Steel, 1/4-20 UNC. Steel, 3/8-16, 1 in long. 3/8-in ID. ASTM A36, 0.25 in thick. ASTM A36, 1 by 3 by 3.5 in. Cold-forged, AISI Type 1040 round, 0.625 by 11.5 in. ASTM A36, 6.5 by 12 by 0.25 in. ASTM A36, 6.5 by 10 by 0.25 in. ASTM A36, 6.5 by 16.5 by 0.375 in. AISI Type 1025, DOM, 1-in OD, 3/16-in wall. Schedule 40, 1-in ID. ASTM A36, 2 by 4.25 by 0.25 in. ASTM A36, 3 by 3 by 3/8 in. 3/8-in ID. 1/8 by 1-1/4 in. Grade 8, 3/4-20 UNEF, 2 in long. 3/4-in ID. Grade 5, 3/8-16 UNC, 1-1/4 in long. Grade 5, 3/8-16 UNC, 3/4 in long. Grade 5, 3/8-16 UNC, 2 in long. 3/8-16 UNC. ASTM A36, cut to fit. M1020, 2 by 2.5 in. Do. Do. M/C 879H453C, crank-type trailer jack. 1 M/C 8802T14. 1 M/C 8353T22, light-duty pneumatic. 1 ! M/C = McMaster-Carr catalog No. 88. 21 AB,L See jack assembly for details Jack handle O, S, X, Y See wheel frame assembly for details Stencil "Maximum load = ton" See retractable foot for details AD,AE Lubricate runners with molybdenum disulfide grease See main frameassembly for details AM ^AC,L Inflate to50psi Figure C-1. -Heavy-component lift-transport See figures C-2 through C-10 for details of parts and assemblies. I.94 3.00 1 L Miscellaneous channels 3 by 7 1 38.00 / \r A Side channel t 2.50 • 10.25 • 0.25 B Plate 1" 1.00 • 10.25 — ♦ f -0.44 diam.4 holes -12.00 13.25 - rf 1.50 ^-0.50 •-0.62 2.50 t 0.25 ^0.25 C Plate D End plate Figure C-2.— Channel and plates used in heavy-component lift-transport 22 0.25 2.50 0.375 T-diam pipe schedule 40 0.312 -diam hole H Pipe E Bar f-16 UNC, 2 holes 0.25 r- r-2.oo-i 0.38 by 45° chamfer 3.00 M Gusset 1.25 F Mounting block 2.50 2 -diam pipe schedule 40 0.406 diam through 2 walls — ^ G Pipe 1.50- -©- S^ 3.00 "T 2.25 3.50 0.62 .00 g -16 UNC, 2 holes through plate N Mounting plate Figure C-3.— Bar, mounting block, and pipe. Figure C-4.— Pipe, gusset, and mounting plate. 23 -+A 10.75 M -B 38.00 16.50 Hm f^^£7T J T ^ Tir 11.50- =t±r 14.50 <2 places TOP VIEW 0.4 4 -j — pr <4 places SIDE VIEW 2 places> Figure C-5.— Main frame assembly for heavy-component lift-transport 24 0.25 chamfer typical 4 places> 2.00 .438 diam,- 4 holes 00 12.50 16.50 8.25 H -•- E^ H.50 14.50 6.50 0.38 0.656 diam through 3 walls, alignwithg-diam shaft Figure C-6.— Wheel frame assembly. 25 0.4 Idiom,- 6 holes through 2 l-diom pipe, schedule 40 r— 1.62 SIDE VIEW •-4.25 2.12 U -Full length 1.00 I 2.00 l! 0.31 3 10.88 11.50 0.131 diom, 2 holes •— 0.625 dlam A, 0.06 by 45' chamfer, both ends O Axle BOTTOM VIEW Retractable foot assembly 0.7 5-h U- OD t| |-wall tubing S Spacer Figure C-7.— Axle and spacer and retractable foot assembly. 26 Cut to fit 0.50 AF 2.50 0.41 diam, 2 holes i D < 2 p* 8 aces AK Figure C-8.— Crank jack assembly. 27 1.38 4_ 1.25 ~t E .38 0.25 by 45" chamfer L 1.94 T 2.38 1.62 ¥■ 25 2.50 •0.531 diam FRONT VIEW SIDE VIEW AG Leg 1.25 /■ 1 r r 0.25 by 45° chamfer typical h^ *■ 1.94 -*| FRONT VIEW 0.69 for AH 1.81 for A/ 0.625 diam AH,AJ Leg Figure C-9.-Legs. 28 AG. -f=^— | — =1- J— —c/ 2.12- §-16 UNC, 2 holes A. 0.50 2.00 8.69 1 W AG AH AJ TOP VIEW 2.88 FRONT VIEW Figure C-10.— Floor jack leg assembly. 29 APPENDIX D.-MINE MUD CART The mine mud cart is illustrated in figure D-l. Table D-l lists the parts and their specifications. Details of individual parts and assemblies are shown in figures D-2 through D-8. The italic letters on the drawings correspond to the letters used in table D-l. All dimensions shown in the drawings are in inches. TABLE D-1. - Mine mud cart parts list Description Material Mount Steel plate, 0.25 in thick. Pivot Cold-forged, AISI Type 1045, 2.0-in diam. Yoke Steel plate, 1.0 in thick. Deck Steel sheet, 14 gauge. Rib Do. Fender Do. Gusset Do. End Steel sheet, 10 gauge. Support Do. End Do. Side Do. Bottom Steel sheet, 14 gauge. . . do Do. Edging Steel tube, AISI Type 1025, 0.75-in OD by 0.035-in wall. . . do Do. Axle Steel channel, 1.5 by 1.5 by 3/16 in. Shaft Steel bar, cold-forged, AISI Type 1045, 1.25-in diam by 8 in long. Pivot Steel plate, 1.25-in OD by 1.125 by 3 in. Pull bar Steel tube, AISI Type 1025, 1.25-in OD by 1/16-in wall. Jab nut M/C 91079A035, 5/8-18. 1 Washer M/C 90126A035, 5/8-in ID, SAE. 1 Spring M/C 92161A035, 5/8-in ID, SS. 1 Ball joint M/C 6072K25, 5/8-in bore, 5/8-in stud. 1 Capscrew, hex head Grade 8, 5/8-18 UNF by 1.5 in. Lockwasher Split type, 5/8-in ID. Grease fitting Steel head, 1/8 in NPT. Bearing M/C 6391 K295, 1.5-in OD by 1.25-in ID by 1 in long. 1 Washer M/C 90126A040, 1-1/4-in bore. 1 Shaft collar M/C 6436K19, 1-1/8-in bore. 1 Screw, hex head Grade 8, 5/8-18 UNF by 3.5 in. Lockwasher Split type 3/8-in ID. Screw, hex head Grade 8, 5/8-18 UNF by 3.5 in. Tire 13 by 6.5-6. Hub 6 by 4.50, 3/4-in bore, 3.0-in hub. 3 Washer, hardened M/C 980232A036, 3/4-in ID. 1 . . do M/C 98023A035, 5/8-in ID. 1 Nut, self-locking M/C 94828A035, 5/8-1 1. 1 Item Quantity A 1 B 1 C 1 D 4 E 4 F 4 G 4 H 3 J 2 K 3 L 4 M 1 N 1 O 1 P 1 Q 2 R 4 S 1 T 1 U 7 V 2 W 2 X 3 Y 2 Z 5 AB 1 AC 1 AD 2 AE 1 AF 4 AG 4 AH 1 AJ 4 AK 4 AL 4 AM 4 AN 4 'M/C = McMaster-Carr catalog No. 88. 2 Armstrong Rubber Co., Ultra Trac. 3 Armstrong Rubber Co. 30 No. 2 cart load area 13.5 by 39 AF,AG No. I cart load area 13.5 by 44 U,Z,AH 29 rf.KZonball joint, in this sequence U,X T.U AJ. Inflate to I4psi Load capacity, 450lbperaxle SIDE VIEW Figure D-1.— Mine mud cart. See figures D-2 through D-8 for details of parts and assemblies. 31 | Ch06^ i **. « — i V 45° • 1" 3.63- - 7.25 T t_ •> 0.2 5 TOP VIEW !! 2.00 £-16 UNC-2B, 4 holes FRONT VIEW A 125 diam 0.06 chamfer 1.2490 diam 1.2495 FRONT VIEW 0.02 radius, 2 places 0.125-diam hole 2.00- diam stock 1 SIDE VIEW B Pivot SIDE VIEW 0. 50-1 1.4995 diam FRONT VIEW L l.00 stock ^5 -18 UNF through TOP VIEW 8 C Yoke Figure D-2.— Mount. Figure D-3.— Pivot and yoke. 32 V4C (press fit) X.Y.Z 4.00 FRONT VIEW SIDE VIEW Figure D-4. -Coupling assembly. 33 3.50-5.00 radius typical U T TOP VIEW 36.00 SIDE VIEW T Pull bar 091 K U81 •—3.00 — • TOP VIEW 2.12 m t^k 0.625 radius 1.25 SIDE VIEW 5 Pivot Figure D-5.— Pull bar and pivot 2 placesy No weld 15.00 V 5 / | -II UNC-2A J typical Grind shaft to fit 25.00 0.01 radius maximum Centers optional 0.06 by 45°chamfer typical 0.75 typical 'V Figure D-6.— Shaft and axle assembly. 34 2.0CM See axle assembly 0.75 SIDE VIEW Trim to fit, 4 places / o -2.00 radius typical , 61-3 |-i ^Location optional SIDE VIEW 4 place sV-^ 0.12 weld lap typical ± — 26.50 (inside)- 44.25 SIDE VIEW 13.75 BOTTOM VIEW Figure D-7.— No. 1 cart assembly. 35 0.12 typical 7.00 REARVIEW 2.00 radius typica See axle assembly i t/ 0.625 diam, — Ml- 2 holes TOP VIEW FRONT VIEW T ' LOa ^w 26.50 (inside) 2.00 — \— •*-&50~ 19.75- SIDE VIEW Figure D-8.-N0. 2 cart assembly. 36 APPENDIX E.-CONTAINER-WORKSTATION VEHICLE The container-workstation is illustrated in figure E-l. Table E-l lists the parts and their specifications. Details of individual parts and assemblies are shown in figures E-2 through E-5. The italic letters on the drawings correspond to the letters used in table E-l. All dimensions shown in the drawings are in inches. TABLE E-1 . - Container-workstation parts list Item Quantity Description Material A . B . C . D . E . F . G . H . J . K . L . M . N . O. P . Q . R . S . T . U . V . w X . Y . z . AA AB AC AD AE AF AG AH AJ AK AL AM AN AO AP AQ AR AS AT AU AV AW AX AY Eye ring Handwheel .... Coupling Setscrew Guide Screw, hex head Nut, self-locking Gear drive .... Screw, hex head Lockwasher . . . Screwjack .... Screw, hex head Nut, self-locking Hand knob .... Nut, plain Bearing, split . . Screw, hex head Nut, self-locking Washer, hard . . Wheel Tire Snap ring Pin, clevis .... Pin, cotter .... Standoff Carry arm .... Crossbeam . . . Trailing arm . . . Cross shaft .... Axle shaft Gusset Guide Mount Pipe Link Runner Track End plate Lug Mount . . do Brace Rail Bottom Side End Washer, flat . . . Lockwasher . . . Shaft M/C 3024526. 1 M/C 6022K37, 5-in diam. 1 M/C 6410K38, 3/8-in shaft. 1 M/C 91375A242, 10-24 by 0.5 in. 1 ASTM A36, 0.25 in thick. Grade 5, 3/8-16 by 3 in. Steel, 3/8-16. M/C 6456K13, 3-way. 1 Grade 5, 10-24 by 1.5 in. Steel, 3/16-in OD. Keyed for traveling nut. 2 Grade 5, 1/4-20 by 1.0 in. Steel, 1/4-20. M/C 6085K17, trim to 1 in. 1 Steel, 1/2-13. M/C 6259K36, 15/16-in shaft. 1 Grade 5, 3/8-16 by 1.5 in. Steel, 3/4-10. M/C 98029A036, 3/4-in ID. 1 8 by 7 in. 3 18 by 8.50-8. 4 M/C 98410A122, external. 1 M/C 98306A387, 0.5 by 1-27/32. 1 Steel, 5/32 by 1.0 in. ASTM A500 grade B, 2 by 2 by 3/16-in tube. Do. Do. Do. Cold-forged bar, AISI Type 1018, 0.93-in diam. Cold-forged bar, AISI Type 1018, 1.25-in diam. ASTM A36, 0.25 in thick. Do. ASTM A36, 3/16 in thick. Schedule 40 steel, 1 .5-in pipe. ASTM A36, 0.25 in thick. ASTM A36, as required. Do. ASTM A36, 0.375 in thick. ASTM A36, 1.0 in thick. ASTM A36, 0.25 in thick. Do. Steel angle, 2 by 2 by 1/4 in. Do. Steel sheet, 10 gauge. Do. Do. 1/2-in ID, SAE. Split type, 1/4-in ID. Cold-forged bar, AISI Type 1018, 3/8-in diam. M/C = McMaster-Carr catalog No. 88. 2 Joyce Dayton Corp., model WJ10O0, worm gear screwjack, 9-in travel. 3 Armstrong Rubber Co., ARCO wheel part 70886. 4 Armstrong Rubber Co., Ultra Trac, part 429331, with rim shown in footnote 3. 37 AN.AX.M AL.AW.W S,T,U,V Container assembly Mainframe assembly L.M.N Bar assembly 0,R,G Subframe assembly SIDE VIEW H,J,K,B,D Machine hub for setscrew FRONT VIEW Figure E-1. -Container-workstation. See figures E-2 through E-5 for details of parts and assemblies. 38 1.124 1.122 0.06 by 45° chamfer typical 8-8-2G acme Full radius "^ 0.745 0.468- ID by 0.039 snap ring groove 0.735 0.312 Centers optional , 0-30 9J pp.7 5 .00 U-2.00-^ AL Runner °rl°Adiam 0.505 2 holes 5.62 n ^ 0.25 AK Link 1.125 1.128 0.03 radius maximum typical — —~ 0.750 0.755 l! 0.316 0.313 J JJ 1.50 r l 9.25 ^,^j^m 0.31 AM Track Z_2by2by^ 0.62 -diam clearance Stop assembly — -20UNC-2B.2 places, 0.75 minimum full thread ati*™' FT r^ 2.25 1.50 1 *- 0.25 0.375 0.50 \ p-0.75 by 45° chamfer t 0.3l2diam, 2 holes 1.00 1.50 4/V End plate Figure E-2.-Runner, link, track end plate, and stop assembly for container-workstation. 39 ?£^DEZir AF.AG -rr — <2 places 90° Section A-A . 3 sides, 3 1/ \2 places 16 TOP VIEW — r^~ \2 places 5.50 |6 £ 39.50 [7^^7f^pT ces Remove sharp edges, typical Tapped holes 2.75 SIDE VIEW 10.50 0.62 — 0.62. 2 places 2 places—^ 3.7 5^ 0.81, 2 places <£ places ^"x \o i^- Stop assembly .____x— -\^r, AP <5 places 2.75,-H 2 places FRONT VIEW Figure E-3.-Maln frame assembly. 40 1.25 diam 8.56 K-2.75-^ 0.62 by 45° k 1.62 7S^ ♦-0.88 |-I0UNC-2B l.000 Hi Q997 diam AE Axle shaft | ^TV-0.12 by 45° chamfer 0.03 radius, 2 places 1.00 I ?H ).50l .510 2.00 diam .00 A0 Lug 3.00, -, 2 places a 2 places > AE 23.38 21.00 fTTI -^1.00 AC 3 2 by 2 by ^ tube 0.50, 2 places n •8.50 0.93 dlam-H bJ 4£? 28.75 28.88 33.62 TOP VIEW r~K -<8 places Ml AO 1.38 -diam clearance holes, 2 places SIDE VIEW * 0.94-diam clearance holes Figure E-4.— Axle shaft, lug and subframe assembly. 41 2.0 typical—^ K — y — <8 places 32 {-2.0 typical 28.00 (outside) AT ^ -0.12 TOP VIEW L 33.75 34.00(outside) AV N 0.250 diam, 5 drain holes 0.12 H 3 [> <2 P I 0.25 \ " 6 >** aces *5 SIDE VIEW FRONT VIEW Figure E-5.— Container assembly. 42 APPENDIX F.-TIMBER CAR The jack components of the timber car are illustrated in figure F-l. Table F-l lists the parts and their specifi- cations. Details of individual parts and assemblies are shown in figures F-2 through F-6. The italic letters on the drawings correspond to the letters used in table E-l. All dimensions shown in the drawings are in inches. TABLE F-1. - Timber car parts list Item Quantity Description Material A B C D E F G H I. J K L M Lift jack Cam follower Extension Upper track guide . . . Lower track guide . . . Extension arm support Track Leveler arm Jack leveler head .... Jackhead Mounting block Jackhead pin Leveler pivot pin . . . . M/C8802T15, 1.5 ton. 1 1.75-in diam. 2 Channel, 4 in, 6 in long. Steel angle, 2 by 1.25 by 0.25 in. Steel angle, 2 by 2 by 0.25 in. Steel angle, 1 by 1 by 1/8 in, 3 in long. Channel, 3 in. Plate, steel, 0.25 by 1 in. Plate, steel. Do. Plate, steel, 3 by 4 by 0.50 in. Cold-forged bar, AISI Type 1018, 1.5-in diam. Cold-forged bar, AISI Type 1018, 0.5-in diam. *M/C = McMaster-Carr catalog No. 88. 2 Torrington bearings, CRS-28, 2.75 in, cam follower. 43 C 6 by 2 channel Weld bottom of jackheod swivel pin to jackhead leveler at assembly N See jock leveler head drawing See jackhead Drill 0.50-diam hole in leveler arm for leveler pivot pins 12 by 1.25 by 0.25 angle Cam follower Track for fore-aft positioning-, see track assembly Cam followers'' Timber car jack assembly Figure F-1 .—Timber car. See figures F-2 through F-6 for details of parts and assemblies. 44 4 by lg channel. 7.25 lb/ft 4.00 — A' Detail A r? 0.50 K Mounting block Cam follower TOP VIEW FRONT VIEW SIDE VIEW Figure F-3.— Mounting block and mounting block cam follower assembly. 46 TOP VIEW ¥^ 1.00 -diam hole 6.00 12.00- 3.00 4.00 12.00 2.00 1 1 3.00 1 6.00 1 I 12.50 reference 0.25 typical A x 45° chamfer grind Detail A 3.00 I -((Typical \ 3 |/ \iypicai Vg — >i i, , — u 1 SIDE VIEW 3 16 0.25 -pJ\ o 33 -o 33 < > H m c c/> m CO o o O > c CO z m (/> 0) T) "0 > -vl O cn CO OT3DDC O o o C C/5 3" Q. CD — \ CD c o co c O g CD CO 6' 3 o ■D co H Bo s 3 3. 3 DO o CO Q. a CD C/> CD ZJ C 5' CD 13 5" CD > z m O c > r- o ■o -o O 33 C Z m O ■< m 33 C 158 89 >*' vwv* vw-v Vw->* *♦ ■■mf- : ,* \ *»?•' .* v **. \ 0* ^ o V * ^ ? • • • _fi$\** %/vSvV* \' *♦_.*♦ ••»&•. \/ :«'•. %<♦* :$Mk. \/ :£fe\ **.,** .-isS^'. V.** » ^ o* t • ' • « "'b A* . " * , <^v ^°«. J ^V 'bV *0« V/ /jflfcfc ^* •#' \/ . % »te-: %/ ^^° *-** o V S% J ^«b- •