Technical Manual
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BI620137
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30MB3 MAINTENANCE MANUAL M01404 BI620137
First Issue Date: 2007
Revision Date: 06/04/2011
Name Department
Prepared by Ron Spencer Documentation
Checked by
Approved by
Revision No. 01
This document is the property of Bucyrus Australia. It shall not be copied or reproduced in any way what so ever and/or passed on to any third party without the written authority of Bucyrus Australia.
Copyright © Bucyrus Australia. All paper copies are uncontrolled.
Disclaimer:
Bucyrus has made every effort to ensure that all instructions contained within this document are accurate and safe, and cannot accept liability for any resulting injury, damage or loss to persons or property arising from the use thereof or otherwise. Contact Bucyrus Australia to obtain the latest updates for this document.
30MB3 Serial No. 177866
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Bucyrus Australia Mechanical Maintenance Manual
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30MB3 Serial No. 177866 Bucyrus Australia Mechanical Maintenance Manual Rev 1 Page 3 Index Machine Description – 30MB3......................................................................................... 7 General........................................................................................................................ 7 Specifications.............................................................................................................. 7 Machine Weights......................................................................................................... 8 Component Layout........................................................................................................... 9 Top View..................................................................................................................... 9 Right Hand View....................................................................................................... 10 Left Hand View.......................................................................................................... 11 Main Chassis............................................................................................................. 12 Cutting Head Assembly............................................................................................. 12 Gathering Head Assembly........................................................................................ 14 Conveyor Assembly.................................................................................................. 15 Traction Drive System............................................................................................... 16 Hydraulic System - CLA............................................................................................ 18 Machine Hydraulic Layout......................................................................................... 19 Drill Rigs.................................................................................................................... 21 Rib Protection............................................................................................................ 21 Articulating Temporary Roof Support - ATRS........................................................... 22 Bolting, Mining and Maintenance Modes.................................................................. 23 Water System............................................................................................................ 24 Machine Water Component Layout.......................................................................... 26 Defects and Hazards....................................................................................................... 28 Safety & Maintenance Practices.................................................................................... 28 Safety Procedures..................................................................................................... 28 Isolation Procedures................................................................................................. 29 Auger Safety Stops......................................................................................................... 32 Conveyor Stop................................................................................................................. 34 General Maintenance...................................................................................................... 35 Maintenance and the Continuous Miner................................................................... 35 Torques........................................................................................................................ 36 Duo-Cone Seals........................................................................................................ 37 Mating Pairs.............................................................................................................. 37 Handling.................................................................................................................... 37 Housing Preparation................................................................................................. 37 Seal Preparation....................................................................................................... 37 Approved Assembly Lubricants*............................................................................... 38 Installation Process................................................................................................... 38 Final Assembly.......................................................................................................... 38 Maintenance Guidelines................................................................................................. 39 Bearing and Gears.......................................................................................................... 41 Bearing Assembly Methods...................................................................................... 41 Assembly Methods.................................................................................................... 42 Micronized Graphite for Bearing Assembly............................................................... 42 Drivers for Bearing Cups and Cones........................................................................ 42 Heating Bearings....................................................................................................... 42 Heating in Oil............................................................................................................. 42 Induction Heating...................................................................................................... 43 Freezing/Shrinking Bearing Cups............................................................................. 43 Tapered Rolling Bearing Adjustment........................................................................ 43 Thermal Expansion................................................................................................... 43 Torque for Zero End Play.......................................................................................... 44 Bevel Gear Adjustment............................................................................................. 45 Lockwiring Fasteners..................................................................................................... 46 Single Wire................................................................................................................ 46 Wired In Pairs............................................................................................................ 46 Special Fasteners............................................................................................................ 46 Self-Locking Screws....................................................................................................... 47 Installation Recommendations.................................................................................. 47 Locknuts....................................................................................................................... 48 Installation Recommendations.................................................................................. 48 BI620137
30MB3 Serial No. 177866 Bucyrus Australia Mechanical Maintenance Manual Rev 1 Page 4 Component Substitution................................................................................................ 48 Safety Maintenance......................................................................................................... 49 General Description........................................................................................................ 49 Removal of Cutting Drums............................................................................................. 52 Pull In Drum Removal............................................................................................... 53 Pull In Drum Assembly.............................................................................................. 55 Drive Drum Removal................................................................................................. 56 Drive Drum Assembly................................................................................................ 58 Intermediate Drum Removal RH and LH.................................................................. 60 Removal of Pull In Assembly Complete....................................................................... 61 Intermediate Drum Removal LH..................................................................................... 64 Intermediate Drum Assembly RH and LH................................................................. 68 Install Complete Pull In Assembly............................................................................. 69 Centre Drum Removal.............................................................................................. 72 Centre Drum Assembly............................................................................................. 74 Removal of Cutting Motor Clutches.............................................................................. 76 Clutch Assembly........................................................................................................ 79 Removal of Cutter Head Gear Case......................................................................... 80 Reinstall Cutter Head Gear Case.............................................................................. 84 Removal of Cutter Motor........................................................................................... 86 Installation of Cutter Motor........................................................................................ 88 Removal of the Cutter Head Input Gear Case.......................................................... 90 Installation of Cutter Head Input Gear Case............................................................. 91 Removal of the Cutting Head Support from the Main Frame..................................... 92 Installation of Cutting Head Assembly to the Main Frame......................................... 96 GATHERING HEAD ASSEMBLY.................................................................................... 98 General Description........................................................................................................ 98 Removal and Replacing Gathering Head Shear Shaft................................................. 99 Conveyor Chain Disassembly...................................................................................... 102 Removal of Foot Shaft and Centrifugal Loading Arms (CLAs)................................ 104 Removing the Centrifugal Loading Arms (CLAs).................................................... 105 Re-Fitting the Centrifugal Loading Arms (CLAs)..................................................... 107 Removal of the Drive Motor Input Gear Case and CLA Pot...................................... 108 Reassembly of Gathering Head Gear Cases.............................................................. 112 Removal of the Gathering Head from the Main Frame.............................................. 114 Installation of the Gathering Head............................................................................... 120 CONVEYOR ASSEMBLY............................................................................................... 123 General Description...................................................................................................... 123 Conveyor Chain Removal............................................................................................. 124 Conveyor Chain Installation......................................................................................... 126 Removal of the Conveyor Assembly from the Miner................................................. 128 Installation of the Conveyor Assembly....................................................................... 132 Removal of Discharge Conveyor................................................................................. 133 Installation of Discharge Conveyor............................................................................. 136 Removal of Tail Roller.................................................................................................. 137 Re-Fitting of Tail Roller........................................................................................... 139 TRACTION SYSTEM...................................................................................................... 140 General Description...................................................................................................... 140 Removal of the Tram Drive Gear Case Assembly...................................................... 141 Installation of the Tram Drive Gear Case Assembly.................................................. 145 Removal of a Tram Drive Motor................................................................................... 148 Installation of a Tram Motor......................................................................................... 150 Crawler Chain Removal................................................................................................ 151 Crawler Chain Installation............................................................................................ 155 Crawler Take-Up Roller Removal................................................................................. 158 Crawler Take-Up Roller Installation............................................................................. 159 Stablising Shoe Assembly........................................................................................... 160 Stabiliser Cylinder Removal.................................................................................... 160 Stabiliser Cylinder Installation................................................................................. 162 Stabiliser Shoe Removal.............................................................................................. 163 Cutterhead Raise and Lower Cylinder........................................................................ 165 Cutter Head Cylinder Removal............................................................................... 166 BI620137
30MB3 Serial No. 177866 Bucyrus Australia Mechanical Maintenance Manual Rev 1 Page 5 Cutter Head Cylinder Installation............................................................................ 167 Gathering Head Raise and Lower Cylinder................................................................ 168 Gathering Head Cylinder Removal......................................................................... 169 Gathering Head Cylinder Installation...................................................................... 170 Conveyor Raise and Lower Cylinder.......................................................................... 171 Conveyor Raise Cylinder Removal......................................................................... 172 Conveyor Raise Cylinder Installation...................................................................... 173 Conveyor Swing Cylinder............................................................................................. 175 Conveyor Swing Cylinder Removal........................................................................ 176 Conveyor Swing Cylinder Installation..................................................................... 177 Plow Cylinders.............................................................................................................. 178 Plow Cylinder Removal........................................................................................... 179 Plow Cylinder Installation........................................................................................ 180 Conveyor Take-Up Cylinders....................................................................................... 181 Conveyor Take-up Cylinder Removal..................................................................... 182 Conveyor Take-up Cylinder Installation.................................................................. 183 TRS Raise and Lower Cylinder.................................................................................... 184 TRS Cylinder Removal............................................................................................ 185 Servicing and Maintenance.......................................................................................... 187 Top View Lubrication.................................................................................................... 188 Left Hand Side Lubrication.......................................................................................... 189 Right Hand Side Lubrication........................................................................................ 190 Lubrication Chart.......................................................................................................... 191 Lubrication – Gear Oil................................................................................................... 192 Tram Gear Cases.................................................................................................... 192 Gathering Head (POT) Gear Cases........................................................................ 195 Gathering Head Input Gear Cases......................................................................... 196 Traction Idler Roller................................................................................................. 197 Greasing....................................................................................................................... 198 Tram Brakes.................................................................................................................. 198 Filters.............................................................................................................................. 198 Left Hand Filters...................................................................................................... 198 Right Hand Filters................................................................................................... 198 Right Hand Filters................................................................................................... 199 Chain Adjustments....................................................................................................... 200 Crawler Track Chain Adjustment............................................................................ 200 Conveyor Chain Adjustment................................................................................... 201 Maintenance Mode........................................................................................................ 203 Check and Fill Hydraulic Oil Reservoir................................................................... 203 Hydraulic Oil Power Fill........................................................................................... 204 Gear Case Oil Power Fill......................................................................................... 206 Repair or Replace Water Sprays................................................................................. 207 Machine Cutting Picks.................................................................................................. 208 HYDRAULIC COMPONENTS ASSEMBLY................................................................... 209 Description.................................................................................................................... 209 Mechanical..................................................................................................................... 210 Hydraulic Pump Removal............................................................................................. 210 Hydraulic Pump Installation......................................................................................... 213 Removal and Replacement of Pump Drive Motor...................................................... 215 Pump Drive Motor Removal.................................................................................... 216 Pump Drive Motor Installation................................................................................. 217 Hydraulics..................................................................................................................... 218 Hydraulic Pump............................................................................................................. 220 Power Cut Off Control – D...................................................................................... 221 Load Sensing Control – S....................................................................................... 221 Valve Bank Information................................................................................................ 221 Adjustments.................................................................................................................. 222 Pilot Circuit.............................................................................................................. 222 Conveyor Tension and Tramming Brake Coolant................................................... 222 Main Relief Valve (Main valve bank inlet) - OPTIONAL......................................... 222 Water Reticulation......................................................................................................... 222 General.................................................................................................................... 222 BI620137
30MB3 Serial No. 177866 Bucyrus Australia Mechanical Maintenance Manual Rev 1 Page 6 Circuit 1 (Right Side)............................................................................................... 223 Circuit 2 (Left Side).................................................................................................. 223 Water Dust Spray.................................................................................................... 223 Tramming....................................................................................................................... 224 Water Sprays................................................................................................................. 224 Flow Switches................................................................................................................ 226 Pumps............................................................................................................................ 226 Traction.......................................................................................................................... 227 Cutters............................................................................................................................ 228 Conveyor........................................................................................................................ 228 Event Monitor................................................................................................................ 229 Fault Log inside Event Monitor................................................................................ 230 Main Control Case Indicators...................................................................................... 231 Water Troubleshooting Guide...................................................................................... 232 Service............................................................................................................................ 233 BI620137
Machine Description – 30MB3
General
The 30MB3 miner is a radio-controlled drum-type continuous miner with appropriate weight balance, cutting and loading power to enable the productive mining of coal and other soft mineral in seams ranging from 1,900mm up to 4, 000mm thick. The machine is mounted on crawler tracks that provide full mobility and sharp turning radius in both bord and pillar and long wall development mining plans. The ranging cutting head mines material from the solid face using a chainless rotating drum, and a CLA-type gathering head with high speed conveyor efficiently moves mined material to a haulage system behind the miner. The machine's weight and balance is designed to mine most efficiently by either sumping into the face at the top or bottom of the seam, and ripping material to the bottom or top of the seam. The above figure shows a general arrangement of major mechanical components. A full description of the various major sub-systems of the 30MB3 follows.
1st = 0 – 10 Metres/Minute
2nd = 13 Metres/Minute
3rd = 26 Metres/Minute
Tracks Crawler Type LH & RH Independent
Brakes Oil Flushed Spring Applied Park Brake
Drives Electrical - Mechanical
Steering Skid Steer
30MB3 Serial No. 177866 Bucyrus Australia Mechanical Maintenance Manual Rev 1 Page 7
Specifications Length 11931 mm Cutting Width 5200 mm Max Cutting Height 4100 mm Weight 83000 kg - Total Ground Clearance 350 mm Undercut Capacity 249 mm
Tramming Speed
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Machine Weights
Complete Machine 83000 kg
- Mainframe complete with track drive gear cases motors and tracks including pump motors 30650 kg
- Total Cutter Head Assembly 22500 kg
a) Cutter Head Frame including motors 9000 kg
b) Cutter Head Gear case 13500 kg
- Conveyor Assembly Intermediate and discharge 7900 kg
- Gathering Head Assembly complete with drill rigs and shields 13600 kg TRS - OPTIONAL
kg
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Maintenance Manual
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Component Layout
Top View
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30MB3 Serial No. 177866 Bucyrus Australia Mechanical Maintenance Manual Rev 1 Page 10 Right Hand View BI620137
30MB3 Serial No. 177866 Bucyrus Australia Mechanical Maintenance Manual Rev 1 Page 11 Left Hand View BI620137
Main Chassis
CONVEYOR PIVOT POINT
GATHERING HEAD PIVOT POINT
CUTTING HEAD PIVOT POINT
GATHERING HEAD PIVOT POINT
GATHERING HEAD PIVOT POINT
Main Chassis
The main chassis of the machine is a robust box-type structure of high-strength steel construction that provides the following:
Mounting of the RH and LH crawler tracks and their independent drive systems and take-up provisions.
• Independent pivots for mounting the cutting head and gathering head and conveyor components and their associated hydraulic cylinders for articulation.
• An integral hydraulic oil tank along with two electric motor/hydraulic pump assembly‘s and associated valves and piping.
• A rear stabiliser and its articulating hydraulic cylinder for improving leverage forces during shear-down in the cutting sequence.
• Mounting provisions for all major electrical system components and their associated wiring.
Cutting Head Assembly
The cutting head assembly is attached to the main chassis at RH and LH independent pivot points around which the assembly is articulated for vertical-ranging cutting of the coal seam. The independent pivots allow removal of the cutting head assembly without disturbing the gathering head or conveyor components.
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HYDRAULIC TANK
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The cutting head assembly consists of the following:
• The cutting head support frame, a robust box structure which includes the RH/LH pivot points for attaching to the main chassis, upper mounting clevises for the two cutting head raise cylinders, and a major bolting flange to which the cutting head drive assembly mounts.
• The cutting head gear case assembly, which consists of a input gear case and water-cooled 173 kW AC electric drive motor for each of the RH and LH sides, a final drive gear case which includes drive gearing, a main drive shaft and mounting points for the 1067mm diameter RH, LH, intermediate and centre drums, and a major bolting flange for mounting onto the cutting head support frame. The outer cutting drums are independently mounted to the major bolting flange and have an extension/retraction of 300mm each side from 5200mm to 4600mm and can be removed as an assembly.
The cutting head assembly is raised and lowered by two (2) heavy-duty hydraulic cylinders mounted to the main chassis at their lower ends and attached at their upper ends to main longitudinal structural members of the cutting head support frame. These cylinders enable the cutting head assembly to range from 249 mm below ground level to a maximum height of 4100mm.
The power train of the cutting head consists of RH and LH sides, which tie together at the common main drive shaft, allowing the combined power of both electric drive motors to be available at any point on the cutting drums.
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Cutter Head Frame
CUTTER HEAD PIVOT POINT
CUTTER HEAD DUST BELT
CUTTER HEAD COVERS
CUTTER HEAD COVERS
ELECTRIC MOTORS
INPUT GEARCASE RIGHT SIDE CENTRE CUTTER
LEFT CUTTER DRUM RIGHT CUTTER DRUM RIGHT PULL-IN ASSEMBLY LEFT PULL-IN ASSEMBLY
WATER SPRAY BLOCKS WATER SPRAY BLOCKS
DRUM
CUTTER CLUTCH
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CUTTER CLUTCH
Gathering Head Assembly
Gathering Head Assembly
The gathering head assembly is attached to the main chassis at RH and LH independent pivot points around which the assembly is articulated to adjust the gathering head for uneven floor conditions and for tramming the miner from place to place. The independent pivots allow removal of the gathering head assembly without disturbing the cutting head or discharge conveyor.
The gathering head assembly includes the following:
• The gathering head structure consists of RH/LH pivot points for attaching to the main chassis, upper mounting clevises for the two gathering head raise cylinders, extendible plows compatible with extendible widths of the cutter head widths and shields mounted on rear of structure to support the roof bolting rigs.
• RH and LH power trains, each of which include a water cooled 38 kW AC electric motor, an input gear case and a gathering head pot which drives a rotating centrifugal loading arm device.
• Mounting provisions for the Temporary Roof Support (TRS) systems in the shields.
The gathering head assembly is raised and lowered by two hydraulic cylinders, which are mounted to the main chassis at their lower ends and attached to points of the gathering head structure at their upper ends. These cylinders allow vertical ranging of the forward edge of the gathering head from 200 mm below floor level to 537 mm above floor level.
The RH and LH power trains are connected to a common foot shaft which provides
(a) Proper timing of the rotating CLA loading arms and
(b) Drive power to a sprocket which drives the conveyor chain. This conveyor chain drives is reversible to aid in clearing debris which might restrict conveyor chain movement
The gathering head structure includes a special noise-damped running deck for the conveyor chain to minimise noise generation
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Conveyor Assembly
The conveyor assembly is attached to the main chassis at RH and LH independent pivot points around which the assembly is articulated vertically to assist in optimum loading into the haulage vehicle. Independent pivots allow removal of the conveyor assembly without disturbing the cutting head or gathering head components.
The conveyor assembly includes the following:
• An intermediate conveyor structure which includes the RH/LH pivot points for attaching to the main chassis, upper mounting clevises for the two conveyor raise cylinders, and a horizontal pivot arrangement at the rear for mounting the rear conveyor subassembly.
• A rear conveyor subassembly which includes (a) a mating horizontal pivot arrangement allowing sideward swinging movement up to 45o on either side of the machine centre line to assist in optimum loading into the haulage vehicle and (b) a tail roller shaft for the conveyor chain and two hydraulic cylinders to maintain proper tension in the chain when the geometry of conveyor assembly changes during the operation. The intermediate and discharge conveyor structures each include a special noise-damped running deck for the conveyor chain to minimise noise generation and 914mm throat clearance for optimum loading rates.
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TAIL ROLLER REAR DISCHARGE CONVEYOR SWING CYLINDER SWING CYLINDER FANTAIL
CONVEYOR CHAIN CROSS-OVER BRIDGE INTERMEDIATE CONVEYOR CONVEYOR PIVOT POINT BI620137
PIVOT
Traction Drive System
Traction Assembly
The traction drive system provides the necessary mobility for the 30MB3 miner to mine coal and to tram from place to place as needed. It includes:
• Independent RH and LH drive systems, each consisting of a water-cooled 55 kW DC variablespeed electric motor mounted to a drive gear case that powers drive sprockets to provide motion to the respective RH or LH crawler chain.
• A forward-mounted crawler chain idler roller on each side which is equipped with a greasepowered piston to adjust the crawler chain to its proper tension; once adjusted by movement of the grease, the idler roller is locked into position by a necessary number of shims, and pressure in the grease piston is relieved. An AC/DC solid-state electronic drive logic system which provides the operator with three speed ranges:
(a) High speed which moves the miner at a rate of 26 metres/min, used mainly for flitting from one working face to another.
(b) Intermediate speed at a rate of 13 metres/min, used mainly for rapid re-positioning of the miner within the face area.
(c) Sump speed, fully adjustable by the operator to a preset value ranging from 0 to 10 metres/min for sumping the miner into the coal face. The adjustable sump speed setting allows the operator to select an optimum cutting speed when face hardness conditions vary, eg. Rock inclusions or roof/floor cutting.
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The traction drive control system provides the operator with the capability to run either RH or LH crawler chain in forward or reverse independently for maximum manoeuvrability, i.e. the miner may be pivoted about its central vertical axis. The RH and LH drive trains are each equipped with fully enclosed multiple-disc fail-safe hydraulic flushed parking brakes that are spring-applied and hydraulically released.
The crawler chains are manufactured from high-alloy wear-resistant steel for maximum life, and are equipped with grouser ridges to enhance traction in both soft and hard floor conditions.
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BI620137
• Thank you very much for reading the preview of the manual.
• You can download the complete manual from: www.heydownloads.com by clicking the link below
• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.
CLICK HERE TO DOWNLOAD THE COMPLETE MANUAL
CLICK HERE TO DOWNLOAD THE COMPLETE MANUAL
