CAT BUCYRUS 25M SERIES CONTINUOUS MINER Operation and Maintenance Manual
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This work contains information protected under trade secret and other intellectual property laws, and is protected under the U. S. Copyright Act of 1976, as amended. This work is provided under license and the license is non-transferable. Distribution and access is limited only to authorized personnel. Disclosure, reproduction, distribution or unauthorized use may be a violation of federal and state laws and may subject the unauthorized user to criminal liability. preface
This manual is intended to provide basic operating information on Bucyrus America, Inc. 25M Series class continuous miners. Additional information can be obtained by referring to the Parts Book supplied with your machine, or by contacting your local Bucyrus America, Inc. representative. The illustrations, descriptions and procedures contained in this manual pertained to the machine as it was originally manufactured and delivered to your mine, and when the manual was approved for printing. Bucyrus America, Inc. reserves the right to discontinue or revise machine models at any time, or change specifications, designs or procedures, without notice and without incurring obligations.
The machine was manufactured under the guidelines, procedures and requirements of the appropriate government regulatory agencies. At the completion of manufacturing, this machine was issued the appropriate approval numbers and nameplates indicating that it met the technical requirements of the appropriate agencies. Any change to the design or structure of this machine, without the consent of Bucyrus America, Inc. and these agencies, may void these approvals and render the machine illegal or dangerous for use.
Strict compliance with all local and national laws, regulations and practices regarding the safe operation and maintenance of underground mining equipment is necessary to ensure the personal safety of those working on, or around, this machine.
While this manual attempts to anticipate the most important operations and maintenance needs for this equipment, unforeseen circumstances may arise that have not been addressed in this manual. If any concerns or questions arise, please contact your Bucyrus America, Inc. Service Representative immediately
Table of contents
About this manual
This chapter contains important information, which will simplify work with this manual for you. In addition, it contains information about the structure of the manual and on the characters and symbols used.
Before starting work
If you use an operating manual which has not been written for your conveyor type, you will endanger yourself and others. Ensure that the data on the Continuous Miner corresponds to those in this operating manual.
This operating manual belongs to:
Bucyrus America, Inc.—Dash Series Continuous Miner
Serial No.: 02-14-05
The operating manual is to be used only for the Dash Series Continuous Miners.
An operating manual for the conveyor must always be available at the place of operation.
Send for a new manual immediately if the present manual is no longer complete or has become illegible.
Who is this operating manual intended for?
This operating manual is intended for all persons working with or on the Continuous Miner
All persons working at the face, at the edge of the face or in the entry must have read this operating manual.
This includes persons: responsible for transport, developing the raise, carrying out erection / disassembly, operating the conveyor, eliminating faults, carrying out daily routine work at the face or in the entry, carrying out maintenance operations, carrying out repairs.
This operating manual is intended to help you work efficiently and safely with our product. It contains important information on all the activities related to the Dash Series Continuous Miners.
Read this operating manual completely and carefully. In particular, pay attention to the safety instructions.
Note the appearance and meaning of the safety and warning symbols.
If any points are not clear, please contact our Service Department. You will find our Service address in chapter 7 ”For your information”.
Pay particular attention to the chapter ”Your Safety”. It contains important information drawing your attention to possible sources of danger. Observe the information and follow the instructions contained in this operating manual.
Characters and symbols used
The following characters and symbols are used for safety instructions and important information in the operating manual. Pay particular attention to these points.
Points in the text marked with this symbol draw your attention to immediately impending danger. Possible consequences are: very serious injury or even death.
These points contain information on dangerous situations. Possible consequences are: Very serious injury or even death.
This symbol draws attention to dangerous situations. Possible consequences are: Light to moderately serious injuries and machine damage.
Points in the text marked with this symbol draw attention to harmful situations. Possible consequences are: Damage to the conveyor or damage in the immediate vicinity.
Points in the text marked with this symbol contain useful tips and information intended to facilitate work for you. They do not warn about harmful or dangerous situations.
Points in sub-lists are marked with a square at the start of the line describe individual work steps. Follow these instructions step-by-step.
Your safety
This chapter provides vital information for your safety. Pay special attention to this chapter. The safety instructions and rules of procedure will help you to avoid hazardous situations and to perform the necessary work as safely as possible.
state of the art
further operating manuals
The machine has been manufactured in accordance with the state of the art and generally recognized safety standards and regulations. You and others can nevertheless be exposed to dangerous situations e.g. as a result of environmental influences, machine damage or operator errors.
Do not make any alterations or modifications which could impair the safety of the machine. All modifications and changes must be approved by Bucyrus America, Inc.
Use only original spare parts from Bucyrus America, Inc. Note that the use of parts from other manufacturers will void the guarantee.
In addition to this operating manual be sure to also observe the respective legal provisions and regulations in your country.
Observe the safety and accident prevention regulations:
■ of the mine.
■ of the Mines Inspector and
■ of the mining supervisory authorities
Please read also the operating manuals of the components required for operation, e.g. of Continuous Miner, electric motors, etc., carefully and thoroughly. Clarify any questions before starting work.
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Your safety
Safety precautions for operating the continuous miner
training
The miner should not be operated until the operator has read and understood the operating instructions for the machine and is thoroughly familiar with the location, operation, and function of all controls.
Miner should not be operated without all covers and guards properly mounted and secured.
Ensure everyone is clear before starting or moving any part of the miner.
Carefully test all machine functions before operating the miner.
Always wear safety glasses. Not only for your protection but for the protection of fellow workers. Should dust, etc. temporarily blind the operator the machine may become a hazard to both the workers and other equipment.
Check work area for loose roof scale, remove as necessary.
Disconnect main breaker to do any maintenance work. Observe all Federal, State, and Mine safety regulations. · Report any malfunctions or damage to supervisory personnel.
Ensure cutter boom and tail conveyor boom are lowered before leaving machine unattended. · Ensure adequate ventilation prior to machine operation.
Obey all safety regulations set forth by MSHA, State, Local, and Mine Management.
Do not leave machine running unattended. ·Shut off main electrical power, unplug and lock out electrical cables/receptacles prior to performing any type of electrical repairs. · Never work or travel underneath a raised cutter boom, conveyor boom, stabilizer shoe, or gathering pan unless they are properly supported.
Your safety
operating conditions
Intended use
The feeder breaker has been designed and manufactured purely for transporting and crushing mined material from a continuous miner to the main conveying system for transporting outside.
Intended uses include: the transport and crushing of mined material between continuous miner and main conveying system
Unauthorized use
Applications not expressly listed as intended uses are unauthorized uses and are not allowed to be performed with the machine.
the transport of persons
Bucyrus America, Inc. accepts no liability for any damage resulting from any such unauthorized use.
Your safety
storage and transport
Maintain the prescribed storage periods and observe the instructions for storage.
Do not store materials or parts in the travel way or in your working area.
Inform the persons involved about the intended transport route and the anticipated duration of the transport.
Ensure that the transport safety devices are correctly fitted.
Fix all moving parts with transport locks.
Never stand under unsupported parts or suspended loads.
Connect the lifting equipment only to the points of attachment provided for that purpose. Observe the different load limits of the attachment points. Also observe the instructions on the transport sheet.
Only use means of attachment which are in good condition and have been designed for the loads to be handled.
For round components use transport straps, only. Never use chains or steel cables for this purpose.
Do not damage the treated or polished surfaces of shafts, sealing surfaces, etc.
When using mobile handling systems for transport make sure that the center of gravity is as low as possible.
Pre-start inspection
Read this entire guide before attempting to operate this machine.
Inspect the machine and have any malfunctioning, broken or missing parts corrected or replaced before use.
Verify that all maintenance has been performed.
Verify that all instruction and safety tags are in place and readable. These are as important as any other equipment on the machine.
Clean any foreign material from the operator’s compartment.
This machine was shipped from the factory equipped with a protective canopy. The canopy must be securely in place before operating the unit.
Your safety
Stopping
operator’s compartment
Do not leave the operator’s compartment with the unit running. Always properly shutdown the unit before leaving the operator’s compartment.
Always park the unit on solid, level ground. If this is not possible, park the unit at a right angle to the slope to prevent accidental movement of the machine.
Use proper flags, warnings or barriers when parking in areas of traffic. Chock all four (4) wheels in both directions whenever possible.
Maintenance and repair
Be sure to observe the prescribed maintenance and inspection intervals.
Inform the supervisory personnel and the face crew of any maintenance and repair operations. Give them information on the intended operations and the anticipated duration.
Secure your working area over a wide range, in order to avoid endangering other persons.
Disconnect the battery from the machine to prevent unauthorized and unintentional restarting.
Protect your work area against falling rocks.
Disconnect the battery from machine to prevent from restarting before replacing any defective components.
Pass defective components removed on for servicing without delay in order to prevent these parts being reinstalled elsewhere.
Use only spare parts which satisfy the specified technical requirements. This is only ensured with original Bucyrus America, Inc. spare parts. Please refer to the spare parts lists for the order numbers.
For raising the feeder breaker use only:
crib blocks with adequate load-holding capacity. hoists, jacks or cranes with adequate load-carrying capacity.
Avoid direct contact between the skin and hydraulic fluids. Hydraulic fluid can penetrate the skin and cause serious infection.
Never use hydraulic fluid for rinsing or cleaning. Hydraulic fluid represents a very serious danger to health.
Your safety
permissible hoses
If hydraulic hose couplers are difficult to disconnect or cannot be disconnected, the hydraulic line may still be pressurized. Be sure to depressurize the line before disconnecting couplers.
Secure the connectors of the hydraulic elements only with the proper coupling clamps. Always fasten the clamps completely and with both sides. Never use nails, wire or similar materials for securing.
After finishing repair work, check all connectors and connections for leaks before pressurizing the system again.
Use only hydraulic hoses approved for the prevailing pressures.
Do not use any hydraulic hoses with damaged connectors or worn orings.
Replace hydraulic hoses only with hoses of the same or a higher quality.
Observe the date of manufacture stamped on the hydraulic hoses. Never use hydraulic hoses which are more than 2 years old, even if they have no visible signs of damage.
1. manufacturer
nominal diameter 2. hose type
flame-resistant and antistatic 3. date of manufacture 1st quarter 2000
Never try to hold a jumping hydraulic hose. Depressurize the line in question immediately.
Never try to repair damaged hydraulic hoses.
Replace hydraulic hoses at the first suspicion of damage.
■ always have a little slack.
Fig. 5: Laying hydraulic hoses, crossing Right Wrong
■ are not kinked.
■ do not have to withstand tensile strains.
■ are protected against thermal radiation.
■ are accessible at all times.
Push hydraulic hoses into the sockets only by hand. Never try to drive the hydraulic hoses in with a tool as this will damage the connections.
When installing the hydraulic hoses, ensure that they cannot be:
■ torn out,
■ kinked,
■ crushed,
■ driven over or
■ twisted by movement of the machine.
Fig. 6: Laying hydraulic hoses, connections on moving parts Right Wrong
Your safety
Fig. 4: Laying hydraulic hoses, bending RIGHT WRONG Cannot chafe.
Fig. 5: Laying hydraulic hoses, crossing RIGHT WRONG
Are not kinked. Do not have to withstand tensile strains. Are protected against thermal radiation. Are accessible at all times.
Push hydraulic hoses into the sockets only by hand. Never try to drive the hydraulic hoses in with a tool, this will damage the connections.
When installing the hydraulic hoses, ensure that they cannot be:
Torn out, Kinked, Crushed, Driven over or Twisted (Fig.: 6) by the movement of the conveyor
Storage and transport
Storage and transport
This chapter contains important information on the correct storage and transport of the Dash series Continuous Miner ® Observance of the instructions and tips will increase the service life and availability of the machine. You will also be able to carry out the transport work quicker and more safely. Careful attention to the points in this chapter will help you to simplify your day-to-day work.
Storage
Components coated with temporary corrosion inhibitor are protected for approximately six months.
Before delivery, the hydraulically operated equipment is operated and all gear boxes, hydraulic oil tank, etc. are filled to their maximum fill point.
Storage of the machine and spare parts
Store the equipment indoors or cover with a tarpaulin to protect against direct exposure to sunlight. Store the electrical equipment, electronic components, spare parts of rubber or plastic – such as seals and hoses – and hydraulic fluids only in closed rooms at temperatures of 60° F (15° C) to 77° F (25°C).
Protect the equipment and all spare parts stored outdoors against moisture and dirt, e.g. using tarpaulins.
The mounting surfaces of hydraulic components must be protected against corrosion and sealed with blind plates. Protect the hydraulic plug connectors and the connectors of the electrical cables with the caps and plugs supplied.
During short-term storage (approximately 4 weeks) of equipment outdoors, but at temperatures above freezing, electrical components need not be removed. Such components must be particularly protected against excessive temperatures, dirt and moisture.
If the equipment is to be stored more than six months, the hydraulic components must be completely filled with a corrosion inhibiting/frostproofing fluid such e.g. CV 50.
Fill the hollow areas of hydraulic components (e.g. the piston chambers) in horizontal position (ports facing upwards) until they start to overflow.
Then seal the ports with plastic or steel plugs.
The equipment must be stored in a well ventilated, dry room. Do not store outdoors.
Storage and transport
In order to prevent plastic deformation of the seal elements, cylinders must be stored in an upright position. Some cylinders must be removed so that they can be stored upright.
After a storage period of approximately two years, a random sample inspection must be performed to determine whether the measures taken and the method of storage has prevented damage. On request, the inspection can be carried out by Bucyrus America, Inc.
Even with proper storage, seals and hoses are subject to natural ageing. Do not use these parts if they have been stored for more than two years.
Instructions on the storage of concentrates for hydraulic fluids can be found, if required, in chapter 6 in this operating manual.
Take care to insure that new supplies are stored separately from existing stock and that removal takes place on the “first in, first out” principle.
Transport
Load units; dimensions and weights
Observe the transport sheets for the machine and spare parts. They contain information on:
■ Dimensions
■ Weight
■ lifting points, etc.
Additional information on the dimensions and weights can be found in chapter 6 in this operating manual.
Use only load handling devices complying with the technical and legal regulations for the transport of loads. You could be seriously injured or even killed by falling loads. Use only suitable load handling devices.
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Transport
Load Units; Dimensions and Weights
Observe the transport sheets for the various transport units. They contain information on:
Dimensions
Weight
Lifting points
Center of gravity, etc.
Where technically possible, the load units have suitable lifting points for transport and erection.
WARNING temperatures below freezing
Use only load handling devices complying with the technical and legal regulations for transporting loads. You could be seriously injured or even killed by falling loads. Use only suitable load handling devices.
Before Transport
Transport of equipment at temperatures between –21° C and -40°C is only permissible when certain measures were taken, to meet these conditions, at the design and manufacturing stages. Nevertheless, the individual parts and devices of this equipment must not be subjected to sudden impact loads at low temperatures.
During transport of this equipment, measures must be taken to ensure that the parts and devices are not subjected to sudden impact loads. At very low temperatures and on poor roads, the transport vehicle speed must therefore be limited to maximum of 25 kph for truck transport.
antifreeze measures for oil cooler
electrical and electronic components
Before transporting, the oil cooler must be flushed with anti-freeze.
Electrical and electronic components must be removed for over seas transport or prolonged storage outdoors unless these components or the complete equipment is protected against harmful environmental influences by a suitable packaging.
If the electrical cables remain in the equipment, they must be carefully protected against transport damage and soiling of the connections.
Storage and transport
Installation Points
to observe prior to installation
Who is allowed to carry out installation?
Installation is only allowed to be carried out by personnel having received adequate training to perform this task.
Work on:
the safety components (pressure relief valves, fire extinguishing equipment etc.)
the electrical equipment (control units, signaling devices, etc.)
And
the hydraulic equipment (cylinders, directional control valves, hoses etc.)
should only be carried out by Bucyrus America, Inc. service engineers or by specially trained personnel.
Which tools are required for installation?
special tools
No special tools are required to put the Continuous Miner ® into service.
The receptacles come with a special wrench for connecting and disconnecting receptacles.
In addition, various items of auxiliary equipment and machines may be required at the point of installation.
These include i.e.:
Blocking
Hammer
Screwdriver
Retaining ring pliers
Pliers
Wire cutters
Pry bar
Chisel
Punch
Rose gun
Welding equipment
Chain falls
Slide hammer (provided by Bucyrus America, Inc. ) with the following adapters:
1”-8
5/8”-11
3/8”-16
An adjustable wrench
7/16” wrench
3/4” wrench
1 1/8” wrench
1 1/2” wrench
7/16” socket wrench
9/16” socket wrench
3/4” socket wrench
15/16” socket wrench
1 1/8” socket wrench
1 1/2” socket wrench
1 7/8” socket wrench
15/16” torque wrench
1 1/2” torque wrench with 20-to-1 multiplier
1 7/8” torque wrench with 20-to-1 multiplier
7/8” torque wrench with 20-to-1 multiplier
3/8” Allen wrench
5/16” Allen wrench
5/8” Allen wrench
3/4” Allen wrench
7/8” Allen wrench
3/8” hex torque wrench
general safety rules
Before attempting any repairs, a DANGER sign must be attached to the appropriate circuit at the power distribution box. It is mandatory, under United States Federal Law, that the trailing cable be uncoupled and locked-out from the power source to provide visual evidence that the miner is de-energized.
A scheduled preventative, maintenance, lubrication, and inspection system should be followed.
Only qualified and authorized personnel should be permitted to maintain, repair, adjust and inspect the miner.
Before beginning any maintenance on the miner, perform the following procedures:
1. Visually disconnect the miner from the power source.
2. Block any and all elevated assemblies before working under them. Make sure that the blocking can support the weight of the assembly without slipping or failing.
3. Relieve all hydraulic pressures.
4. Position all levers and controls in NEUTRAL or OFF
5. Work on the miner only in an area where the roof is properly supported.
6. Test the air for methane before beginning any maintenance work.
Perform all procedures in accordance with accepted practices and applicable regulations.
The following general safety precautions should be observed:
Any operation to check performance of the miner must be conducted in an area with sufficient safe clearance.
Methane monitoring of the air must occur before and during all maintenance
Avoid fire hazards and have fire protection equipment present whether working above or below ground.
Do not use open pans of fuel or flammable cleaning fluid for cleaning parts.
Control mechanisms, lights, overload devices, guards, and safety devices must be inspected regularly and maintained in safe operating condition.
All parts of component assemblies and frame members must be carefully and regularly inspected and maintained in safe operating condition.
The original approved safe operating features of the miner must be maintained.
Operation, warning, and maintenance instruction plates, tags or decals must be maintained in a legible condition. general maintenance safety
Modifications and additions that affect safe operation must not be performed without prior written approval from Bucyrus America, Inc. Warning, operations, and maintenance instruction plates, tags, or decals must be changed accordingly.
The hydraulic system should be regularly inspected and maintained in conformance with accepted practices. Cylinders, valves, and other similar parts should be checked to ensure that “drift” has not developed to the extent that it could create a hazard.
Motors, controllers, switches, protective devices, electrical conductors, and connections should be inspected and maintained in conformance with accepted practices and applicable regulations. Special attention should be paid to the condition of electrical insulation.
The miner should be kept as clean as possible to minimize fire hazards and to help in the detection of loose or defective parts.
Care should be taken to ensure that all replacement parts are interchangeable with the original parts and are of quality equal to that provided in the original equipment.
When performing maintenance, do not wear rings, watches, loose shirt sleeves, worn or tattered gloves, loose jackets, neck ties, or other apparel that could become entangled in the miner.
Always wear the proper, approved safety clothing. Maintenance personnel must know how to properly operate the miner in order to perform test and inspection procedures. The miner must be maintained in “Permissible” condition, where applicable.
When working on or operating a miner from the Operator’s Platform area, do not reach out of the cab with your foot. Never touch a rotating or moving assembly or component. Be careful to avoid pinch points while operating or maintaining the miner.
Be careful when working around high-pressure hydraulics. The high-pressure jet of fluid from a pinhole leak in a hydraulic hose can penetrate through skin and into the tissue below, causing serious problems such as blood poisoning.
lubricate every shift
Cutter head shear cylinder
Cutter head shear cylinder pin (left and right)
Cutter head shear cylinder to frame pin (left and right)
Cutter head pivot pin (left and right)
Conveyor roller
Trailing cable for breaks or cracks in the cable cover
Lighting systems for damage
Conveyor flights for excessive wear or damage, and replace as necessary
Cutter head mining bits for wear or damage, and replace as necessary
Scrubber spray nozzles for blockage
Check the lubrication levels of all the following components and fill as necessary:
Conveyor swing cylinder jack pins (front and rear)
Conveyor-to-tractor frame pin
Tractor frame stabilizer shoe pins (left and right)
Clean and remove accumulated sludge:
Scrubber filter screens
Scubber inlet duct work
Mist eliminator and sump
All seals for leakage
Gear case breathers (primary, gathering head) for airflow obstructions
Entire front end for damage, and tighten all hardware
Tram track for missing parts, wear, or damage
All sprockets and idlers for wear or damage
Hydraulic lines for wear and damage
Drive sprocket shear pin bushings for wear/ damage
check daily
replace when necessary
electric motor maintenance every month
Electrical system for damage, malfunctioning components, and loose or corroded connections
The methane monitor is maintained according to manufacturers and regulatory specifications.
Trailing cable connection at the power center of r permissibility according to Federal Regulations ( Part 75, Title 30 ).
All lubrication fittings and plugs for proper installation as well as damage
All bolts and capscrews, and tighten as necessary
All chain tensions, and adjust as necessary
Drum drive clutch, and adjust as necessary
Tram track tension, and adjust track take-up cylinder as needed
Required hydraulic pressures, and make corrections to the hydraulic system by readjusting the appropriate relief valves
Gathering head hinge pins for excessive movement, and adjust as necessary
Conveyor tension springs for proper expansion and contraction during conveyor operation, and adjust as necessary.
Return filter element
Pilot circuit primary oil filter
Clean all debris from motor frames
Clean all heat exchangers
Inspect motor bearings for lubricant leakage
Check temperatures of bearings and frames
Start motor and confirm that it accelerates to operating speed in an appropriate time
Listen to the running motor for any unusual noises
Drain and Fill lubricant in all gear cases (drum drive, gathering head, tram primary planetary, tram secondary planetary). Take oil sample prior to draining. Send Sample to Bucyrus America, Inc. for analysis. To gather the oil Sample for analysis please follow the following steps outlined on the following page.
This process applies to the CLA Gear case and Pot Lube Check. Presently, the lube checks require the removal of the check plugs, which are beside the fill port, and observation of the gear’s lube flow from the check port. It has been found that this does not insure the true gear lube level. To assure the proper gear lube level apply the following procedure.
1. Remove all plugs.
2. Using a rose gun or lube bucket force gear lube in the fill port until lube flows from the check port.
The diagram below gives a description of the location of the ports for both the upper and lower ports.
Inspect CLA’s for excessive wear and damage, and replace as necessary.
Cutter gear case mounting is secure, and tighten as necessary CLAs for looseness, and tighten as necessary
Lubricate scrubber fan motor.
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Clean motors thoroughly.
Inspect couplings, belts, belt guards, mounting frame bolts, end-shield bolts, and mechanical fastenings for mechanical soundness and tightness
Check end play of rotor shaft
Operate motors at normal load and temperature
Measure and record motor insulation resistance and temperature
The DC tram motors require regular preventive maintenance. Inspect the commutator, cable rigging, and brushes. The commutator should be dark brown with no signs of burning.
Check for brush wear and spring tension. replace all of the brushes when replacement is necessary.
Replace oil reservoir breather.
Lubricate the right and left cutterhead motor bearings (front and rear).
Clean motor thoroughly.
Lubricate ball bearings, if required. Record the date the motor was lubricated.
Inspect all gaskets, particularly lubricant seals, and replace as needed.
Check operating speed.
Inspect and tighten all electrical connections
Inspect fans for loose or damaged blades
Run motor and examine drive for smooth operation and lack of excessive Vibration.
Check current readings and compare with normal value on motor nameplate and previously recorded values
Check motor mounts, end-shields, couplings, and shaft keys for looseness.
Inspect all covers, belt guards, and other guards for damage, and tighten until securely fastened.
Drain, flush, and refill the entire hydraulic system.
Inspect all windings and insulation
Clean and repair insulation as needed
Measure resistance and record
Check for and remove any magnetic particles
Notes on installation
Serious damage can be caused to the continuous miner ® as a result of incorrect installation. The unit should therefore only be installed under the instruction of specialists from Bucyrus America, Inc.
The sequence of operations during installation must be adapted to the individual conditions prevailing at the site. Before starting the work a detailed list of steps to be taken with respect to transport and assembly should be prepared and a corresponding plan established.
The sequence of operations during installation must be adapted to the individual conditions prevailing at the site. Before starting the work a detailed list of steps to be taken with respect to transport and assembly should be prepared and a corresponding plan established
superbolt installation and specifications
tightening procedures
IMPORTANT
Thread Diameter 1 1/4”
Jackbolt Diameter 5/16”
Jackbolt Socket Size 1/4”
Required Jackbolt Torque 35 (in./lb.) Read all these instructions completely before you begin.
This procedure is typical for the majority of SUPERBOLT products. Specific installation procedures that are shipped with all products may supersede this general procedure. Use the appropriate instructions shipped with the product you are installing. Contact SUPERBOLT, Inc. at (412) 279-1149 with any questions.
Air or electric power wrenches of the appropriate size may be used for running up jackbolts. Attempt to tighten as consistently as possible and remove the power wrench frequently; do not tighten all at once. Use a standard torque wrench to verify final torque values.
1. SUPERBOLT products are designed for use with hardened surface washers. Slide the washer onto the bolt or stud first.
2. VIEW A - Check the base of the tensioner(s) and verify that all jackbolts are flush with the bottom of the tennsioner body.
3. VIEW A - Clear any dirt or chips from the threads of the bolt or stud and from the main internal thread of the tensioner
4. VIEW A - Spin the tensioner body down on the main thread of the bolt or stud by hand. The tensioner body should be in light contact with the hardened washer.
5. Determine the target jackbolt torque value for the desired preload, either from the installation sheets shipped with the product or the catalog tables, or by calling SUPERBOLT, Inc. The jackbolt torque value stamped on the tensioner is a standard value for that part, and may not be appropriate for your specific application. Since jackbolt torque is directly proportional to the tension load, you can easily figure other values as required (e.g., 1/2 preload = 1/2 jackbolt torque).
loosening procedures
6. Start by snugging the jackbolts to 10% of the target jackbolt torque value from step 5. This seats the thread and eliminates clearances. The star pattern shown in VIEW B should be used for this initial tightening sequence.
7. VIEW B - Tighten the jackbolts in the star pattern to 50% of the target jackbolt torque value.
8. VIEW C - Change to a circular pattern and torque the jackbolts to 75% of the target jackbolt value.
9. VIEW C - Continue one more pass in the above circular pattern with 10% more torque than that of the target jackbolt torque value.
10. VIEW C - Long bolts will stretch, so by the time you get back to the first jackbolt, it will be loose again.
11. VIEW C - Set the torque wrench for the final torque value and continue to repeat the circular pattern until all jackbolts are torqued to the same value. do not exceed the torque value stamped on the tensioner without specific approval from SUPERBOLT, Inc.
Jackbolts should be loosened with care. For longer bolts and studs, this procedure is even more important. Loosening can be accomplished quickly, but do not rush to completely loosen individual jackbolts. Remember that the intent is to slowly release the preload force. All jackbolts should be loosened uniformly, and usually there is no need to remove any jackbolt from the tensioner body during loosening.
1. Turn the first jackbolt counter-clockwise until it feels loose (no more than one half turn). The idea is just to unload each jackbolt, not to completely loosen it.
2. Move in a circular pattern to the next jackbolt and repeat step 1.
3. Continue repeating until all jackbolts have been unloaded.
4. By the time you get back to the first jackbolt, it will be tight again. Repeat the process moving in a circular pattern.
5. Usually after two or three passes, the tensioner can be spun off the bolt or stud by hand. Long bolts or studs that stretch more may require extra passes.
6. Before reusing any tensioner, the jackbolts should be removed in the appropriate manner. The body and jackbolts should be cleaned and re-lubricated with SUPERBOLT approved lubricant to ensure proper jackbolt torque vs. preload performance upon reinstallation.
The torque-preload relationship of SUPERBOLT tensioners depends on the tension body and jackbolt materials, heat treatment, plating, lubricants and many other factors. SUPERBOLT engineers have performed extensive tests to determine the best lubricants for the various materials utilized by SUPERBOLT, Inc. Two custom lubricants, JL-G and JL-M, are offered by SUPERBOLT, Inc.
JL-G is a lubricant paste made from selected flaky graphite and prime mineral oil. It has a relatively uniform friction factor of 0.130 under widely varying conditions. JL-G is used in the assembly of most SUPERBOLT products.
A number of commercially available graphite - or nickel - based lubricant compounds such as Fel-Pro C102 or Fel-Pro N5000 can be used for re-lubrication in the field. Copper bearing compounds have not performed well as jackbolt lubricants.
JL-M is a lubricant paste made from molybdenum-disulifide powder and pure mineral oil. It has a friction factor of 0.045 to 0.070. Tests have shown that when jackbolts are tightened the first time, the friction of JL-M is approximately 0.070. Each subsequent tightening reduces the friction factor lower until at the fourth tightening it levels out at approximately 0.050. SUPERBOLT, Inc. uses an average friction factor of 0.055 for torque calculations. It must be emphasized that the tensioners must be tightened several times to stabilize at the low values. After many repeat tightenings, the friction factor can be as low as 0.045. Due to these variations in friction factor, molybased lubricants are used instead of graphite-based lubricants only in the following cases.
1. On very large jackbolts when the torque required for a specific preload would be too high; or,
2. Where space restrictions prohibit the use of sufficiently large torque wrenches.
In some cases, SUPERBOLT tensioners are “broken in” at the factory to lower the friction factor for field installation.
Fel-Pro C-870 molybdenum-disulfide paste has performed similarly to JL-M. Other molybdenum pastes and greases tested had much high friction factors. Testing for friction factor is recommended for all critical installations where lubricant and/or bolt and nut materials are unknown.
Safety features
The operator must become familiar with all the safety features and their location on the machine prior to installation or operation. Safety features include:
The machine is equipped with panic strips. The panic strip(s) are used to break the control circuit only in emergency situations, stopping all motors. Striking with a small amount of force will actuate either panic strip.
The machine was shipped from the factory with a protective canopy. Ensure that the canopy is in place and secure at all times to protect the operator from fall debris.
The machine is equipped with fire suppression (remote) actuators. This particular suppression system is pneumatically actuated and extinguishes with dry chemicals. To actuate the system from either of the actuators, pull the safety pin and strike downward on the plunger. Immediately after the plunger is struck, dry chemical will be dispensed throughout the machine. The fire suppression system must be completely recharged with dry chemicals and expellants after it has been actuated.
If either of the fire suppression actuators is actuated, the system must be completely recharged with dry chemicals and expellants.
The machine is equipped with guards and covers to reduce the possibility of personnel coming in contact with rotating or moving parts. All guards and covers must be installed and securely fastened during operation.
Do not operate the machine any of the guards or covers removed. You or other personnel could be seriously injured from moving or rotating parts.
The machine is equipped with a circuit breaker reset. The circuit breaker reset may be used to shutdown the machine in emergency situations.
Operation
This chapter contains important information on the operation of various components of the miner. It also includes instructions on the replacement of wear parts. Read this chapter carefully and thoroughly. In particular, observe the safety instructions in chapter 2 “Your safety”.
The cutter head assembly for each Dash Series miner model is unique. Therefore the procedures in this section are identified by miner modelDash Zero, Dash One, Dash Two, and Dash Three.
Lower the gathering head and the cutter head to the floor. Position the conveyor tail section level with the floor. Remove and lock-out the electrical power ti the miner.
1. Disconnect the power cables and water hoses from the cutter motors - follow the procedure in CUTTER MOTOR. Be sure to tape up the power cables since electrical power will be connected to the miner.
2. Disconnect the water hoses to the dust suppression sprays.
3. VIEW A -Remove both boom pivot pins - follow that procedure.
4. Disconnect electrical power to the miner.
5. Extend the shear cylinders to push the boom pivots out of their tractor frame clevises.
6. Block the shear cylinders to keep them stationary during their pin removal.
Provide support and lift to the cutter boom assembly.
Never work under any raised assembly without proper blocking.
7. Remove the shear cylinder boom clevis pins - follow the procedure in SHEAR CYLINDER.
8. Connect electrical power to the miner.
9. Retract the shear cylinders to pull their bearings free from the boom clevises. Disconnect electrical power.
10. VIEW B -Raise the rear of the boom assembly until it is above the top edge of the gathering head backboard. Reconnect electrical power.
11. Slowly tram the miner backwards until the cutter boom pivot points clear the front of the gathering head.
12. To install the boom assembly - reverse the above procedure.
cutter head assembly
Dash Zero, Dash One, Dash Two Removal / Installation.
Lower the gathering head and the cutter head to the floor, position the conveyor tail section with the floor. Remove and lock-out the electrical power to the miner.
1. VIEW A -Remove the capscrew and lock washer that secures the front rub rail to the tractor frame and open the front rub rail.
2. VIEW B -Remove the front idler take-up jack bracket -follow the FRONT IDLER TAKE-UP JACK procedure in SECTION 5, TRACTOR FRAME.
3. VIEW C -Remove the pivot pin retaining plate and its support block.
4. Connect electrical power to the miner.
5. VIEW C -Insert the slide hammer’s 1”-8 NC adapter into the end of the pivot pin.
Pressure from the cutter boom onto the pivot pin can make its removal very difficult. The shear cylinders can be used to find the boom position that puts the least pressure on the pin.
When the pivot pin pull point is found, block the cutter boom to prevent it from dropping or moving when the pivot pin is removed.
6. VIEW D -Attach the slide hammer to its adapter and pull the boom pivot pin.
7. To install a boom pivot pin - reverse the above procedure.
Lower the gathering head and the cutter head to the floor. Position the conveyor tail section level with the floor. Remove and lock-out the electrical power to the miner.
1. VIEW A -Remove covers or scrubber duct work to access the boom pivot.
2. VIEW B -Remove the pivot pin grease line and retaining plate.
3. VIEW B -Insert the slide hammer’s 1”-8 adapter into the end of the pivot pin.
4. Connect electrical power to the miner.
Pressure from the cutter boom onto the pivot pin can make its removal very difficult. The shear cylinders can be used to find the boom position that puts the least pressure on the pin.
When the pivot pin pull point is found, block the cutter boom to prevent it from dropping or moving when the pivot pin is removed.
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5. VIEW B -Attach the slide hammer to its adapter and pull the boom pivot pin.
6. To install a boom pivot pin - reverse the above procedure.
Position the conveyor tail level with the floor. Lower the gathering head to the floor. Raise and block the cutter head assembly. Remove and lock-out the electrical power to the miner.
Never work under any raised assembly without proper blocking.
Remove necessary covers to access the clutch at the rear of the cutter motor.
1. VIEW A -Remove the eight capscrews and lockwashers that secures the clutch cover to the motor frame.
2. VIEW A -Remove the clutch cover to expose the clutch assembly.
3. VIEW A -Remove the retaining ring that secures the motor shaft inside the clutch assembly.
4. VIEW A -Pull the motor shaft from the motor and clutch assembly. Store the motor shaft in a clean place.
5. VIEW B -Remove the sixteen locknuts on the out side of the pressure plate.
6. VIEW B -Remove the pressure plate and the out put hub assembly ( with seal and bearing ) from the clutch.
7. VIEW C -Remove the retaining ring found on the exterior of the keeper plate.
8. VIEW C -Remove the three capscrews and serrated washers that secures the keeper plate to the input hub.
9. VIEW C -Remove the keeper plate and disc spring to reveal the motor shaft secured by a retaining ring.
The remaining clutch assembly is very heavy. Verify the weight can be supported.
10. VIEW D -Remove the retaining ring from the motor shaft. The input assembly of the clutch is unattached and can be slipped off the motor shaft.
11. VIEW D -Remove the final retaining ring from the motor shaft.
12. To install the Drum Drive Torque Limiting Clutch - reverse the above procedure.
Position the conveyor tail level with the floor. Lower the gathering head to the floor. Raise and block the cutter head assembly. Remove and lock-out the electrical power to the miner.
Never work under any raised assembly without proper blocking.
1. VIEW A -Remove brackets and covers to access the drum drive motor.
2. VIEW B -Remove the capscrews and lock washers that secure the cover for the drive shear shaft. Remove the cover and o-ring.
3. VIEW B -Remove the retaining ring, the plug and the o-ring. Pull the drive shaft out of engagement with the gear case. Replace the shaft cover. Keep the shear shaft in a clean place.
4. VIEW C -Remove the capscrews on the motor junction box cover and remove the cover and o-ring.
5. VIEW D -Mark the motor and power cable leads and disconnect the leads.
6. VIEW E -Remove the stuffing box clamp and slide the power cables out of the motor junction box.
7. Disconnect the cooling water hoses from the motor. Plug the motor and hose ends to keep them clean.
The drum drive motor is very heavy. Verify its weight can be supported.
8. VIEW A -Remove the four bolts which mount the drum drive motor to the gear case.
9. VIEW A -Slide the motor out of the gear case.
10. To install a drum drive motor - reverse the above procedure. Be sure to isolate and jog the new motor to check for correct rotation. Note: Reuse top and bottom water manifolds.
1. VIEW A -Remove brackets and covers to access the drum drive motor.
2. Remove the torque limiting clutch assembly - follow that procedure.
3. VIEW B -Remove the four capscrews and lock washers on the motor junction box cover and remove the cover and o-ring.
4. VIEW C -Mark the motor and power cable leads and disconnect the leads.
5. VIEW C -Remove the stuffing box clamp and slide the power cables out of the motor junction box. Replace the junction box cover and o-ring.
6. Disconnect the cooling water hoses from the motor. Plug the motor and hose ends to keep them clean. -
7. VIEW D -Remove the caps from the Superbolts and remove the four Superbolts that secure the drum drive motor to the boomfollow the procedure in SUPERBOLT.
8. To install a drum drive motor - reverse the above procedure. Be sure to isolate and jog the new motor to check for correct rotation.
Never work under any raised assembly without proper blocking. The drum drive motor is very heavy. Verify its weight can be supported. DANGER
Position the conveyor tail level with the floor. Lower the gathering head to the floor. Raise and block the cutter head assembly. Remove and lock-out the electrical power to the miner.
1. Advance the conveyor chain so that a conveyor flight does not block the shear cylinder piston end pin access plate in the conveyor bed.
2. VIEW A -Remove covers to access both ends of the shear cylinder.
3. VIEW B -At the Cutter boom clevis remove two capscrews and lock washers and remove the retaining plate.
4. VIEW B -Using the slide hammer with a 1”-8 adapter pull the pin from the clevis bushing.
5. Connect electrical power to the miner.
Stand clear of the blocked cutter head assembly during contraction of the shear cylinders.
6. Slowly contract the shear cylinder until the rod comes free from its cutter boom clevis.
Remove and lout-out the electrical power ti the miner.
7. Raise and lower the shear cylinder control lever to release any pressure from the shear cylinder.
8. VIEW C -At the tractor frame clevis, remove the two capscrews and lock washers that secure the pin retaining plate to the frame. Remove the retaining plate.
The shear cylinder is very heavy. Verify its weight can be supported.
9. VIEW C -Using the slide hammer with a 1”-8 adapter pull the pin from the clevis busing.
10. Mark for reconnection then disconnect and cap the hoses to the shear cylinder.
11. The shear cylinder can now be removed.
12. To install a shear cylinder - reverse the above procedure.
shear cylinder dash-3
1. VIEW A -Access both ends of the shear cylinder.
2. VIEW B -At the Cutter boom clevis remove two capscrews and lock washers and remove the retaining plate.
3. VIEW B -Using the slide hammer with a 1”-8 adapter pull the pin from the clevis bushing.
4. Connect electrical power to the miner.
DANGER
cutter drums dash-0
The shear cylinder is very heavy. Verify its weight can be supported. Remove and lock-out the electrical power to the miner.
5. Slowly contract the shear cylinder until the piston end comes free from its cutter boom clevis.
6. Raise and lower the shear cylinder control lever to release any pressure from the shear cylinder.
7. Mark the hoses for reconnection then disconnect and cap them.
8. VIEW B -At the tractor frame clevis, remove the two capscrews and lock washers that secures the pin retaining plate to the frame. Remove the retaining plate.
9. VIEW B -Using the slide hammer with a 1”-8 adapter pull the pin from the clevis bushing.
10. The shear cylinder can now be removed.
11. To install a shear cylinder - reverse the above procedure.
1. Manually rotate the cutter head drums slowly until the center drum connecting flanges are parallel to the mine floor. .
2. Before you do any disassembly, familiarize yourself with the position of the cutter drum alignment marks / arrows.
DANGER
center cutter drums
The cutter drums are extremely heavy. Verify its weight can be supported. Remove and lock-out the electrical power to the miner.
1. VIEW A -At the split line of the two halves remove the weld straps using a cutting torch.
2. VIEW A -Remove the twelve capscrews and retainer plates holding the center drum flanges together. Store the capscrews and retainer plates for reinstallation.
3. Attach lifting chains or other lifting device to the top half cutter drum.
4. Break the seal between the center drum’s halves with a pry bar.
5. Lift the upper half of the center drum and move it away from the miner.
6. Connect electrical power to the miner.
7. Raise the cutter head assembly slowly until it is completely clear of the lower half of the center drum and tram the miner away from the drum halves.
8. To Install the center cutter drum - reverse the above procedure. Remember to torque the twelve capscrews to 1700 lb.-ft. alternating front to back starting from one end and working toward the other.
Verify the lifting device is capable of listing the drum’s weight. Use care when handling the cutter drum.
Follow welding safety instructions.
1. Drain the gear case oil before starting to remove the drums.
2. VIEW F -Remove the long capscrews and nuts on the two studs which secure the end drum to the cutter drum drive assembly.
3. Remove plug and center drum input shaft.
4. VIEW D -Remove the drum sliding it off of the hub.
5. Remove the key and store for reinstallation.
6. To install the end drum - reverse the above procedure.
7. Be sure the match timing arrows are aligned.
8. VIEW F -Torque the capscrews to 350 lb.-ft.
The end cutter drums are very heavy. Verify the supports can support its weight.
1. The end cutter drum must be removed. Follow that procedure.
2. VIEW E -Using a cutting torch remove the straps tack welded to the strut capscrews.
3. VIEW E -Remove the eight strut capscrews.
4. VIEW F -Remove the remaining nuts on the two studs.
5. Slide the strut and hub assembly from the gear case over the two studs.
6. VIEW B -Remove the capscrews from the main cutter drum..
7. VIEW C -The cutter drum can now be removed from the output shaft by sliding it off the hub and two dowel pins.
8. To install the main cutter drum reverse the above procedure. Apply red loctite and torque the capscrews to 350 lb.-ft.
The main cutter drums are very heavy. Verify the supports can support its weight.
cutter drum
1. Manually rotate the cutter head drums slowly until the center drum connecting flanges are parallel to the mine floor.
2. Before you do any disassembly, familiarize yourself with the position of the cutter drum alignment marks / arrows.
CAUTION
installation / removal dash-1 CAUTION
center cutter drum
Position the conveyor tail section level with the floor. Lower the gathering head until it is level with the floor. Raise and block up the cutter head assembly. Allow for removal of the cutter drums.
Never work under any raised assembly without proper blocking.
Remove and lock-out the electrical power to the miner.
The cutter drums are extremely heavy. Verify its weight can be properly supported and use extreme case when handling.
1. VIEW A -At the split line of the two halves remove the weld straps with hammer and chisel.
2. VIEW A -Remove the sixteen capscrews and retainer plates holding the center drum flanges together. Store the capscrews and retainer plates for reinstallation.
3. Attach lifting chains or other lifting device to the top half cutter drum.
4. Break the seal between the center drum’s halves with a pry bar.
5. Lift the upper half of the center drum and move it away from the miner.
6. Connect electrical power to the miner.
7. Raise the cutter head assembly slowly until it is completely clear of the lower half of the center drum and tram the miner away from the drum halves.
8. To Install the center cutter drum - reverse the above procedure. Remember to torque the sixteen capscrews to 1900 lb.-ft. alternating front to back starting from one end and working toward the other.
1. Drain the gear case oil before staring to remove the drums.
2. Remove the lock-ring tack welded to the capscrews using a cutting torch.
3. VIEW F -Remove the long capscrews and nuts on the two studs which secure the end drum to the cutter drum drive assembly.
4. Remove plug and center drum input shaft.
5. VIEW D -Remove the drum sliding it off of the hub.
6. Remove the key and store for reinstallation.
7. To install the end drum - reverse the above procedure.
8. Be sure the match timing arrows are aligned.
9. VIEW F -Torque the capscrews to 900 lb.-ft. Tack weld the lockring.
The end cutter drums are very heavy. Verify their weight can be supported. Follow welding safety procedures.
1. The end cutter drum must be removed. Follow that procedure.
2. VIEW E -Using a cutting torch remove the retainer tack welded to the strut capscrews.
3. VIEW E -Remove the eight strut capscrews.
4. VIEW F -Remove the remaining nuts on the two studs.
5. Slide the strut and hub assembly from the gear case over the two studs.
6. VIEW B -Remove the capscrews from the main cutter.
7. VIEW C -The cutter can now be removed from the output shaft by sliding it off the hub and two dowel pins.
8. To install the main cutter drum reverse the above procedure. Torque capscrews to 500 lb.-ft. If never size is used reduce the torque value to 300 lb.-ft. ( If loctite is used reduce the torque value to 425 lb.-ft. )
9. Tack weld the lock-ring and capscrew retainer.
The strut and hub assemblies are very heavy. Be prepared to supports its weight.
The main cutter drum is extremely heavy. Verify its weight can be supported.
cutter drums dash-2 installation / removal
1. Manually rotate the cutter head drums slowly until the center drum connecting flanges are parallel to the mine floor.
2. VIEW C - Before you do any disassembly, familiarize yourself with the position of the cutter drum alignment marks / arrows.
3. VIEW A -At the capscrews remove the weld straps with hammer and chisel.
4. VIEW C -Remove the twenty capscrews and retainers holding the center drum flanges together. Store the capscrews and connecting plates for reinstallation.
5. VIEW B -Attach lifting chains or other lifting device to the top half cutter drum.
6. Break the seal between the center drum’s halves with a pry bar.
7.
8. VIEW B -Lift the upper half of the center drum and move it away from the miner.
9. VIEW C -Remove the center drum alignment keys from the keyway if the cuttting drums are key driven ( not square drive ). Store for reinstallation.
10. Connect electrical power to the miner.
11. Raise the cutter head assembly slowly until it is completely clear of the lower half of the center drum and tram the miner away from the drum halves.
12. To Install the center cutter drum - reverse the above procedure. Remember to torque the twenty capscrews to 1850 lb.-ft. alternating front to back starting from one end and working toward the other.
Position the conveyor tail section level with the floor. Lower the gathering head until it reaches the floor. Raise and block the cutter head assembly. Allow space for the removal of the cutter head.
Never work under any raised assembly without proper blocking.
Remove and lock-out the electrical power to the miner. Follow welding safety procedures.
The cutter drums are extremely heavy. Verify the supports willhandle its weight.
Verify the lifting device is capable of lifting the drum;s weight. Use care when handling the cutter drum.
end cutter drums
1. VIEW D -Remove the weld straps between capscrews using a cutting torch.
2. VIEW D -Remove the twelve capscrews which secure the end drum to the cutter drum drive assembly.
3. VIEW D -Remove the drum from the miner.
4. To install the end drum - reverse the above procedure.
5. VIEW C -Be sure the match timing arrows are aligned.
6. VIEW D -Torque the twelve capscrews to 1200 lb.-ft. Tack weld the straps.
The end cutter drums are very heavy. Verify the supports can handle its weight. Follow welding safety procedures.
Position the conveyor tail section level with the floor. Lower the gathering head until it reaches the floor. Raise and block the cutter head assembly. Allow for removal of the cutter drums.
Never work under any raised assembly without proper blocking.
Remove and lock-out the electrical power to the miner.
1. Manually rotate the cutter head drums slowly until the center drum connecting flanges are parallel to the mine floor.
2. VIEW C -Before you do any disassembly, familiarize yourself with the position of the cutter drum alignment marks / arrows.
The cutter drums are extremely heavy. Use extreme care when handling.
center cutter drum
1. VIEW A -At the capscrews remove the weld straps using a cutting torch.
2. VIEW C -Remove the eighteen capscrews holding the center drum flanges together. Store the capscrews for reinstallation.
3. VIEW B -Attach lifting chains or other lifting device to the top half cutter drum.
4. Break the seal between the center drum’s halves with a pry bar.
5. VIEW B -Lift the upper half of the center drum and move it away from the miner.
6. VIEW C -Remove the center drum alignment keys from the key way if the cuttting drums are key driven ( not square drive ). Store for reinstallation.
7. Connect electrical power to the miner.
8. Raise the cutterhead assembly slowly until it is completely clear of the lower half of the center drum and tram the miner away from the drum halves.
9. To Install the center cutter drum - reverse the above procedure. Remember to torque the eighteen capscrews to 1850 lb.-ft. alternating front to back starting from one end and working toward the other.
Follow welding safety procedures.
Verify the lifting device is capable of lifting the drum’s weight. Use case when handling the cutter drum.
1. VIEW D -Remove the weld straps between capscrews using a cutting torch.
2. VIEW D -Remove the twelve capscrews which secure the end drum to the cutter drum drive assembly.
3. VIEW D -Remove the drum from the miner.
4. To install the end drum - reverse the above procedure.
5. VIEW C -Be sure the timing arrows are aligned.
6. VIEW D -Torque the twelve capscrews to 1200 lb.-ft. Tack weld the strap across the capscrews.
Follow welding safety procedures.
The end cutter drums are very heavy. Verify the supports can handle its weight.
Follow welding safety procedures. gear case dash-0
1. Remove the cutter drums - follow that procedure.
2. Remove the covers and water spray manifolds, hosing, and remove cutter motor power leads attached to the gear case.
3. Securely block the cutter drum drive gear case to support it when it becomes separated from the boom.
4. VIEW A -Remove the two capscrews which adjust the special key.
5. Remove the strapping from the capscrews securing the gearcase to the boom using a cutting torch.
6. VIEW D -Remove the fourteen hex head capscrews that secure the cutter drum drive gear case to the cutter drum.
7. Remove the cutter motor.
8. Connect electrical power to the miner.
9. Slowly tram the miner in reverse away from the blocked gear case.
10. VIEW B -Remove the special key and store for installation.
11. To install a gear case - reverse the above procedure. Torque the fourteen capscrews to 1700 lb.-ft.
Position the conveyor tail section level with the floor. Lower the gathering head to the floor. Raise and block-up the cutter head assembly. Allow for removal of the cutter drums.
Never work under any raised assembly without proper blocking.
Remove and lock-out the electrical power to the miner.
The gear case is very heavy. Verify the supports can handle its weight.
Stand clear of the gear case and the miner when tramming.
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