CAT MAINTENANCE MANUAL Bucyrus 30MB3 BI643655 - PDF DOWNLOAD

BI643655

30MB3 MAINTENANCE MANUAL M01404

BI643655

Bucyrus Australia

30MB3 Serial No. 177866 Mechanical Maintenance Manual

First Issue Date: 2007

Prepared by

Revision Date: 06/04/2011 Name

Department

Ron Spencer

Documentation

Revision No. 01

Checked by Approved by 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.

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30MB3 Serial No. 177866 Mechanical Maintenance Manual

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 Rev 1

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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 Rev 1

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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 Rev 1

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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

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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.

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

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

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Skid Steer

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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 b) Cutter Head Gear case -

Conveyor Assembly Intermediate and discharge

-

Gathering Head Assembly complete with drill rigs and shields

TRS - OPTIONAL

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9000 kg 13500 kg 7900 kg 13600 kg 1500 kg

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Component Layout Top View

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Right Hand View

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Left Hand View

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Main Chassis

CONVEYOR PIVOT POINT

GATHERING HEAD PIVOT POINT CUTTING HEAD PIVOT POINT GATHERING HEAD PIVOT POINT

HYDRAULIC TANK

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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LEFT CUTTER DRUM

CENTRE CUTTER DRUM RIGHT CUTTER DRUM RIGHT PULL-IN ASSEMBLY

LEFT PULL-IN ASSEMBLY

WATER SPRAY BLOCKS

WATER SPRAY BLOCKS INPUT GEARCASE RIGHT SIDE ELECTRIC MOTORS CUTTER CLUTCH

CUTTER CLUTCH

CUTTER HEAD COVERS

CUTTER HEAD COVERS

CUTTER HEAD PIVOT POINT

CUTTER HEAD DUST BELT

Cutter Head Frame

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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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

TAIL ROLLER

REAR DISCHARGE CONVEYOR

CONVEYOR CHAIN

SWING CYLINDER

FANTAIL PIVOT

SWING CYLINDER

CROSS-OVER BRIDGE

INTERMEDIATE CONVEYOR

CONVEYOR PIVOT POINT

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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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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Hydraulic System - CLA The 30MB3 hydraulic systems is fed from the main reservoir contained as an integral part of the main chassis structure. Capacity of the reservoir is 750 litres; capacity of the total system including the main reservoir, full cylinders, hoses, etc is 1000 litres. Hydraulic oil level in the reservoir can be monitored by sight glasses are which are fitted on either side of the mainframe beside traction motors and the tank is equipped with an oil level float switch which shuts off the machine operation in the event that reservoir level goes below a safe limit. Hydraulic power for the miner is provided by two 67 kW water-cooled AC electric motors which drives two (2) Rexroth variable displacement hydraulic pumps. The RH pump delivers oil to the main control valve for hydraulic mining functions.

The LH pump delivers oil to the drill rigs and the rib protection system when switched into bolting modes. The pump/ motor assembly are located within the RH and LH crawler frames. The pumps provide 260 Litres/min @ a maximum pressure of 200 BAR. Main Valve Bank

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Machine Hydraulic Layout

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Drill Rigs The 30MB3 miner drilling capabilities consist of a single roof drilling unit on a traversing slide and single rib drilling on both sides of the machine. The roof rigs are independently mounted to a shield which is coupled to the gathering head chassis and the rib drilling unit is mounted to the mainframe chassis. Both units are operated from an operator’s platform and consist of side platforms down both sides of the machine for accessing roof bolting supplies.

Roof Rig

Single Rib Rig

Rib Protection Rib protection consists of a hydraulic extendible shield towards the rib horizontally for the operators placement and also vertically for his/her placement. This safety device must be used in conjunction with rib drilling. The shields are to be fully retracted before cutting can take place from face to face due to proximity switches fitted.

Rib Protection Shield

NOTE:

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Refer to Section 9 for the procedures to satisfy the Bolting Mode.

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Articulating Temporary Roof Support - ATRS The Temporary Roof support system consists of two cylinders, one each side of the machine located in the gathering head in bye of the Roof drilling rigs.

The cylinders are operated via the transmitter and can only be operated whilst you are in BOLTING mode.

When the selector valve is placed in bolting mode, oil is directed to the drilling rigs.

A diversion valve on the right hand side of the machine, situated above the main mode selector valve, is then positioned in the ATRS mode, directing the oil onwards to the cylinders.

By operating the [SHIFT] and ATRS UP or ATRS DOWN toggles on the transmitter, the cylinders will raise or lower in the desired direction.

When the cylinders are set to the roof, pressure is detected by a pressure switch. Once pressure has been detected, two pips will be heard from the banshee. This will also be known by a message on the main screen that ATRS mode is initiated.

When the ATRS cylinders are set to the roof and the main mode selector valve (MINING / MAINTENANCE / BOLTING) is selected in mining mode, the pumps will stop. Thus, this is protection of the ATRS cylinders via the pressure switches.

The machine is also fitted with two proximity switches, one each ATRS cylinder. These proximity switches indicate whether the cylinders are fully parked or retracted.

If for any reason the ATRS cylinders are not fully retracted and the operator proceeds to select MINING mode, a message will be displayed on the main screen – ATRS park switch fault and the machine will not be able to be operated for mining functions.

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Bolting, Mining and Maintenance Modes Bolting, Mining and maintenance modes have been fitted to the 30MB3 Miner and can be selected by operating a diversion valve as per its tagging, this valve is mounted upon the Right Hand side of the Miner beside the rib drilling rig.

The selections for the diversion valve are as follows:Mining Mode Maintenance Mode Bolting Mode

-

Raise the handle to the top position Move the handle to the centre position Lower the handle to the lowest position

Mode Selection Valve

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Water System The water distribution system on the 30MB3 miner serves several primary purposes: a. It is circulated through the electric motors for the hydraulic pumps, cutting head, gathering head and traction system, the main control case and traction transformer case, to provide cooling, as well as supply to the bolting rigs. b. It feeds water sprays around the cutting head, gathering head and conveyor to help control and contain dusty air. Fitted in the spray circuit are two 3 – way ball valves for changing the direction of spray patterns to suit mining conditions. (See below) These two valves are mounted on the top of the cutter head frame structure Auxiliary circuits provide flow to wash-down hoses on each side of the machine.

3-way ball valve for redirection of sprays mounted on top of cutter head

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Mine Water Supply

Return Power Tram Outlet

Essential components of the water system, and their locations, are shown on water spray schematic drawing located in this section.

A power tram unit can supply water to be pumped via the main supply inlet which provides cooling water to the pump and traction motors, the main control case, and the traction transformer and a quick-disconnect coupling allows water to be returned to the power tram unit (see above) during flitting of the machine from one working face to another.

The ball valve which isolates the discharge conveyor sprays when using a power tram for flitting.

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Machine Water Component Layout

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Defects and Hazards The machine should be regularly checked for any defects or hazards and rectified where possible or dealt with according to mine specific action plans.

Safety & Maintenance Practices It is essential that all personnel are clear of machine prior to start once operating all personnel to be clear of conveyor boom and cutter head. Operator must be aware of his location to avoid crush potential.

Never put yourself or any other person in any position that should machine fail to respond correctly or if in normal operation creates a position whereby no escape is possible.

“One fraction of a second of carelessness can result in a lifetime of suffering for yourself or other team members”.

To understand this statement is the beginning of effective safe work practices.

• Safety risks are created when you shortcut Standard Procedures.

• Machinery is like a loaded gun - even if it is not running or is switched off.

• When doing tests with the machine on running:

• • •

− Stop machine and isolate to set up test. − Stand clear and observe test. − Stop machine and isolate before disconnecting test.

When repairing, replacing or fitting heavy components: − Use blocks, and supports to prevent components tipping, sliding or moving out of position.

When working under the heads, shovel or tail: − Make sure that safety stops are securely in place at all times.

When testing the machine in any way: − Ensure that personnel are clear of the machine at all times when testing.

Safety Procedures All safety procedures shall comply with mine specific and relevant Mine Managers Rules and particularly any documents relating to the use and maintenance of Remote Control Continuous Miners.

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Isolation Procedures Below is an example of a generic isolation procedure which is common to some coal mines throughout NSW and QLD. NOTE:

Mine Specific Isolation Procedures are to be adhered to and take precedence over example isolation procedures mentioned in this document.

Generic 12 Step Isolation Procedures

The 12 steps must include consideration of the following actions:

1.

Identify all plant or equipment and their energy sources that require isolation •

• •

• •

2.

Advise relevant parties • •

3.

Notify all people who will be affected by the isolation to ensure no safety or operational problems will be created.

Where necessary advise operators that the plant or equipment is to be isolated to allow for machines to be left in a safe position prior to isolating.

Isolate and secure energy sources •

•

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Identify all primary energy sources and confirm that the isolation point e.g. switches, circuit breakers, de-contactors, whole current isolators, battery isolators, valves etc., you isolate are the correct ones for the plant or equipment. Where appropriate refer to schematic diagrams to confirm that the isolator will give complete isolation.

Identify any associated plant or equipment that could create a hazard.

Isolation can only be achieved by isolating the plant or equipment from all sources of energy. While the plant or equipment may be electrically isolated, other sources of energy must be considered e.g. hydraulic/water/air pressure, gravitational energy (continuous miner head or loader bucket in the air, conveyor counterweights) etc.

Determine the type of isolation that you will require (Individual, Group, High Voltage) and apply as required Check to see if any specific isolation procedures apply to that equipment or circuit.

Isolate primary isolator in an approved manner or using site procedures and/or manufacturers recommended instructions e.g., operate whole current isolator, remove plug, close valve etc. Shedding of loads prior to operating primary isolator may need to be considered in some instances.

Isolate or secure/control all secondary energy sources. For example: - bleed off stored hydraulic or pneumatic pressure from pressure vessels, accumulators etc, - Release stored energy such as springs, conveyor belt tension, etc.

- secure/barricade/chock elevated equipment or material hang-up in chutes, truck bodies etc Page 29

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•

4.

- Chock machinery and equipment to prevent unplanned movement.

Do not use auxiliary devices for isolation e.g., push buttons, control circuit devices, emergency stop buttons, key-switches, conveyor lanyards, etc. except where these remote isolator devices control an approved (to relevant Australian Standard) whole of current isolation device e.g. Motorised lanyard controls on conveyors to AS1755.

Apply Personal Danger Tags / Locks, or Permit Danger Tags / Locks • •

•

A Personal Danger Tag or lock is to be placed on the appropriate isolation point/s by a competent person.

In the case of a permit: - a Permit Danger Tag / Lock is to be placed on the relevant isolation point/s by the Authorised Isolator after the Permit Holder has raised the appropriate permit - All members of the work party shall sign onto, or attach their Personal Danger Tag or lock to the appropriate permit after checking the work they are performing is covered by the Permit.

Any visitor requiring to place a Personal Danger Tag or lock or sign onto a permit can only do so under direct supervision of a competent person or Permit Holder

NB. Depending on the circumstances, it may be necessary to reverse steps 4 & 5 eg.

When access to switchboards is necessary for verification purposes and a tag or lock will prevent entry.

5.

Verify the effectiveness of the isolation All isolations must be checked to verify the isolation has been effective by: •

Testing the test equipment is in good operating condition and is set to correct scale eg.

Pressure gauges, non-contact voltage detector multi-meters etc • Checking the operation of test equipment before and after isolation • Test the isolation has been effective by: Checking for the presence of voltage for electrical isolations Attempting to start the equipment. Eg. mobile equipment/machinery Opening valves in pipelines Confirming secondary energies are secured eg. Chocks etc.

Check for test methods that may have been developed and approved for use for various isolations.

6.

Commence Work • •

Carry out the required tasks.

Monitor work area for any new introduced hazards

7.

Complete Work

8.

Check Work

• • •

9.

Complete all tasks related to the isolation.

Review all work that has been carried out to confirm the work-area has been left in a safe condition e.g. Guards and covers are back in position etc.

Attach an Out of Service Tag to the plant or equipment isolation point if it is not safe or ready for service.

Clear Area • •

Ensure all persons working on the affected plant or equipment have completed their tasks and are clear of the work area.

Confirm area associated with restoring energy has been cleared i.e. remove rubbish from rotating parts, roll up hoses, removal of spare or replaced parts etc.

10. Remove Personal Danger Tags / Locks, or Permit Danger Tags / Locks •

Rev 1

Remove Personal Danger Tags / Locks associated with the work being done. Each person to remove only their own Personal Danger Tag / Lock.

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• •

In the case of a Permit, each individual is to sign off all permits, or remove Personal Danger Tag / Lock, associated with the Permit. The Permit Holder may then cancel the Permit.

Visitors may only remove their own Personal Danger Tags / Locks or sign off a Permit under the direct supervision of a Competent Person/Permit Holder.

11. Restore Energy • •

Advise all relevant or affected parties of your intention to restore energy.

Restore energy to the plant or equipment in accordance with the operation’s energy restoration procedures.

12. Check Operation • • • •

Rev 1

Tests run the plant or equipment to confirm that the work carried out has been successful and that the plant or equipment is operating normally.

Attach an Out of Service Tag to the plant or equipment isolation point if it is not safe or ready for service, or testing is required using approved procedures.

Attach an Information Tag if required Fill out shift report of status and works completed and communicate details of work undertaken to all relevant persons.

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Auger Safety Stops Before commencing work near or under auger head - fit head stops as shown in photo. Stops (L) (R) is carried on board machine.

1.

•

Also isolate main circuit breaker, traction, conveyor and cutter breakers and tag prior to working in this area. Procedure for fitting head stops are as follows: Isolate cutter circuit breaker – conveyor circuit breaker – traction circuit breaker NOTE:

• • •

Control

Operations

for

With an operator by your side, start the machine, lower the gathering head to the floor and raise the auger head to a suitable height to fit stops.

Carefully slide stops into cutter head areas Left and Right hand sides.

With Miner still running slowly lower auger head onto the manufactured stops ensuring to take the weight of the auger head.

WARNING:

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Refer to Mines Remote Continuous Miners.

Isolate Miner as per Mines isolation procedures.

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Auger Safety Support Pins

Auger Stop Positions

Handle and Locking Plate for Safety Support Pin.

Side View

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Conveyor Stop Before commencing work in or around conveyors ensure the conveyor stop bar is used. Ensure conveyor is rested on conveyor stop before any work is commenced. Also isolate and tag machine prior to any work in this area. Procedure for fitting conveyor stop is as follows: • Isolate CONVEYOR, CUTTER head and TRACTION circuit breakers.

• With operator by your side, start the machine NOTE:

• • •

Refer to Mines Remote Control Operations Continuous Miner – RCCM rev.doc.

Raise the conveyor to a suitable height to slide the stop horizontally (3.3).

Check that the sliding bolt is secure and locked into place.

Lower the conveyor onto stop.

WARNING:

Isolate Miner as per Mines Isolation Procedures.

Position of the pin while supporting the conveyor.

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General Maintenance Maintenance and the Continuous Miner The continuous miner is inherently subjected to a severe working environment. Keeping the miner productive in these conditions requires an ongoing dedicated preventative maintenance program.

Such a maintenance program includes: • Thorough inspections • Periodic adjustments • Proper scheduled lubrication • Accurate maintenance and repair records which are available on the working section.

• Routine servicing of the various systems on the machine, i.e., hydraulic, electrical, mechanical systems.

While most mines have underground maintenance personnel trained to care for the equipment, the continuous miner operator is in the best position to monitor the machine’s performance and its condition on a regular basis. He must be properly trained to monitor constantly specific areas of the machine for developing trouble. For example: • Missing or worn cutting bits and bit holders. The cutting head takes major punishment during mining, and the cutting bits and their holders are at the front of this action. Worn cutting bits will impact cutting productivity, while missing bits or bit holders will induce vibration to the cutting head and the miner which can damage the pivot, hydraulic cylinders and even electrical components mounted on the miner chassis.

• Low oil levels in gear boxes. All gear boxes on the 30MB3 miner have either oil level sight gauges or oil level check plugs which facilitate checking oil levels. These essential checks should be made each shift whether by trained maintenance personnel or the operator himself. Where visible, the external areas of gear boxes should be inspected for signs of leaks.

• Low hydraulic oil. Whilst the 30MB3 miners have their hydraulic suction pipe located optimally at the bottom centre of the hydraulic oil reservoir, a major hydraulic oil leak could soon result in pump cavitation and damage. The oil level in the main tank should be checked daily and topped off as necessary. The operator is in the best position to detect significant hydraulic leaks.

• Improperly adjusted chains. The 30MB3 miner uses constant hydraulic pressure tensioning devices to maintain proper tension on the conveyor chain.

• Unusual noises. The operator must be aware of unusual noises from gear boxes or electric motors which could be a sign of impending failure.

• Dirt and debris accumulation. The operator should keep his miner as clean as is practical of dirt and debris. Heavy rock slabs falling off the roof should be cleared with a pry bar to prevent them from slipping off the miner and causing serious injury to nearby personnel, or falling into the conveyor and causing a jam. Wash down hoses are available on each side of the miner for use in washing off lesser debris and dust. Keeping dirt and debris from accumulating is the best way to be able to spot leaks or other signs of trouble.

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Torques It is important that all cap screws be tightened as specified in the maintenance procedures, diagrams, or the torque chart in Table 2-1.1 in this manual, and in assembly drawings shown in the Parts Book. Special tightening torques as noted in the text or shown in the illustrations should be maintained. Any specific torque information given in these sections regarding the maintenance of a component manufactured by a company other than BUCYRUS AUSTRALIA and installed on this machine shall prevail for that particular component. If a specific torque is not found, consult with your local BUCYRUS AUSTRALIA representative.

Table 2-1.1 Recommended Torque Values for Fasteners Commonly Found on 30MB3 Miners

Fastener

Grade 2

Grade 5

Recommended Torque

No Washer

No Washer

Washer

No Washer

Washer

No Washer

Washer

1/2-13

Tightening Torque, ft-lb

49

57

80

57

114

89

118

5/8-11

Tightening Torque, ft-lb

98

116

161

116

226

172

236

3/4-10

Tightening Torque, ft-lb

93

196

261

196

392

302

416

7/8-9

Tightening Torque, ft-lb

150

333

420

333

646

490

675

1-8

Tightening Torque, ft-lb

225

498

595

498

970

734

1010

1-1/8

Tightening Torque, ft-lb

318

720

842

720

1370

1055

1430

1-1/4-7

Tightening Torque, ft-lb

450

980

1190

980

1940

1470

2020

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Grade 8

Socket Head

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Duo-Cone Seals Duo-Cone seals consist of a pair of matched sets. Each set is made up of a metal seal ring and a rubber toric (see Figure 2-1.1).

The special seal rings are precision lapped to ensure positive sealing at the mating surfaces. The torics position the seal rings and furnish the floating action that allows for shaft deflection and end play. They also provide a constant sealing face pressure, seal the back sides of the sealing rings to adjacent parts, and transmit the force needed to turn one metal ring, while holding the other stationary.

The faces of the mated sealing rings form a sealing band 0.8 mm (1/32”) wide that retains the oil lubricant and keeps out dirt. As wear occurs, the contact band broadens, moving slowly inward until the inside diameter is reached. Thus, a simple visual check will show the amount of remaining life.

Mating Pairs Duo-Cone seals must always be installed in mated pairs, two new seals together or two seals that have previously run together. Never assemble one new seal and one used seal together, or two used seals that have not previously run together.

Handling Proper handling and installation of these seals is vital to get maximum life and positive sealing protection given by these precision units.

Figure 2-1.1 Duo-Cone Seal Components

Special attention was given during shipping to ensure absolute cleanliness. For maximum service, keep seals clean during installation and when filling with oil.

Housing Preparation The housing components that contact the rubber toric rings (3 and 4) must be free from foreign material (oil, grease, dirt, metal chips, dust or lint particles, etc.) before installing the seal. This should be done with a lint-free wipe and a nonpetroleum based solvent. Dry with a clean wipe.

Figure 2-1.2 Preparation

Seal Preparation Remove any foreign material from the rubber torics (2) and the ramps (7) and lips (8) of both seal rings. This should also be done with a lint-free wipe and a non-petroleum based solvent. Dry with a clean wipe.

Place the rubber torics on the metal seal ring at the bottom of the seal ring ramp and against the retaining ring (see Figure 2-1.2). Make sure the rubber toric is straight on the seal ring and not twisted. Be careful not to nick or cut the torics during this assembly, as this can cause leaks.

Put the installation tool onto the metal seal ring and rubber toric (see Figure 2-1.3). Lightly dampen the lower half of the rubber toric with the appropriate assembly lubricant.

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Figure 2-1.3 Lubricating the

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Techniques to dampen the toric include wiping with a lint-free towel, lubricating using a clean foam brush, or dipping in a container lined with towels saturated in the assembly lubricant (see also Figure 2-1.3).

Approved Assembly Lubricants* Isopropyl Alcohol** Houghton-Grind 60 CT Quaker® Solvo Clean 68-0 (*) do not use Stanosol or any other liquid that leaves an oil film or does not evaporate quickly. (**) all applicable safety and disposal guidelines for flammable liquids must be followed.

Installation Process With the lower half of the rubber toric seal still wet, use the installation tool to position the seal ring and the rubber toric squarely against the housing (see Figure 2.1.4). For smaller diameter seals, use sudden and even pressure to push the rubber toric under the retaining lip of the housing.

For larger diameter seals which will not press in with sudden and even pressure, it is acceptable to work the toric past the retaining lip by starting on one side and tapping the opposite side of the installation tool with a Figure 2.1.4 Seal Installation rubber mallet until it is engaged past the retaining lip of the housing.

Check the assembled height (A) (see Figure 2-1.5) in at least four places, 90o apart, using a caliper, tool makers’ rule or any other calibrated measuring device.

The difference in height around the ring must not be more than 1mm. If small adjustments are necessary, do not push or pull directly on the seal ring. Use the Figure 2-1.5 Checking the Installation installation tool to push down and your fingers to pull up uniformly on the rubber toric and seal ring.

The rubber toric can twist if it is not wet all around during installation or if there are burrs or fins on the retaining lip of the housing. Twists, misalignment, and bulges of the toric will result in seal failure. If correct installation is not obvious, remove the seal from the housing and repeat the process.

The rubber torics must never slip on the ramps of either the seal ring or the housing. To prevent slippage, allow adequate evaporation time for the lubricant before proceeding with further assembly. Once correctly in place, the rubber toric must roll on the ramp only.

Wipe the face of each seal ring using a lint-free wipe. No particles of any kind are permissible on the sealing surfaces. (Even a hair can hold the seal surfaces apart and cause a leak.) Apply a thin film of oil on the entire seal face of one or both seals using a clean finger or a lint-free applicator.

Oil must not contact surfaces other than the sealing faces.

Final Assembly While completing the assembly of the unit, make sure that both housings are in correct alignment and are concentric. Slowly bring the two housings together. High impact can scratch or break the seal components.

If the rubber toric slips at any location, it will twist, causing the seal rings to cock. Cocked seals create uneven pressure on the seal faces, resulting in galling, scoring and leakage. Any wobbling action can cause dirt to enter by pumping mud past the torics.

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Maintenance Guidelines Mechanical maintenance requires you to know your machine and be ready to perform correct servicing when needed. This includes several factors.

Use the proper procedure Consult this manual, the parts book, operators and your BUCYRUS AUSTRALIA Australia representative as often as needed to be sure maintenance is done right. They will also alert you to any special conditions or hazards that may arise during a procedure.

Exercise safety precautions at all times Every effort has been made to be sure that the manual covers major hazards that arise during a procedure, but it is not comprehensive. Common sense is needed.

If you work under an elevated component, be sure the lifting device - whether hydraulic cylinders, a make-shift block and tackle, or a jacking device - works properly, is secure, and correctly positioned.

Do not ever position yourself under an assembly until it is also securely blocked. Failure to do this could result in loss of life.

Practice sound disassembly and assembly methods Be sure the tools you need are available. Set the miner so that your work area is easily and comfortably accessible. Be sure help is available.

Disassemble in correct sequence, according to the manual or the instructions of the BUCYRUS AUSTRALIA Australia representative. Cover removed parts and lay them out neatly for reassembly.

During disassembly, take care of parts intended for reuse. As strip down progresses, inspect each part for wear or damage. Pay particular attention to failed components for cause. Determining what failed and why may show how to fix the problem and prevent more failures.

When reassembling, again follow the steps recommended by BUCYRUS AUSTRALIA Australia.

Be sure that proper tolerances, fits, and clearances are followed. Bearing end play, bearing preload, tooth patterns, and gear back lash should all be correct and to specifications. Be sure that reinstalled or newly installed parts are correctly lubricated before they are put on.

During reinstallation, particularly at the very end, be sure that the end cap screws just installed are all tightened to proper torque. You should recheck fastener torque after the first 40 hours of operation. Do this a few times until the fasteners are 'set', and then every six months.

The time factor in repair is usually critical, especially for unscheduled maintenance. All mines try to get machinery into production as soon as possible; but this should not be done by sacrificing quality of maintenance.

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Have the proper tools available for the job Tools that may be needed for mechanical service include:

Socket set w/ratchet.

Extensions, adapters, and universal joints.

Crescent and spanner wrenches.

Allen wrenches various sizes.

Various hammers (including soft hammers to change bits) Extension ("cheater") pipes - drift pins and pry bars.

Bearing puller.

Portable hydraulic tools.

A lifting device or set-up.

Channel locks pliers.

Internal snap ring pliers.

External snap ring pliers.

Special tools required.

Plenty of rags.

If any gear cases are being serviced, also include:

Feeler gauges.

A micrometer.

Dial indicator for backlash.

Various screwdrivers.

Proper gear oil.

If the problem is electrical, include the following:

Rev 1

Multimeter compatible with miner voltages.

Various test leads.

Insulated materials.

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Bearing and Gears Cleanliness Try to prevent chips or dirt from getting between the bearing face and the shaft or housing shoulder. Contamination keeps the bearing from seating properly. The dirt may then work out and cause the bearing to work back against the shoulder, resulting in too loose bearing adjustment.

Chips or dirt on one side of the shoulder could cock the bearing on the shaft, causing a misaligned condition similar to an off square shoulder.

Keep Clean – Keep Dry Bearings are originally packed in cardboard cartons, tubes or spiral wrapping at the factory to give the proper protection against dirt and moisture. Leave bearings in these containers and store in a clean, dry place until ready to be used. Bearings should not be removed from cartons and left in open trays, pans or in open cabinets exposed to dirt, dust or moisture.

You need not wash new bearings to remove the slushing grease put on at the factory for rust protection. This grease has little lubricating value, but it will not harm to the lubricant used in the bearings.

In special cases, you must wash bearings before assembly because they become dirty. Use a clean solution. Cover bearings with a lubricant as soon as possible after washing to prevent rust.

Bearing Assembly Methods Bearing cones and cups can be assembled in many ways. Smaller bearings can be pressed or driven onto shaft or into housings. Bearing cones can be heated and shrunk onto shafts. Cups can be frozen and contracted to slip into housings easier.

Proper bearing operation hinges upon correct mounting. With any method used, seven factors should be remembered.

1. Mount in a relatively clean environment. Dirt and debris affect internal clearances and fits. Dust can keep two mating surfaces from being tight, causing out-of round bores. Dirt on a shaft contact area can cause seal wear. Debris mixing with gear oil forms a lapping compound that wears the bearing. Keep the bearing in its container until ready to mount it.

2. Do not drop or roughly handle the bearings.

3. Do not subject bearings to sudden, large temperature changes. This could cause condensation onto the bearing surfaces.

4. Do not handle them more than necessary. Fingerprints can be a starting point for rust.

5. When installing, be sure the cone or cup is solidly seated against its shoulder. After the part has been pressed, shrunk, or cooled on, check with a thickness gauge to make sure it is properly seated.

6. Be sure the bearing being installed is O.E.M. This ensures that an exact duplicate is put on.

Bearings and shafts are designed for each other, and changes can cause failure, loss of warranty, and extended downtime.

7. Be sure the bearing fit is not too loose or too tight. A loose bearing will creep, slip and cause it to overheat and be subjected to abrasive wear on the bore or shaft. On a tight bearing, the inner ring of the cup will be stretched to where there is no room for the rollers or balls to revolve freely.

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Assembly Methods There are generally three basic methods to mounting bearings - cold mounting, temperature mounting, and hydraulic mounting.

Bearings up to 4" (102 mm) in diameter can be cold mounted, using a sleeve and a hammer or press. Soft-metal hammers, while less likely to cause damage, have a tendency to chip and send metal flying into the bearing.

The end faces of a driving sleeve should be flat, parallel, and free of burrs. The bearing seating on the shaft and in the housing should be lightly smeared with thin oil.

Micronized Graphite for Bearing Assembly Micronized graphite can be used on shafts, cone seats, and in the cone bores to help the assembly and removal of bearing cones on the shaft. Considerably less pressure is needed to press on a cone if micronized graphite is used. Removal is easier too, since it reduces or eliminates oxidizing on the cone seat (fretting corrosion).

Drivers for Bearing Cups and Cones Drivers should be used wherever possible to assemble cups and cones. They save time, ease installation by driving/pressing cups onto cones straight, prevent damage to bearing cages and nicks in bearing parts, and in general assure better assembly.

Do not damage the cage of the bearing cone by pressing or driving against it. This will distort and loosen it. Distortion causes skewing of the rollers and early failure of the bearings. Loosening the cage will cause cage and rollers to fall off the cone.

Drivers can be hardened for longer life. If they are not available, mild steel bars can be used, although they are not preferred. Use mild steel, not hardened drifts or brass bars. Hardened bars damage the bearing. Brass will chip easily and get into the bearing or behind the bearing face, preventing it from becoming seated against the shoulder.

When bars are used as drivers, see that they are tapered to clear the bearing cage, and hit only against the bearing race.

Heating Bearings Temperature mounting is done by one of three ways:

Heating one part Cooling one part Heating one and cooling another

Heating is recommended for larger bearings. Cooling is suitable for any size, straight or tapered, although if temperature mounting is to be done to smaller assemblies, cooling is preferred. Be absolutely sure that no bearings are ever heated over 135o-150oC (275°-300°F). If they are, they will begin to draw, or soften.

Heating in Oil This method is common. Before heating, the oil and the container should be clean. Quenching oils with a minimum flash point of 150 C (300 F) should be used. The oil quantity should be large in relationship to the bearing being heated. A smaller volume heats and cools too rapidly. Where oil is heated in a pan or metal container over an open flame, there should be a screen on which the bearings will rest. It should be raised an inch from the bottom of the pan.

The bearing must not rest on the bottom, since heat would be transferred directly from the flame through the pan to the bearing. This temperature will be very high and will draw the bearing. A wire rack can be installed about 3" from the bottom. This will keep the bearing away from the direct heat, and also out of contamination. Another method is to suspend the bearing in the bath.

Once the bearing is heated, wipe the bore clean, place the assembly immediately on the shaft, and lock it in place. If there is no locking device, use a mounting tool to hold the inner ring in place until it has cooled. Oil baths are not recommended for sealed bearings.

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Induction Heating Induction heating is not recommended. Surface temperatures will get too high and draw the bearings.

WARNING:

When bearings are heated for assembly, the part heated should be checked after cooling to see that it is seated properly against the shoulder. Bearings have a tendency to pull away from the shoulder

Freezing/Shrinking Bearing Cups Where cups are to be assembled in housings with a press fit, they can be shrunk in a deep freeze unit or an alcohol bath cooled with dry ice. In some cases, you must also heat the housing to get the cup to slip into place readily.

Tapered Rolling Bearing Adjustment The accurate location and mating of rotating parts depends on the internal running clearance and stability of the support bearings. Running clearance of tapered roller bearings can be readily adjusted to meet a variety of operation conditions. This is through the axial adjustment of either the cone (inner race) or cup (outer race).

Proper initial adjustment should compensate for thermal changes and/or deflections produced by normal operation. Tapered roller bearings operate well over a relatively wide adjustment range.

The optimum initial bearing adjustment results in an operating adjustment of almost "metal to metal", or no appreciable end play within the bearings.

WARNING:

Again, check a heated bearing for assembly after cooling for proper shoulder seating.

Though the surface hardness of bearings resists abrasion, dirt in the lubricant speed up wear. After long periods of operation, this wear increases running clearance and causes a loss of the original adjustment. The adjustable feature of a tapered assembly allows readjustment to compensate for this condition. This increases life to bearings, seals, gears, and other rotating parts.

These general recommendations for adjusting tapered roller bearings cover most applications.

Thermal Expansion Thermal expansion reduces end float. As a bearing rotates, heat is generated, causing successive thermal expansions. Usually the cone and roller assembly expands first, followed by the cup. When the cup is in a rigid housing with a tight fit, it cannot expand until the housing itself heats and expands.

In a typical gear drive or transmission, the operating temperature of the cup is lower than the cone and roller assembly. This is due to the cooling effect of the housing, since normally it can more effectively dissipate heat than can the shaft on which the cone is mounted.

Under operating conditions, the component parts of the bearing do not expand uniformly. When a single-row tapered roller bearing is used at each end of a shaft, consider the axial expansion of the shaft and housing in determining the proper initial bearing adjustment.

Lubrication is important in the thermal characteristics. Bearings rotating at high speed partially or completely submerged in oil may cause a high degree of heat from their churning action in the lubricant.

Bearings usually are first adjusted with slight running clearance or end float. On applications such as gear cases, initial end float will be about .001" to .003" (.025 - .076 mm) on the small sizes and proportionately greater as the bearings size increases. Generally, running bearings at higher speeds and temperatures increases the amount of initial end float or running clearance required.

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Torque for Zero End Play The following recommended procedure for adjusting tapered roller bearings is usually used. Pull up on the end cap or bearing cup carrier, or end plate, without shims in place, until bearings bind slightly in rotation. Then the gap between the cap flange and housing or the end of the shaft, can be measured with a thickness gauge. The measured gap plus the end float desired will give the total shim pack required.

Another good way is to put a lead wire where the shims go and then pull up until all end float is taken up. The wire, which has to be larger than the original gap, is then flattened and can be measured with micrometers and the shim pack made up in the same manner as when thickness gauges are used. The shaft should then be tapped with a hammer so that the adjusted bearing member (cup or cone) is likewise backed off and seated against the adjusting device.

Where large tapered roller bearings are adjusted, it may be hard to manually feel when a "metal to metal" setting is reached. In such cases, a simple torque measuring device is commonly used.

With this method, as the bearings are being adjusted, an increase in bearing torque can be detected which indicates that a close setting has been reached.

Do not confuse this torque with torque generated by gears and seals. When bearings are being set for desired initial end float, check the axial movement of the shaft as the bearings rotate. Rotating bearings ensures that the rollers will align and seat against the cone rib, resulting in a true end float measurement.

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Bevel Gear Adjustment Bevel gears connect perpendicular shafts. Alignment of bevel gears is more critical than that of spur gears or helical gears. An adjustment on all bevel gear sets corrects any tooth contact errors.

Bevel gears run with a localized tooth contact as shown in the figure. Since the area of contact does not cover the whole tooth, slight tolerance in positioning the gears, and some displacement under normal loads is possible without concentrating the loads on the ends of the teeth.

Regarding tooth contact pattern, the contact length is usually about half the tooth length and toward the inner end of the tooth (small end). Under a heavy load, the tooth contact will spread out and shift toward the heel (large end of tooth). The resulting contact is called "central toe contact."

The figures below show examples of recommended tooth contact patterns for straight bevel gears.

Also shown are typical examples of incorrect contact patterns due to errors in gear assembly and the changes necessary to correct them. To check tooth pattern, paint gear teeth with a gear marking compound, and run gears briefly under light load two or three revolutions.

NOTE:

Rev 1

A mixture of marking compound and spindle oil is good lube for the gears under light loads for 2-3 revolutions only. Check tooth patterns all round to make sure the pattern/markings are uniform.

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Lockwiring Fasteners Single Wire Insert the wire through the fastener from inside the bolt circle toward outside the bolt circle, advancing in clockwise direction.

Wired In Pairs Establish the left and right hand fasteners as viewed from centre of the bolt circle. Insert left hand fastener from inside to outside of the bolt circle. Insert the right end of the wire through right hand fastener from outside of the bolt circle.

Special Fasteners Various types of self- locking bolt and nut fasteners are in use. They are to be used in the same manner as standard fasteners with regard to tensile strength and torque; but they provide better locking qualities and reduce the number of parts used in fastening. Most special fasteners, once used, should not be re-used because of the locking material retention limitations.

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Self-Locking Screws This socket head screw has a number of threads with wide, offset sections, which produce the selflocking effect by causing a high friction bind against the matting threads. This type fastener is identified by a triangle at the base of the socket. Because of this self- locking feature, the use of washers is usually not necessary. It is suitable in assemblies subjected to high vibration.

Installation Recommendations 1. The self- locking screw is generally used where measured torque is required. When this is specified, hand wrench only - do not power wrench. This is to obtain an accurate reading and not due to structural limitations of the screw.

2. The top performance of this screw is reduced with each use. Re-use of this fastener should be limited to twice.

3. For assemblies that need shims with self- locking screws, establish the shim set using standard fasteners. For final assembly remove the standard fasteners and install the self- locking type, then torque down as required.

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30MB3 Serial No.177866 Mechanical Maintenance Manual

Locknuts Locknuts reduce use of (but do not replace) cotter pins, jam nuts, lock tabs and safety wire. These others are usually better used, in certain cases where permanent fastening is required, or in areas inaccessible or hidden after final assembly.

Locknuts with nylon or fibre inserts should not be re-used. A locknut with unlimited reuse contains a spring steel lock ring in the head. The locking feature is an elliptical insert, which is permanently bonded to the nut Installation Recommendations 1. Be sure bolt or stud has a 35-45 degree chamfer on threaded end and the end is flat. The flat diameter should be 1/32" below root diameter of thread on bolt or stud. These features are necessary to allow the lock ring to thread on for maximum grip without damage.

CAUTION:

Do not power wrench the lead thread of the lock ring insert until it is engaged by hand turning. Then tighten normally.

2. Make sure the bolt or stud threads extend at least 2 1/2 threads beyond the top of the insert, as shown in the figure.

NOTE:

Anti-seizing compounds may be used with this type of locknut.

Washers are not normally required here, but if assembly does, include them; they are needed due to high stress torque.

Component Substitution When parts need changed, O.E.M. equipment is totally recommended. This includes less obvious components such as hydraulic hoses, couplings, and valves, as well as the more obvious ones such as relays, gears, and torque shafts. Components not meeting specifications can fail, cause serious injury, and damage equipment.

WARNING:

Do not substitute materials or compounds not complying with OEM. Use of non OEM supplies may void warranty.

When performing maintenance on the machine, remember that fabrication, installation, modifications or adjustments must be according to O.E.M. specifications (See Product Warranty in Preface) WARNING:

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Not meeting OEM conditions can cause serious injury, damage equipment and void warranty.

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Safety Maintenance Proper service and repair is important to the safe, reliable and productive operation of the 30MB3 continuous miner. The maintenance procedures recommended by BUCYRUS AUSTRALIA and described in this manual are effective methods of performing maintenance operations.

CAUTION:

It is important to note that some statements against using some maintenance procedures that can damage the machine render it unsafe for operation, or cause physical danger to working personnel, are stated in this manual. These statements are neither exhaustive nor complete, and it would be impractical for BUCYRUS AUSTRALIA to attempt to produce such a complete document of warnings and cautions. Anyone who uses a maintenance procedure or tool which is not recommended by BUCYRUS AUSTRALIA must first satisfy himself that neither his safety nor machine safety will be jeopardized by the maintenance methods he selects.

Certain dangers common to performing maintenance on continuous miners are emphasized in this manual. Typically, they involve working under major components which include • • • •

the cutting head the gathering head the conveyor the stabilizer shoe

and which are supported and activated by hydraulic cylinders. A worker should never rely on the locked-in hydraulic pressure of a cylinder to maintain its position, and his own safety, because unexpected leaks or other maintenance work could cause this pressure to be lost unexpectedly and result in serious injury or loss of life. The cutting head, gathering head and conveyor should each be blocked securely in their raised position if work is to be performed under them.

Likewise, when the stabilizer shoe is used to raise the rear of the miner for maintenance, the miner chassis should be blocked securely in its raised position before working around it.

Two other examples related to hydraulic pressure are the constant-pressure take-up cylinders maintaining tension on the conveyor chains. When the miner is shut down, circuit pressure remains locked in these cylinders. If a worker should attempt to undo a fitting in the hydraulic circuit, the sudden release of this pressure could cause injury. The circuit has either a needle valve or a vent which can be used to release pressurized oil before performing maintenance.

Specific warning plates are attached to 30MB3 miners to alert personnel to these dangers.

General Description The cutting head assembly of the 30MB3, shown in Figure 5.1, is powered by two 175 kW AC electric motors mounted either side of the centre axis of the cutting head support frame.

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L.H. CUTTER MOTOR

R.H. CUTTER MOTOR

CUTTING HEAD FRAME

Figure 5.1 The drive arrangement for the cutting head is shown in Figure 5.2. Each motor drives through a torque-limiting clutch to an input gear case, which in turn drives a main gear case in the drum. The two input gear cases drive a common shaft, allowing the two drive motors to share the cutting load.

Each input gear case is removable as a separate unit from the main cutting head gear case.

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R.H. CUTTER MOTOR TORQUE-LIMITING CLUTCH

INPUT SHAFT

CUTTING HEAD FRAME COMMON DRIVE SHAFT

R.H. INPUT GEARCASE

Figure 5.2 The cutting final drive is shown in Figure 5.3.

Figure 5.3 The cutting head is attached to the main frame at a heavy-duty pivot (see later Figures 5.21 and 5.22). Two double-acting hydraulic cylinders raise and lower the cutting head.

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Removal of Cutting Drums

Figure 5.4

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Pull In Drum Removal

Weight of Pull In Drum 500 Kg TOOLING REQUIRED 5/8’” A.F. Allan Key or 1 Tonne Lifting Gear (Chain block or pull lift) Sling 3 metres long x 2 General Tools, hammers, chisels, shifters, pliers, etc 3 – Long threaded ¾” UNC bolts for Jacking off drum Electrical Tape 1-2 rolls

Figure 5.5 1.

Place the miner so the front can easily be reached and there is side clearance to pull the end drums off one or both ends of the cutting head.

2.

Lower the cutting head to a comfortable work height, and block it so the drums can be removed without affecting the supports.

WARNING:

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Inadequate or improper support while this work is performed can cause serious injury of death.

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3.

Remove all power from the machine and trip all circuit breakers to "OFF".

WARNING:

Isolate machine as per mines isolation procedures.

CAUTION:

Ensure when removing the 6 off retaining bolts (3/4” UNC x 3 ½” long – see figure 5.5) from the retaining flange. With caution, pressure may build up.

WARNING:

Trapped air pressure from drums being retracted, MUST be removed before total withdrawal of mounting bolts.

WARNING:

Ensure to remove any Residual Hydraulic pressure that may be behind the following retaining flange (point 4), before proceeding from this point forward.

4.

Remove the six (6) ¾” UNC x 3-1/2” nylock socket head cap screws from the centre flange of the outer pull in assembly and remove retaining flange. See Figure 5.5. (See Notes, Cautions and Warnings above).

5.

Match mark the pull in drum with the drive drum and the banjo arm section for re-assembly.

This is to ensure correct pick block lacing.

6.

Secure drum with lifting devices.

NOTE:

Before the next step, ensure that the lifting devices have adequate tension of the drum.

7.

Remove twelve (12) ¾“UNC x 3” nylock socket head cap screws from outer pull in assembly.

See Figure 5.5.

8.

Remove the three (3) ¾” x 1” nylock socket head cap screws from the three (3) jacking holes. See Figure 5.5.

9.

Proceed to remove the pull in drum assembly from the cutting head via the three jacking threads.

10.

Repeat steps 4 through 9 to remove the opposite side.

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Pull In Drum Assembly 1.

With machine in the same position as pull in drum removal and machine still isolated as per mines procedures position pull in drum for reassembly.

WARNING:

2.

Isolate machine as per mines isolation procedures.

Secure drum with lifting devises used for removal.

WARNING:

Before next step ensure that lifting devices have adequate tension on the drum.

3.

Using lever bars turn cutter head to line up the match marks and four keys in the fixed drum with the four long keyways in the pull in drum. Electrical tape may be useful in holding the keys in place.

4.

Slide pull in drum into position lining up the match marks.

NOTE:

If no match marks are on drum being fitted looking across the cutter head line up the pick blocks on the other side drum. Check for welded arrow matchmarks.

5.

Using new retainers start all 12-¾” x 3” long nylock socket hex cap screws. See Figure 5.5.

6.

When all 12 socket hex cap screw are started in tapped holes torque to 416 ft lbs or 564 Nm.

7.

Replace centre retaining flange and start (6) ¾” x 3½” long socket hex cap screws and torque to 416 ft lbs or 564 Nm.

8.

Clear area of all tools parts and debris.

9.

Remove isolation tags as per mines procedures.

10.

Restore power to miner as per mines to re-power procedure.

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Drive Drum Removal TOOLING REQUIRED - General tools hammers, chisels, shifters, pliers etc - ½” AF Allen Key or ½” drive in hex socket - 5/8” AF Allen Key or ½” drive in hex socket - 3/8” UNC sliding hammer - 2 tonne lifting block (chain block or pull lift) - Porter Power and Jack

Figure 5.6

1.

Place the miner so the front can easily be reached and there is side clearance to pull the end drums off both ends of the cutting head.

2.

Lower the cutting head to a comfortable work height, and block it so the drums can be removed without affecting the supports.

WARNING:

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Inadequate or improper support while this work is performed can cause serious injury or death.

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3.

Remove all power from the machine and isolate all circuit breakers to "OFF".

WARNING:

Isolate machine as per mines isolation procedures.

4.

Follow steps 4 through 9 of pull in drum removal.

5.

Remove pull in retainer and its six (6) 5/8” UNC x 2 ½” nylock socket head cap screw.

Ensure that the entire shim pack stay with the retainer. See Figure 5.6.

6.

Remove drum pull in adaptor plate.

7.

Remove eight (8) ⅝” UNC x 2½” socket head cap screws from drive drum retainer.

8.

Remove drive drum lock tube and extension cylinder Figure 5.6. Ensure that the entire shim pack stay with the lock tube.

9.

Remove double seal carrier using 3/8” UNC sliding hammer. It is possible to leave this retainer in place as it will not hinder the removal of the drum.

10.

Secure drive drum with lifting device.

NOTE:

Before the next step, Ensure that the lifting devices have adequate tension of the drum.

11.

Proceed to remove drive drum. You may require a porter power and jack to start the removal of the drum initially.

12.

Repeat steps 4 through 8 for opposite side.

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Drive Drum Assembly 1.

With the machine in the same position as the drive drum removal and the machine still isolated as per mines procedures position drive drum for reassembly.

WARNING:

2.

Secure drive drum with lifting devices used for removal.

NOTE:

3.

4.

Isolate machine as per mines isolation procedures.

Before the next step, Ensure that the lifting devices have adequate tension of the drum.

Using lever bars turn cutter head to position the match marks on the female spline to the top. Match marks are a small drill hole in spline tooth or welded arrows on the drums.

Check the (O ring 1/8 x 1-7/8 inch OD) on the drive drum retainer and replace if damaged.

Check 2off O rings (1/4 x 9-1/2 inch OD) on splined shaft and replace if damaged. Fit the splined shaft into the centre of the female spline lining up the match marks. Push into the splined shaft into the drum.

5.

6.

Secure strut arm with lifting devices used for removal.

Using a FBL or LHD fitted with a jib thread the strut arm along the splined shaft taking care not to damage the rotating seals or O rings on the splined shaft.

7.

Push the arm into place until the mounting holes of the arm line up with the holes in the cutter head support frame. Insert a couple of 1-1/4 inch by 12 inches long mounting bolts and start the nuts.

8.

By now the 2off 1-1/4 dowels should be close enough to drive the dowels home using a hammer. When the 2off dowels are fitted the rest of the mounting bolts can be fitted and torqued. Use antiseze or simular compound on the bolts and torque the 1-1/4 inch bolts to 1455Ft Lbs or 1974Nm. (this is allowing 25% decrease for using antiseze)

9.

10.

Using suitable slings prepare drive drum for assembly.

Secure the drive drum assembly to the jib lining up the matched marks on the spline or the barrel.

Looking through the splined bore of the drive drum line up the spline tooth closest to the matched marks and push drum onto the spline.

Prepare drum / cylinder retainer for fitting. NOTE retainer is to be fitted without the cylinder to determine shim pack to be fitted.

11.

12.

13.

Assemble the retainer tube using the solid shim originally supplied with assembly adding more shims to allow lead reading to determine shim pack to be used with the retainer.

Position lead wire onto the face of the splined shaft. This can be done using Silastic.

14.

Fit cylinder lock tube, start 8 off 5/8” x 2-3/4“ long SHCS. Taking care not to dislodge any shims torque to 236 ft lbs or 320Nm.

15.

To check lead readings remove the cylinder lock tube.

16.

Using micrometers measure thickness of squashed lead wire and the shimpack including the solid steel shim.

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17.

18.

19.

Subtract the measurement of the lead wire from the total measurement of the shimpack. Eg if shim pack including the solid steel ring is .175 inches and the lead wire is .025 inched the result would be .150.

To preload the assembly the required .005 to .007 inches you will add between .005 and .007 inches to the .150 inches. The shimpack to be fitted under the retainer would be .155 to .157 inches.

Fit cylinder into the splined shaft taking care not to damage the O ring on the cylinder rod foot. Push the cylinder all the way home to allow easer fitting of the cylinder lock tube

20.

Fit shim pack to the cylinder lock tube.

21.

Reassemble the lock tube using the shim pack See Figure 5.6, using the 8 off 5/8” x 2-3/4“ long SHCS and tighten.

22.

23.

Torque retaining bolts to 236 ft lbs or 320Nm. When cylinder lock tube is tightened check the extension cylinder has movement. The cylinder should be free to float and should be checked by using hands to lift up and down. If cylinder is tight and has no movement this will mean the lock tube is too long and the shim pack will be loose not pulling the assembly together.

24.

25.

Assemble pull in drum as per pull in drum assembly.

Clear area of all tools parts and debris.

26.

Remove isolation tags as per mines procedures.

27.

Restore power to miner as per mines to re-power procedure.

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Intermediate Drum Removal RH and LH LH INTERMEDIATE DRUM

RH INTERMEDIATE DRUM

Figure 5.7

Intermediate Drum Removal RH TOOLING REQUIRED - General tools - hammers, chisels, shifters, pliers etc, - 1 – 2 tonne lifting block - 2 – lifting chains (adjustable) 2 metres long - 1 – 1” drive impact socket 1 7/8” AF - 1 – 1” drive impact socket 2” AF - 1 – torque wrench hydraulic or air driven 1” drive torque requirement 2000 ft lbs - 1 – porter power pump - 1 – small hollow ram 4” stroke for ¾” thread bar - 1 – 3/4 “UNC thread bar 12” long with nut and washers - 1 – Heavy soft hammer

NOTE:

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To carry out this procedure the complete pull in assembly is to be removed as follows.

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Removal of Pull In Assembly Complete 1.

Place the miner so the front can easily be reached and there is side clearance to pull the end drums off both ends of the cutting head.

2.

Lower the cutting head to a comfortable work height, and block it so the drums can be removed without affecting the supports.

WARNING:

3.

Inadequate or improper support while this work is performed can cause serious injury or death.

Remove all power from the machine and trip all circuit breakers to "OFF".

WARNING:

4.

Isolate machine as per mines isolation procedures.

Secure RH pull in assembly with lifting devices, utilizing lifting rud links attached to the banjo arm section and wrapping sling around drum.

RH INTERMEDIATE DRUM RH PULL-IN ASSEMBLY

MACHINE CENTRELINE

CENTRE DRUM

1-1/4" UNC x 9" LG HEX HEAD CAP SCREWS

1-1/4" UNC x 12" LG HEX HEAD CAP SCREWS

1-1/2" DOWEL (REMOVE)

1-1/4" UNC x 12" LG HEX HEAD CAP SCREWS 2" DOWEL (LEAVE) HYDRAULIC DRUM EXTENSION INLET 1-1/2" DOWEL (REMOVE)

1-1/4" UNC x 7" LG HEX HEAD CAP SCREWS

Figure 5.8

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5.

Remove eight (8) off 1-1/4” x 12” long hex head cap screws, Leaving two (2) 1-¼ x 9” long hex head cap screws supporting the assembly. See Figure 5.8.

6.

Using Porter – power rams remove two (2) 1-½” dowels (see Figure 5.8) with the ¾” thread bar. Leave the 2” dowel, see Figure 5.8.

7.

Remove ¾” NPT x 8” long hydraulic fitting from rear of cutter head flange.

NOTE:

Before next step ensure that lifting devices have adequate tension on the assembly.

8.

Remove remaining two (2) 1-1/4 “x 9” long hex head cap screws from assembly. See Figure 5.8.

9.

Move assembly horizontally away from the centre of the machine approximately 12”.

10.

NOTE:

If removing the left side assembly when viewing from rear of machine a ¼ I.D pressure pipe will be connected to the extending cylinder. Unscrew pipe from left side assembly. If right side assembly is being removed pipe will not be screwed into assembly.

NOTE:

When complete pull in assembly has been removed commence removal of intermediate drum.

Loosen the eighteen 1" socket head cap screws that secure the wedge block assembly and the drum to the cutting head hub. Remove the cap screws and wedge. Figure 5.9.

1" UNC x 2-3/4" LG SOCKET HEAD CAP SCREWS RH INTERMEDIATE DRUM

WEDGE ASSEMBLY

Figure 5.9

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CAUTION:

11.

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It is important to matchmark both the end drum and the cutting head hub to which it is attached, so that the pick block lacing is not disturbed upon reassembly.

Slowly pull the intermediate drum off the main assembly, and manoeuvre it away from the miner.

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Intermediate Drum Removal LH

NOTE:

To carry out this procedure the complete pull in assembly is to be removed as follows.

1.

Place the miner so the front can easily be reached and there is side clearance to pull the end drums off both ends of the cutting head.

2.

Lower the cutting head to a comfortable work height, and block it so the drums can be removed without affecting the supports.

WARNING:

3.

Remove all power from the machine and trip all circuit breakers to "OFF".

WARNING:

4.

Rev 1

Inadequate or improper support while this work is performed can cause serious injury or death.

Isolate machine as per mines isolation procedures.

Secure LH pull in assembly with lifting devices, utilizing lifting rud links attached to the banjo arm section.

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LH INTERMEDIATE DRUM LH PULL-IN ASSEMBLY

MACHINE CENTRELINE

CENTRE DRUM

1-1/4" UNC x 9" LG HEX HEAD CAP SCREWS

1-1/4" UNC x 12" LG HEX HEAD CAP SCREWS

1-1/4" UNC x 12" LG HEX HEAD CAP SCREWS

1-1/2" DOWEL (REMOVE)

2" DOWEL (LEAVE)

1-1/2" DOWEL (REMOVE)

1-1/4" UNC x 7" LG HEX HEAD CAP SCREWS

Figure 5.10 5.

Remove the two (2) 1 ½” dowel pins from the rear of the head structure with a slide hammer or pressing equipment. There is a ¾” UNC thread in the 1½” dowels for ease of removal. See Figure 5.10. Leave in the 2” dowels.

6.

Remove six (6) 1-1/4” x 12” Hex head cap screws, as well as two (2) 1-1/4” x 9” Hex head cap screws,1-1/4” heavy hex elastic stop nuts and 1-1/4” hardened washers. These screws are torqued to 1,940 Ft-Lb. Figure 5.10.

7.

Carefully move the LH pull in assembly laterally away from the inboard side of the auger gear case, stopping some 6”-8” away from the gear case bearing in mind that there is a pressure tube mounted internally of the pull in assembly. In full view should be the pressure tube, using multigrips or stilsons undo the tube from the pull in assembly and continue to remove pull-in assembly from auger head. See Figure 5.11.

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Figure 5.11 Proceed with intermediate barrel removal from this point (RH and LH) 8. Remove the two (2) key caps situated on the outer side of the intermediate barrel 180 degrees apart. Using a slide hammer remove key steel packer and then the barrel key. Ensure to match mark these keys with there allocated keyways see Figure 5.12.

9. Attach a lifting device to the intermediate drum being removed and apply lifting tension.

10. Loosen the eighteen 1" socket head cap screws that secure the wedge block assembly and the drum to the cutting head hub. Remove the cap screws and wedge. See Figure 5.12.

CAUTION:

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It is important to matchmark both the end drum and the cutting head hub to which it is attached, so that the pick block lacing is not disturbed upon reassembly.

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11. Slowly pull the intermediate drum off the main assembly, and manoeuvre it away from the miner.

3/4" UNC SOCKET HEAD CAP SCREWS KEY RETAINER 1" UNC x 2-3/4" LG SOCKET HEAD CAP SCREWS

LH INTERMEDIATE DRUM

SPLINED HUB

WEDGE BLOCK ASSEMBLY

BARREL KEY SPACER

Figure 5.12

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Intermediate Drum Assembly RH and LH

1.

With the machine in the same position as intermediate drum removal left or right hand and the machine still isolated as per mines procedures. Position the intermediate drum for reassembly.

WARNING:

2.

Isolate machine as per mines isolation procedures.

Secure drum with lifting devices used for removal of intermediate drum.

NOTE:

Before next step ensure that lifting devices have adequate tension on the drum.

3.

Using lever bars turn cutter head to line up the match marks with the match marks on the centre drum or the intermediate drum on the opposite side. Match marks are a small drilled hole or welded arrows.

4.

By lining up the match marks two keyways 180o apart in the intermediate drum should be lined up with the keyways in the mating part.

5.

Push the intermediate drum onto the mating part and force drum into position. To force drum into position use a rubber or soft hammer.

6.

Using lever bars rotate the drum to line up both keyways and drive in the keys from the outside of the drum. Fit key retainers.

7.

Position wedge block assembly see figure 5.12 and start the 18-1”x2 ¾” long socket head cap screws.

8.

Torque the 18-1”x2 ¾” long socket head cap screws alternatively 180o apart to 550 ft lbs or 746Nm.

CAUTION:

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Tightening wedge block assembly over 550 ft lbs or 746Nm will squash the splined hub preventing the pull in assembly spline entering the splined hub.

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Install Complete Pull In Assembly

1.

With the machine in the same position as pull in assembly removal ensure the machine is isolated as per mines procedures.

WARNING:

Isolate machine as per Mine’s Isolation Procedures.

2.

Position the complete pull in assembly as per removal procedure.

3.

Secure pull in assembly with lifting devices utilising lifting lugs attached to the banjo arm section and wrapping sling around drum.

4.

Ensure threaded pipe for cutter barrel extend is in position through the centre hole of the cutter head shaft.

NOTE:

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The threaded end of the pipe should be on the left hand side of the machine when viewed from the rear of the machine. See Figure 5.13.

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Figure 5.13 5.

If fitting the left side pull in assembly position the assembly almost in position allowing enough room to screw the pipe into the internal tee using multigrips or vice grips and thread tape tighten pipe into tee.

If fitting right side the threaded pipe is already screwed into tee on left side. The right side is tapered to start into the hole of the cylinder in the centre of assembly. See figure 5.13.

Check ‘o’ ring in cylinder where tapered pipe end fits is ok before proceeding.

6.

Line up the match marks with intermediate barrel and manoeuvre the assembly into the splined hub figure 5.12.

7.

Line up the face plate 1 ¼ bolt holes.

8.

Start the 2-7x1 ½” long hex head cap screw and tighten enough to bring the faces together.

See figure 5.10.

9.

Drive in the 2-1 ½” diameter hardened steel dowel pins.

10.

Install the 8-1 1/4x9” long hex head cap screw. See figure 5.10.

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11.

The 10-1 ¼ diameter hex head cap screw need to be tightened to 1940 ft lbs or 2630Nm. If no torque wrench is available this can be done by tightening all 1 1.4 bolts to 600 ft lbs or 814 Nm. By using a slogging spanner tighten the nut five flats.

NOTE:

Reduce torque by 25% if lubricant is used on threads.

12.

Replace ¾” NPT x 8” long hydraulic fitting back into the rear of the cutter head and connect hydraulic hose. Replace covers.

13.

Clear area of all tools parts and debris.

14.

Check oil level in cutter head gear case and top up as required.

15.

Remove isolation tags as per mines procedures.

16.

Restore power to machine as per mines procedure to repower.

17.

Start machine and test cutter head by rotating and extending and retracting the drums several times.

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Centre Drum Removal TOOLING REQUIRED - General tools, hammers, chisels, shifters, pliers, etc - 1 ½” AF Socket - ¾” Drive breaker bar and rachet - ¾” Square extension bar 12” & 24” long - 1 Tonne lifting - 2 slings/chains 2 metres long - Timber Wedges

CENTRE FLANGE

END FLANGE CENTRE FLANGE

1" UNC x 7" LG HEX HEAD CAPS SCREW

END FLANGE

Figure 5.14

Rev 1

WARNING:

Inadequate or improper support while this work is performed can cause serious injury or death.

WARNING:

Isolate machine as per Mine’s Isolation Procedures.

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1.

With cutter head at a comfortable working height remove the four (4) 1” UNC x 7” long hex head cap screws from the closest centre flange. Leave the eight (8) 1” UNC x 7” long hex head cap screws in the end flanges of the drum. See figure 5.14.

2.

Rotate cutter head by lever bars 180o.

3.

Remove isolating tags and lower cutter head to floor. Ensure bottom half of centre drum is supported by the floor or otherwise lowered onto timber packing.

4.

Isolate again as per mines isolation procedures.

5.

Remove eight four (4) as per opposite side 1” UNC x 7” long hex head cap screws from centre flanges.

6.

Remove eight (8) 1” UNC x 7” long hex head cap screws from the drum end flanges.

7.

With lifting devices attached to each end of the top half of the centre drum.

NOTE:

Before the next step, ensure that the lifting devices have adequate tension on both ends of the top half of centre drum.

8.

Slowly raise the top half of the centre drum until it is free from the shaft.

9.

Lower top half of centre drum to the floor.

10.

Remove isolating tags and re-power machine

11.

Raise cutter head and reverse machine away from bottom half of cutter drum.

12.

There are six keys attached to the centre drum, 4 off 1” x 3/4” square and 2 off 1 ¾” x 1 ¾” square keys. Do not lose the keys if they are in good condition, they can be reused.

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Centre Drum Assembly 1. With the machine in the same position as centre drum removal and the machine still isolated as per mines procedures position the bottom half and top half of the centre drum in front of the machine.

WARNING:

Isolate machine as per mines isolation procedures.

2. Pack up bottom half of centre drum using match marks lined against intermediate drums.

3. Remove isolating tags and re-power machine as per mines procedures.

4. Tram machine with cutter head raised enough to clear bottom half of centre drum. Tram into position that allows cutter head to be lowered into the bore of the drum.

5. Check keys are in position and lower cutter head onto bottom half of centre drum.

6. Isolate machine as per mines procedures.

WARNING:

Failure to isolate machine as per mines procedures may cause injury or death.

7. Using lifting gear as per disassembly procedure position top half of drum over cutter head.

WARNING: Ensure that lifting devices have adequate tension on both ends of the top half of centre drum.

8. Position the 4 keys into keyways of the cutter head shaft.

9. Lower the top half of the drum into position resting the top half against the bottom half.

10. Start all bolts and tighten the nuts finger tight.

11. Tighten all retainers using ¾” square drive and socket.

12. Remove isolating tags and re-power machine as per mines procedures.

13. Raise cutter head to a comfortable working position to allow torquing of the fasteners.

Rev 1

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14. Isolate machine as per mines isolation procedure.

WARNING:

Failure to isolate machine as per mines procedures may cause injury or death.

15. Torque the 8-1” hex head cap screw within easy reach to 970 ft lbs or 1315Nm.

NOTE:

Reduce torque by 25% if lubricant is used on threads.

16. Using lever bars rotate head 180o and torque the remaining 8-1” hex head cap screws to 970 ft lbs or 1315Nm.

NOTE:

Reduce torque by 25% if lubricant is used on threads.

17. Clear all tools, parts and debris around work area.

18. Remove isolation tags as per mines procedures and re-power machine as per mines re-power procedure.

19. Start machine and check centre drum by rotating and stopping cutter head several times.

Rev 1

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Removal of Cutting Motor Clutches TOOLING REQUIRED - General tools – hammer, chisel, shifting spanner, pliers etc, - Medium size long screw driver - 15/16 AF socket ¾” square drive - ¾” drive ratchet - ¾” square drive extension - 10 mm AF Allan Key - Special tool part number 482287 The cutting head top cover must first be removed to gain access to remove the clutch.

WARNING: Isolate machine as per Mine’s Isolation Procedures.

1.

Remove all power from the machine, and isolate all circuit breakers to "OFF".

CUTTER MOTOR CLUTCH COVER

CUTTING HEAD GEARCASE

CUTTING HEAD FRAME

5/8" UNC x 1-3/4" LG HEX HEAD CAP SCREWS

Figure 5.15

2.

Place clean rags or cardboard on this area and keep dirt off these parts by keeping them covered until needed.

3.

Remove the cutting motor cover on top of the auger head structure.

4.

Remove eight (8) 5/8”UNC x 1-½” hex head cap screws from clutch cover. See Figure 5.15.

5.

Remove clutch cover by sliding to the rear of the machine and position to allow long shaft to be removed.

6.

Remove six (6) 5/16” UNC x 1 ¼ long hex head cap screws from seal cap and remove seal cap and internal retaining ring including shims. See Figure 5.16.

Rev 1

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RH INPUT GEARCASE CUTTER MOTOR MACHINE CENTRELINE DRIVE SHAFT

INPUT SHAFT RETAINING RING SHIMS

SEAL CAP

5/16" UNC x 1-1/4" LG HEX HEAD CAP SCREWS

O'RING

Figure 5.16

NOTE:

Do not misplace the drive shaft shim, as they will be required when a new or the existing clutch is refitted.

7.

Using 5/8 UNC hex head cap screws remove the input motor shaft from the clutch-motor.

8.

Remove six (6) socket head cap screws 12 mm x 40 mm long from clutch assembly. This allows the pressure plate to be removed. Figure 5.17.

9.

Remove the output hub and friction plates from the clutch. The spring cup assemblies will also come with the output hub.

10.

Using screwdriver remove spiral retaining ring and remove the lock-screw securing the locknut.

11.

Remove multipoint locknut using special tool or chisel. Special tool part number 482287.

12.

Remove input hub from motor.

Rev 1

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INPUT HUB

LOCKING SCREW

SPIRAL CIRCLIP

OUTPUT HUB

SOCKET HEAD CAP SCREWS (12mm x 40mm LG)

SECTION A-A A

A

MULTI-POINT LOCKNUT (TORQUE TO 150 Ft lbs) Figure 5.17

Rev 1

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Clutch Assembly 1.

With the machine in the same position as for clutch removal and machine still isolated as per mines procedures get clutch ready for mounting.

WARNING:

Isolate as per Mine’s Isolation Procedures.

2.

Dismantle clutch to be fitted by removing six socket head cap screws from clutch assembly see Figure 5.17.

3.

Remove the output hub, friction plates and spring assemblies from clutch.

4.

Fit input hub onto the spline of the electric motor.

5.

Fit and tighten multipoint locknut to retain clutch see figure 5.17 using clutch retaining tool part number 482287 torque to 150 ft lbs or 203Nm.

6.

Line up slot of multipoint locknut with the ¼” UNC tapped hole in the input hub and fit locking screw see figure 5.17.

7.

Fit spiral circlip.

8.

Reassemble springs, friction discs and output hub to the input hub.

9.

Fit six 12 mm x 40 mm long socket head cap screws to output hub and pressure plate and torque to 102 ft lbs 138Nm.

10.

Check ‘o’ ring in seal cap and replace if necessary 3/32 x 2 7/8” od.

11.

Fit seal cap and tighten 5/16” retaining bolts.

12.

Fit clutch cover and tighten bolts to 226 ft lbs or 306Nm.

13.

Refit top covers.

14.

Re-power machine as per mines re-power procedure and test for correct operation.

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Removal of Cutter Head Gear Case (Complete with pull in assemblies)

TOOLING REQUIRED - General tools – hammer, chisels, shifters, pliers etc, - Hydraulic or pneumatic operated torque wrench torque requirement 2000 ft lbs - ½” x 400 long steel round bar - 7 lb hammer - 1 7/8” AF slogging spanner - 1 7/8” AF impact socket 1” drive and ¾” drive - ¾ drive ratchet - ¾ drive extension short and long - 2 lifting devices 10 tonne each - 4 lifting chains adjustable 5 tonne each - 2 crow bars - 1” x 12” long round bar CENTRE DRUM LH PULL-IN ASSEMBLY

RH INTERMEDIATE DRUM

LH INTERMEDIATE DRUM

CUTTING HEAD REMOVAL.

RH PULL-IN ASSEMBLY

RH PULL-IN RETAING SCREWS

CUTTING HEAD GEARCASE RETAINING SCREWS

Figure 5.18

The cutting head gear case must sometimes be removed from the miner by itself for replacement of internal components such as the input gear cases. The cutting head gear case assembly may be removed with the cutting drums installed.

1.

Lower the gathering head to the mine floor.

2.

Support the auger head frame by using manufactured safety support pins in the locations provided on either side of gathering head.

3.

Remove all power from the machine and isolate all circuit breakers to “OFF”.

WARNING:

Rev 1

Isolate as per Mine’s Isolation Procedures.

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4.

WARNING:

Inadequate or improper support while this work is performed can cause serious injury or death.

WARNING:

Access to area under cutter head boom is required.

Improper setting of safety supports while this work is performed can cause serious injury or death.

Remove eighteen (18) 1-¼” UNC x 11” long hex head cap screws from the bottom of the mounting flange. Leave the 2 (one each side) 1 ¼” x 9” long hex head cap screws securely tightened as they will support the cutter head extensions. Figure 5.19.

WARNING:

Isolate machine as per mine’s Isolation Procedures.

LH INTERMEDIATE DRUM LH PULL-IN ASSEMBLY

MACHINE CENTRELINE

CENTRE DRUM

(4-0FF) 1-1/4" UNC x 9"LG HEX HEAD CAP SCREWS DO NOT REMOVE (20-OFF) 1-1/4" UNC x 11"LG HEX HEAD CAP SCREW

(16-OFF)1-1/4" UNC x 12" LG HEX HEAD CAP SCREWS

CLUTCH COVER

Ø2" DOWEL PIN

1-1/4" UNC EXTENDED HEAD HEX HEAD CAP SCREW

(4-OFF) Ø1-1/2" DOWEL PIN CUTTER MOTOR

Figure 5.19

Rev 1

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5.

Remove bottom cover. Figure 5.20.

A

A

BOTTOM COVER

5/8" UNC x 1-1/2"LG HEX HEAD CAP SCREWS

VIEW A-A

Figure 5.20 6.

Using 1-7/8” A/F slogging spanner remove four (4) 1 ¼” UNC extended head cap screws from bottom of motors. Note: 2 each motor.

7.

Remove isolation as per mines re-power procedures.

8.

Apply power to miner.

9.

Raise cutter head and remove safety support pins.

10.

Lower cutter head to floor.

NOTE:

Do not force cutter head into floor.

11.

Re-isolate and tag as per mines procedures.

12.

Remove covers from top of auger head allowing access to the auger motor and clutch mounts.

13.

Remove the cutting motor clutch cover from the RH and LH side motors hex. As per clutch removal procedure.

14.

Remove the seal cap and internal retaining ring which restrains the motor input shaft.

Rev 1

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15.

Remove internal retaining ring including shims.

16.

Disengage the motor (input) shaft from the inside of the RH and LH cutting motors going into the input gear case assemblies using 5/8” UNC bolt to pull out.

17.

Using 1-7/8” A/F slogging spanner remove top four (4) extended head hex head cap screw from motors. 2 each motor.

CAUTION:

In this configuration, each cutting head motor is held in place by the motor spigot and bore in the support frame at the front. Raising the cutter head to an excessive height might cause the motor to dislodge. Do not raise cutter head motors to a position above horizontal.

18.

Remove the top row of 1-¼” x 11” long socket head cap screws 18 off holding the cutting head gear case to the cutting head support frame. Do not remove the 4 (two each side) 1 ¼” x 9” as they support the cutter head extensions. Figure 5.19.

19.

Disconnect hydraulic extend and retract hoses and extended fittings. One each side of cutter head. There is no need to disconnect water hoses.

20.

There are two (2) – 2 inch dowel pins which are press fitted into the support frame. See figure 5.19. Upon separation, they should remain in the support frame and care must be taken to prevent damage to these points.

21.

Using lifting gear and crow bars lever cutter head complete assembly away from support frame flange.

22.

Isolate the cutting head circuit breaker located on the display box. This will lock out power to the cutting head while power is applied to the miner for tramming.

23.

Remove isolation as per mines procedures from the main circuit breaker.

24.

Apply power to the miner.

WARNING:

25.

Slowly tram the miner away from the cutting head gear case.

CAUTION:

Rev 1

Ensure that the cutting head circuit breaker is isolated and do not attempt to start the head.

In this configuration, each cutting head motor is held in place by a support spigot and the motor bore hole in the support frame at the front.

Excessive bumping might cause the motor to dislodge.

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Reinstall Cutter Head Gear Case (Complete with pull in assemblies) 1.

With the machine in the same position as removal procedure and isolated as per mines isolation procedure, position the cutter head in front of machine.

2.

Using the same lifting gear as gear case removal lift cutter head into a position that the 2 faces to be bolted are parallel.

3.

Re-power machine as per mines re-power procedure.

4.

Ensure cutter head circuit breaker is isolated.

5.

Tram miner onto the cutter head gear case until faces are as close together as possible.

6.

Remove all power from machine and isolate as per mines procedures.

WARNING:

Failure to isolate machine as per mines procedure may cause serious injury or death.

7.

Using lever bars (crow bars) manoeuvre gear case to allow top row of bolts to be started use 1 ¼ bolt. Lengths as shown in figure 5.18.

8.

Position all top row bolts and pull faces together until slightly touching.

9.

Enter and drive home 2 (one each side) 2” hardened steel dowels.

10.

Tighten top row of bolts (do not torque to requirement).

11.

Start 4 motor bolts, the top 2 of each motor and torque to 1940 ft lbs or 2630Nm.

NOTE:

To achieve this, torque the 1 ¼ bolts to 600 ft lbs or 814Nm. By using a slogging spanner tighten the nut.

Five flats.

NOTE:

Reduce torque by 25% if lubricant is used on threads.

12.

Re-power machine as per mines repower procedures.

13.

Start machine in mining mode.

14.

Raise cutter head and set cutter head safety support pins. One each side.

15.

Reisolate machine as per mines isolation procedures.

Rev 1

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WARNING:

16.

Failure to isolate machine as per mines procedure may cause serious injury or death.

Fit bottom row of 1 ¼ bolts and torque to 1940 ft lbs or 2630Nm. This can be achieved by torquing bolts to 600 ft lbs and using a slogging spanner tighten nut. Five flats.

NOTE:

Reduce torque by 25% if lubricant is used on threads.

17.

Start and torque 4 bottom motor bolts as above.

18.

Replace bottom cover and torque 5/8 retaining bolts to 226 ft lbs or 306Nm.

19.

Re-power machine as per mines re-power procedures.

20.

Apply power to machine.

21.

Raise cutter head and remove safety support pins and lower cutter head so drums are almost touching floor.

22.

Torque the top row of 1 ¼ bolts as described above.

23.

Replace motor input shaft.

24.

Replace internal retaining ring including shims.

25.

Replace seal cap and retaining bolts.

26.

Replace clutch cover and torque 5/8 hex head cap screws to 226 ft lbs or 306Nm.

27.

Replace top cutter head covers.

28.

Refill gear cases with ISO 460 EP gear oil. Refer to section 11 for details.

29.

Refit hydraulic extend and retract fittings and hoses.

30.

Clean up all tools, parts and debris around work area.

31.

Remove isolation tags as per mines procedures and re-power machine as per mines repower procedure.

32.

Start machine and check cutter head rotation and extend and retract functions.

33.

Extend and retract cutter extending drums several times to bleed air out of cylinders.

Rev 1

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Removal of Cutter Motor Weight of Cutter Head Motor 1250 kg TOOLING REQUIRED - General tools – hammer, chisel, shifting spanner, pliers etc - Medium size long screw driver - 15/16 AF socket ¾” square drive - ¾ drive ratchet - ¾ square drive extension - ½ AF Allan key - 1 ⅞” AF Slogging spanner - 2 off 1 tonne lifting blocks - 2 off 1 tonne slings 2 metres long - 2 off crow bars

WARNING:

Inadequate or improper support while this work is performed can cause serious injury or death.

WARNING:

ISOLATE MACHINE AS PER MINES ISOLATION PROCEDURES.

NOTE:

Access to area under cutter head boom is required.

Lower gathering head and fit safety support pins to cutter boom.

1.

Raise cutter head and fit safety support pins.

2.

Isolate as per mines isolation procedures.

3.

Remove bottom cover item. Figure 5.20.

4.

Using 1-7/8” A/F slogging spanner remove bottom two (2) 1-¼” UNC extended head cap screws on motor. See figure 5.19.

5.

Remove isolation tags and lower cutter head using mines re-power procedures for continuous miners for mechanical maintenance.

6.

Isolate machine as per isolation of continuous miner for electrical and mechanical maintenance.

7.

Follow procedure for removal of cutter motor clutch 1 to 12.

8.

Using 1-7/8” A/F slogging spanner remove top two (2) 1-¼” UNC extended head cap screws from motor.

Rev 1

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9.

Remove water hoses from electric motor and mark so reconnection will be correct.

10.

Electrician is to disconnect and insulate left of right hand cutter head contactor in the main flameproof enclosure depending which motor is being removed. Disconnect the load side cables and the Thermistor leads. Then disconnect cable from motor.

11.

The motor is now ready to be lifted from the cutter head frame.

12.

Using lifting devices lift cutter motor from cutter head frame.

13.

Remove isolation tags from traction circuit breaker.

WARNING:

14.

Rev 1

Cutter head and conveyor circuit breaker must be isolated and locked in the off position.

Tram machine away from cutter motor.

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Installation of Cutter Motor 1.

Using the same lifting gear and setup as cutter motor removal lift the motor high enough to tram the miner under the motor.

2.

When miner is in position to allow the motor to be lowered into the cutter head isolate machine as per mines procedures.

WARNING:

Failure to isolate machine as per mines isolation procedures may cause serious injury or death.

3.

Before lowering the motor into position smear a light coating of Silastic on the face of the motor and use o-ring that is supplied.

4.

Lower the motor into position and lever the motor forward using crowbars until motor spigot enters the bore in the cutter head frame.

5.

Start and tighten the 2 top motor mounting bolts and pull the faces together. No need to torque at this point.

6.

Remove isolation tags as per mines procedures and re-power machine as per mines procedures.

7.

Raise cutter head and place cutter head safety support pins in position.

8.

Isolate machine as per mines procedures.

WARNING:

9.

Failure to isolate machine as per mines procedures may cause serious injury or death.

Start 2 bottom motor mounting bolts and torque to 1940 ft lbs or 2630Nm.

NOTE:

Access to area under cutter head boom is required.

Lower gathering head and fit head safety support pins to cutter boom.

10.

Replace bottom cover and torque 5/8 unc mounting bolts to 226 ft lbs or 306Nm.

11.

Remove isolation tags as per mines procedures and reapply power as per mines procedures.

12.

Remove cutter head safety support pins and lower cutter head to floor.

Rev 1

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13.

Isolate machine as per mines procedures.

WARNING:

Failure to isolate machine as per mines procedures may cause serious injury or death.

14.

Electrician to rewire electric motor and reconnect the contactor in the main flameproof enclosure.

15.

Remove isolation tags as per mines procedures reapply power to machine as per mines procedures.

16.

Start machine and check direction of motor.

17.

NOTE:

RHS MOTOR – Rotates clockwise when looking at clutch end.

NOTE:

LHS MOTOR – Rotates anti clockwise when looking at the clutch end.

Isolate machine as per mines procedures.

WARNING:

Failure to isolate machine as per mines procedures may cause serious injury or death.

18.

Torque top motor bolts as per above instructions on torque of bottom motor bolts.

19.

Replace splined shaft, clutch and clutch cover as per clutch replacement procedure at start of this section 5.

20.

Replace water fittings and connect water hoses.

21.

Replace top cutter head covers.

22.

Clean up all tools, parts and debris around work area.

23.

Remove isolation tags as per mines procedures and repower machine as per miner repower procedure.

24.

Start machine and check cutter head for rotation.

Rev 1

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Removal of the Cutter Head Input Gear Case Input gear case weight 300 kg TOOLING REQUIRED - General tools – hammer, chisels, shifters, pliers etc, - Internal circlip, pliers medium size

NOTE:

The complete cutter head gear case needs to be removed from the machine to carry out this procedure.

WARNING:

Inadequate or improper support while this work is performed can cause serious injury or death.

SHIMS SHIM GAP TO 0.020" - 0.044"

O'RING

RETAINING RINGS

2 THREADS EXPOSED WHEN TIGHTENED

DRIVE SHAFT

ACCESS PLUG

1/2" x 2-1/2" LG DOWEL

MACHINE CENTRELINE

Ø1" DOWEL PIN RH INPUT GEARCASE

SECTION A-A

(8 OFF) 3/4" UNC NYLOC SOCET HEAD CAP SCREWS

A

A

ACCESS PLUG

Figure 5.21 1.

Rev 1

Remove the access plug at the rear of the input gear case (see Figure 5.21)

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2.

Remove the first of two retaining rings and a plug and its captive O-ring. Figure 5.21.

3.

Remove the second retaining ring and any shims installed behind the retaining ring. This will expose the drive shaft. Keep shim pack for reassembly.

4.

Using the threaded 5/8 UNC puller, hold in the end of the drive shaft, extract the shaft completely.

5.

Remove the eight (8) ¾” UNC nylock socket head cap screws. The case is also secured by a ½“dowel as shown in Figure 5.21. This may require the removal of a couple of the ½” UNC cap screws securing bearing retainers on either side of the case, and using a sliding hammer with a ½” threaded end to ease the case away from the main gear case structure.

Installation of Cutter Head Input Gear Case 1.

Clean down mating faces and apply light smear of grease to stop corrosion.

2.

Position gear case and line up mounting bolt holes.

3.

Start and lightly tighten 8 ¾ socket head cap screws. See figure 5.21.

4.

Fit ½ x 2 ½ long hardened steel dowel.

5.

Torque ¾” socket head cap screws to 118 ft lbs or 160Nm.

6.

Remove access plug at rear of input gear case. See figure 5.21.

7.

Install driveshaft the end with the spline that has a circular undercut at the rear of the spline is the end that goes into the cutter head.

8.

Install shims see figure 5.21 and fit retaining ring.

9.

Measure clearance between end of shaft with the shims and the cir-clip. Clearance should be .020” to .044”. Add or remove shims as required.

10.

Refit ‘o’ ring plug and second retaining ring.

11.

Screw in access plug and tighten. Make sure 2 threads are exposed to ensure access plug does not contact inside sleeve.

Rev 1

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Removal of the Cutting Head Support from the Main Frame Weight 9000 kg – without the cutter head gear case attached to the faceplate.

TOOLING REQUIRED - General Tools – hammers, spanners, chisels, shifters, pliers etc - 2 lifting blocks/devices 10 tonne - 2 lifting blocks/devices 5 tonne - 2 lifting chains adjustable 10 tonne each 2.5 metres long - 2 lifting chains adjustable 5 tonne each 2.5 metres long - Sliding hammer 1” UNC

NOTE:

The support frame can be removed with or without the cutter head gear case attached or removed.

1.

Place the machine to a location where both sides are accessible in front of the crawlers and can be reached easily.

2.

Lower the gathering head until the shovel blade rests on the mine floor.

3.

Lower the cutting head until its frame rests on the floor or gathering head frame if the cutter head gear cases have been removed.

4.

Remove all power from the machine, and trip all circuit breakers to "OFF".

WARNING:

Isolate machine as per Mine’s isolation procedures.

5.

Clean off an area of the machine where parts can be set. Place clean rags or cardboard on this area and keep dirt off the parts by keeping them covered until needed.

6.

Remove any necessary access covers and isolate machine as per mines procedures.

NOTE:

7.

Rev 1

A competent Electrician is needed from this point.

Electrician to disconnect and insulate left and right hand cutter head contactors, horizon control unit and headlights in the main flameproof enclosure. Disconnect and insulate the load side wiring of each component.

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WARNING:

Failure to isolate machine as per mines procedures may cause serious injury or death.

NOTE:

Ensure to remove mine water supply from the machine.

8.

Disconnect electrical leads from the RH and LH cutting head drive motors, horizon control unit and headlights and flow switches. Tag these leads for identification in re-assembly. Pull them rearward off the support frame and lay them on the machine chassis.

9.

Disconnect water lines going to the cutting head. Tag them and lay them on the chassis.

10.

Disconnect lubrication and hydraulic lines going to the cutting head, and all lubrication lines to the main pivot pins and hydraulic cylinder pins. Tag them and set on the machine chassis.

NOTE:

Cables, water and hydraulic lines to the gathering head do not need to be disconnected or removed.

11.

Position 10 tonne lifting blocks one each side above lifting lugs at front of cutter head position 5 tonne lifting blocks above rear lifting lugs.

12.

Relieve pressure in each cutting head raise circuit.

13.

Remove the two (2) 3/4" UNC flat head cap screws and keeper plates from the upper cylinder pins on each side (see Figure 5.22 & 5.23).

CUTTING HEAD SUPPORT FRAME PIVOT PIN RETAINING KEY

CUTTING HEAD PIVOT PIN

A

KEEPER PLATE

UPPER CYLINDER PIN CUTTING HEAD RASIE CYLINDER

KEEPER PLATE

A

LOWER CYLINDER PIN

Figure 5.22

Rev 1

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MAINFRAME OUTER PIVOT BUSHING CUTTING HEAD PIVOT BUSHING 5/8" UNC x 2-1/2"LG SOCKET HEAD CAP SCREW

MAINFRAME INNER PIVOT BUSHING

PIVOT RETAINING KEY

CUTTING HEAD PIVOT PIN

CYLINDER PIN BUSHING

CUTTING HEAD SUPPORT FRAME

KEEPER PLATE

CYLINDER PIN BUSHING

LOWER CYLINDER PIN 5/8" UNC x 1-3/4"LG HEX HEAD CAP SCREWS

LOWER CYLINDER CLEVIS

Figure 5.23

WARNING:

Place timber blocking under the forward end of both raise cylinders before removing the upper cylinder pins.

14.

Using 1” UNC threadbar use a slide hammer to remove the upper cutting head cylinder pin from both sides of the cutting head frame.

15.

When pin is removed cylinder should fall onto timber blocking.

16.

Remove the two (2) 5/8” x 2 ½” long socket head cap screws from the retaining keys on the RH and LH main pivot pins (see Figures 5.22 and 5.23)

17.

Remove the retainer keys.

WARNING:

Rev 1

Ensure that the cutting head support frame is well supported at both main pivot pins.

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18.

On either side of the miner, force the main pivot pin inward from the outboard side, using a long 2” diameter bar or 1” sliding hammer from the inside of the machine.

NOTE:

Should the pivot pin be difficult to remove, recheck to see that the support frame is properly blocked and weight is removed from the pivot.

19.

Repeat Step #17 for the other side of the machine.

20.

The cutting head assembly can now be lifted using the lifting gear from the machine.

21.

Ensure cutter head and conveying systems are isolated and locked out as per isolation procedures.

22.

Remove isolating tags and re-power machine tram machine away from cutter head.

Rev 1

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Installation of Cutting Head Assembly to the Main Frame TOOLING REQUIRED - Slings/Rope - Sandpaper/Emery - Grease - Hammers - Porter-power, various jacks and packing - Loctite 242 - Pneumatic oil pressure pump to control head cylinders - 5/8” in-hex - 1 1/8” socket - Ratchet and breaker bar - ½’ in-hex - Chains suitable to support frame weight - Several Rated chain blocks - 15/16” socket - 15/16” open/ender - Internal cir Clip pliers (small set) - 5/8” UNC thread bar and slide hammer - SPECIAL – clutch locknut removal tool - Sealant/Silastic

WARNING:

1.

Isolate machine as per mines isolation procedures.

For each side of the miner, inspect the bushings to the following: • • • • •

Main frame pivot (inner and outer) both sides Cutting head pivot both sides Cylinder both ends Raise cylinder clevis on cutter head frame Raise cylinder clevis on mainframe

2.

Be sure that the bushings and eyes are free of dents, scratches, and peening.

3.

Be sure that the bushing ends are not mushroomed over. If necessary, consider replace the bushing.

NOTE:

Rev 1

All bushings are interference fit. If a new one is to be installed, it must be frozen to shrink it before installation.

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4.

Before attempting to install any pin, make sure that it and its bushings are well-coated with grease to aid assembly.

5.

With the machine cutter head motors, horizon control unit, headlights and flow switches still isolated as per procedure for removal of cutter head support frame.

6.

Re-power machine as per mines re-power procedure.

7.

Be sure that the pivot bushing is in place on each side of the support frame. Using lifting gear set up as per disassembly lift cutter head assembly to allow miner to tram onto cutter head assembly. Tram miner onto cutter head and line up bores as close as possible.

WARNING:

Failure to isolate machine as per mines procedures may cause serious injury or death.

8.

Remove all power from the machine and isolate as per mines procedures.

9.

On one side of the machine, with the grease connection at the top, install the cutting head pivot pin into the main frame and the cutting head frame pivot bushings from the inboard side out.

10.

Repeat above to the other side of the miner.

11.

Secure each pivot by installing the pivot pin retainer with two 5/8" x 2 ½” long socket head cap screws with LOCTITE No. 242 on the threads. Tighten them to 236 ft lbs or 320Nm.

12.

Align the cutting head frame to insert each cylinder pin through the frame clevis and the end of the cylinder. Line up by using external power supply e.g. Pneumatic oil pressure pump connected to one cylinder at one time.

13.

Install each pin keeper plate using the two cap screws with lock washers, tightened to 226 ft lbs or 306Nm.

14.

Connect water lines and electrical leads to the head. Also connect all lubrication and hydraulic lines to the cutting head and any to the pivot pins.

15.

Grease the support frame pivots and the cylinder pins before operating.

CAUTION:

Failure to grease pivots and cylinder pins can cause damage to these parts during subsequent operation.

16.

Remove all blocking, and clean all rags, cardboard, extra parts, and tools from the machine area.

17.

Check the oil levels in both RH and LH cutting head final / input gear cases and grease the cutting head motors if required.

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CAUTION:

18.

19.

Do not attempt to start the cutter head until points 18 & 19 have been carried out.

Remove one of the auger motor drive shafts. Refer to this section removal of cutter head motor clutches and follow procedure 4 to 7 for removal of drive shaft.

Electrician to reconnect the contactors, horizon control, lights and flow switches in the main flameproof enclosure.

WARNING:

20.

21.

Be sure that all personnel are clear of the miner prior to conducting the following checks.

Restore power to miner as per mines re-power procedure. Check the hydraulic raise and lower functions for smooth operation.

Close auger cutting circuit breaker and test motor phasing. When phasing correct, reassemble the cutting motor drive shafts as per clutch assembly this section.

GATHERING HEAD ASSEMBLY General Description

R.H. HINGED PLOW

R.H. GEARCASE (POT)

RETAINER PLATE

CLA

FOOTSHAFT

RETAINER PLATE

CLA

POT COVERS (3 PER SIDE)

INPUT GEARCASE COVER (BOTH SIDES)

DRIVE MOTOR (BOTH SIDES)

L.H. GEARCASE (PO

The gathering head assembly is shown in Figure 6.1. The two drive motors are shown; each is connected to an input gear case through a torque shaft. This torque shaft is easily replaced and provides protection to the drive train from severe shock loadings which might occur during loading and conveying.

Each input gear case drives a gathering head gear case, or “pot”, which turns a 6-blade centrifugal loading arm (CLA). The RH and LH pots are connected to a common foot shaft with a sprocket which drives the conveyor chain.

The gathering head is raised or lowered by two hydraulic raise cylinders.

Figure 6.1

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Removal and Replacing Gathering Head Shear Shaft TOOLING REQUIRED - General Tools – spanners, pliers, hammer, chisel etc - ¾” x 4” long unc hex head cap screw - ½” x 6” long unc hex head cap screw Removal The torque shaft in the gathering head input gear case is designed to shear in the event of sudden overload. In order to protect from gear or other component failure it is designed to transmit normal overloads without nuisance failure.

In the event that this shaft should break replace as follows.

1. Isolate machine as per mines procedures

WARNING:

Failure to isolate machine as per mines procedures may cause serious injury or death.

2. Open gathering head access cover on side of gathering head frame. See Figure 6.2.

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MOUNTING BOLTS

INPUT GEARCASE

WEDGE BLOCK

POT

MOUNTING BOLTS 7/8" UNC x 2" LG HEX HEAD CAP CREWS

3/4" UNC x 10" LG MOTOR BOLT

3/4" UNC x 10"LG MOTOR BOLTS

3/4" x 20" LG MOTOR BOLTS

ACCESS COVER

Figure 6.2 B

R.H. POT CASE 1" UNC x 2-1/2"LG HEX HEAD CAP SCREWS

INPUT GEAR CASE

Ø1" DOWEL (2 PER SIDE) 1" UNC x 2-1/2"LG SOCKET HEAD CAP SCREWS TORQUE SHAFT

B

DRIVE MOTOR

VIEW B-B BEARING CAP COVER

PLUG SNAP RING

Figure 6.3

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3. Remove the bearing cap cover from the exposed end of the motor. See Figure 6.3.

4. Remove the snap ring using standard pliers.

5. Using ½” x 6” long hex head cap screws remove ‘o’ ring plug. This should come free by pulling hex head cap screw with hands.

6. Using ¾” x 4” hex head cap screw, remove the torque shaft.

NOTE:

If shaft has not broken complete shaft will come from the assembly.

7. If the shaft has sheared at the shear, groove the ¾” hex head cap screw will only remove the broken end of the torque shaft.

8. Using the ½” x 6” hex head cap screw. Screw the hex head cap screw into the remaining shaft and remove.

Replace 1.

Check shaft to be fitted and clean off all corrosion protection coating from splines.

NOTE:

Failure to remove protective coating may make removal of shaft more difficult next time it has to be removed.

2.

Fit shaft to outer spline and push forward until shaft reaches the inner spline.

3.

Rotate shaft until both splines line up and push shaft into position.

4.

Check ‘o’ ring on ‘o’ ring plug and if OK, insert plug.

5.

Refit snap ring.

6.

Refit bearing end cap to motor.

7.

Re-power machine using mines re-power procedure.

8.

Test correct operation of conveyor system.

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Conveyor Chain Disassembly TOOLING REQUIRED - Cincinnati chain breaker - Long screwdriver - General tools – hammers, chisels, pliers, shifters etc The conveyor chain is a Cincinnati chain with flight and swivel less joint sections. The flight swivel less joint sections are intended to be replaced as a unit. All sections of the chain have connecting pins.

UNIVERSAL CONNECTOR FLIGHT PIN

RETAINING PIN CONNECTING PIN CHAIN FLIGHT

SIDE STRAP RETAINING PIN

Figure 6.4 To separate the conveyor chain a Cincinnati chain breaker is required. The chain breaker tool is used for disassembly and assembly.

WARNING:

Isolate machine as per mines isolation procedures.

WARNING: If access to area under cutter boom is required. Lower cutter head and fit cutter head safety support pins.

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1.

Lower shovel and discharge conveyor to their lowest positions. Straighten conveyor.

2.

Depending where chain is to be broken if working under cutter head position the safety support pins provided.

WARNING: Isolate machine as per mines isolation procedures.

3.

Remove accumulated pressure from chain tension cylinders by opening needle valve next to pressure gauge on right side of the machine as per decals.

WARNING: Failure to relieve pressure in take up cylinders could cause injury.

4.

Position chain breaker over chain on deck of machine with cylinder retracted. The cylinder on the chain breaker does not automatically retract with valve open on pump use cylinder retractor or long screwdriver to lever cylinder back.

5.

Line up pusher pin with centre of connecting pin to be removed, close valve on pump and pump until connecting pin is through the front side plate. Open valve on pump and retract cylinder with screwdriver. Repeat procedure on second connecting pin.

NOTE:

The retaining pins retaining side plate need not be removed. The pins will shear off when pushing out the connecting pin.

6.

The other side plate and both connecting pins can now be removed separating the chain.

7.

To assemble bring chain together and insert the assembled part of the side strap assembly.

Position loose side plate over protruding connecting pins. Tap on lightly to hold in place.

Position chain breaker over chain so that the pushing pin is in the centre of the side plate.

Close valve and push on until the two connecting pins expose the retaining pin holes.

8.

Release valve and remove unit from machine.

9.

Fit 2 retaining pins and bend over towards the rear of machine to prevent dropping out.

NOTE:

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Ensure to close the conveyor take up needle bleed off valve prior to testing.

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Removal of Foot Shaft and Centrifugal Loading Arms (CLAs) Weight of Foot Shaft – 200 kg

TOOLING REQUIRED - General tools – hammer, chisel, shifters etc - 1/2 “Sisal rope 6 metres long - Allan Keys 3/8” - 2 – crow bars The foot shaft will differ slightly with machine model depending on what conveyor chain is specified. All foot shafts have the same basic components and can be removed and replaced according to the following procedure.

WARNING:

Isolate machine as per mines isolation procedures. Lower shovel, raise cutter head and fit cutter head safety support pins.

1.

Refer to Figures 6.5 and 6.6.

2.

Disconnect the conveyor chain as per conveyor chain disassembly procedure at front of this section.

3.

Remove the foot shaft by removing the four (4) ½” socket head cap screws on each clamp ring, and remove the clamp rings.

4.

Slide both adapter shafts toward the machine center against the sprocket shaft, if having trouble remove the four 1-1/4” plugs and hose internal bores to remove build up. This will free the sprocket shaft and adaptor shafts from the protruding shafts of the pot pinion gears and the sprocket shaft can be removed.

5.

Using sisal rope attach to each end of the sprocket shaft. Position self and assistant clear of the shovel and pull shaft out of position and down the face of shovel.

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LUBE FITTING 1/8" NPT PLUG (8 PLACES) SPROCKET SHAFT

1/2" UNC SOCKET HEAD CAP SCREWS (4 PER SIDE)

CLAMP RING

1" NPT PLUG

ADAPTOR SHAFT SEAL CARRIER POT OUTPUT PINION GEAR SHAFT

Figure 6.5

Reassemble by reversing procedure. Remove ⅛” NPT plug opposite grease fitting both sides fill cavity at lube fittings until grease purges from opposite side. Replace plug. This Lubrication is only required at assembly.

Removing the Centrifugal Loading Arms (CLAs).

Weight 450 kg each TOOLING REQUIRED - General tools – hammer, chisel, shifters, pliers etc - 3 – ¾ “NPT eye bolts - 3 – small slings with shackles each 200kg capacity - Lifting block 1 tonne - ¾ “– 5/8 “ /AF Allen Keys

1.

Rev 1

WARNING:

Failure to isolate machine as per mines procedures may cause serious injury or death.

WARNING:

Ensure to raise cutter head and fit cutter head safety support pins as required.

Remove the eight (8) 1” socket head cap screws from the CLA retainer plate, and remove the retainer plate. See figure 6.1 and section AA below. Two 1” diameter puller holes, protected by cup-point set screws, are provided in the retainer plate to assist with its removal.

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2.

From the center of each arm, remove the three (3) ¾” x 4” long hex head cap screws, The CLA is now free to come off. Three ¾” lifting holes, protected by cup-point set screws, are provided to aid removal.

NOTE:

On the CLA, there are three (3) 2” dowels which secure and position the CLA to the pot disc (see section AA below)

3.

Using crow bars lever the CLA off the gear case disk until CLA is free from 2” dowels.

4.

Using the lifting equipment raise the CLA off the disk and lower down the shovel.

3/4" UNC x 4" LG SOCKET HEAD CAP SCREWS (3 EACH SIDE)

RETAINER PLATE

1" UNC x 2-1/2"LG SOCKET HEAD CAP SCREWS (8 EACH SIDE)

PULLER HOLES (3 EACH SIDE)

CLA

Ø2" DOWEL (3 EACH SIDE)

R.H. POT

SECTION A-A

L.H. POT

A

A

Figure 6.6

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Re-Fitting the Centrifugal Loading Arms (CLAs) Use the same lifting equipment as removal.

1.

With the machine isolated as per mines procedures and the cutter head raised with the cutter head safety stops in position the CLA.

2.

Position CLA over disk.

3.

When fitting the CLAs the arm of one side is to be lined up in the centre of two arms on the opposite side.

4.

With the 3 – 2” dowels in place on the gearcase disk lower the CLA onto the disk.

5.

When CLA is lowered onto the dowels start the 3 – ¾” x 4” long hex head cap screw and torque to 392 ft lbs or 531Nm.

6.

Replace centre retainer plate and fit 8 – 1” x 2 ½” long socket head cap screw and torque to 1010 ft lbs or 1370Nm.

7.

Re-power machine as per mines re-power procedure and test the conveyor system

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Removal of the Drive Motor Input Gear Case and CLA Pot Weight of Drive Motor 800 kg Weight of Gear case Assembly 1500 kg TOOLING REQUIRED - AF Sockets 15/16” – 1 1/8” – 1 5/16” - AF Allan Keys ¾” - 5/8” - ½ “ UNC hex head cap screws 6” long - ¾ “ UNC hex head cap screws 6” long - 2 tonne lifting block - ¾” UNC eye bolt - 1 adjustable lifting chain 1 metre long 1 tonne capacity - 1 adjustable lifting chain 2 metre long 1 tonne capacity - General tools – hammer, chisel, shifter, pliers, etc Information The conveyor drive motors can be removed from the side of the shovel without interference from the gear case drives. The gear cases cannot be removed unless the drive motor mounting bolts are removed and the drive motor spigot is removed from the input gear case bore.

Position miner at intersection, so as to allow access to the side of the gathering head. Consider roof bolts position when positioning miner.

1.

Lower the gathering head to the mine floor.

2.

Raise the auger cutting head and securely fit in manufactured head stops to the gathering head and lower auger head onto the stops.

3.

With power on machine open gathering head plows fully for access to decking covers.

WARNING:

4.

Isolate machine as per mines isolation procedures. Remove CLA’s as per CLA removal procedure.

Remove the 5/8” hex head cap screws (a total of 11 per side) securing the three pot covers on the corner of the pot (see Figure 6.7).

NOTE:

There are two different lengths of these screws, 2 ¼ “ (Qty. 6) and 4” (Qty 5). They should be tagged for replacement in their correct locations during re-assembly.

5.

Remove the top cover over the input gear case (figure 6.7). Remove a total of sixteen (16) 5/8” countersunk socket head cap screws from the edge of the top cover.

6.

Remove the foot shaft cover by removing the two (2) ¾” UNC socket head cap screws securing the cover.

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R.H. TOP COVER

5/8" UNC x 2"LG COUNTERSUNK SOCKET HEAD CAP SCREWS

FOOTSHAFT COVER

POT COVER

FOOTSHAFT

MUFF COUPLING SPLINED ADAPTOR

POT COVER

POT COVER 5/8" UNC HEX HEAD CAP SCREWS

Figure 6.7

7.

Hydraulic pressure has to be removed from conveyor chain tensioning cylinders by opening needle valve next to chain tensioning pressure gauge as described in conveyor chain disassembly.

8.

Remove the clamp ring and slide back the adaptor shaft as explained in removal of footshaft.

If only one side gearcase assembly is to be removed it is only necessary to disengage the side being removed.

9.

Remove the motor access cover on the side of the gathering head frame (see Figure 6.8).

NOTE:

The drive motors can be removed from the side of the shovel frame as described below there is no need to remove or disturb other components.

If the input or C.L.A pot has to be removed they have to be removed as an assembly. The gear cases cannot be separated on the machine and removed individually

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INPUT GEARCASE

MOUNTING BOLTS

WEDGE BLOCK

POT

MOUNTING BOLTS 7/8" UNC x 2" LG HEX HEAD CAP CREWS

3/4" UNC x 10" LG MOTOR BOLT

3/4" UNC x 10"LG MOTOR BOLTS

3/4" x 20" LG MOTOR BOLTS

ACCESS COVER

Figure 6.8

10.

If electric motor is not to be changed out there is no need to disconnect the electrical cable and water lines from the motor.

11.

Remove the bearing cap cover from the exposed end of the motor (See Figure 6.9).

12.

Remove the snap ring and plug from the end of the motor, exposing the torque shaft.

13.

Remove the torque shaft as per torque shaft change out procedure at start of this section.

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B

R.H. POT CASE 1" UNC x 2-1/2"LG HEX HEAD CAP SCREWS

INPUT GEAR CASE

Ø1" DOWEL (2 PER SIDE) 1" UNC x 2-1/2"LG SOCKET HEAD CAP SCREWS TORQUE SHAFT

B

DRIVE MOTOR

VIEW B-B BEARING CAP COVER

PLUG SNAP RING

Figure 6.9 14.

Remove the eight (8) motor bolts on the motor (see Figure 6.8). Carefully back the motor out of its pilot-hole engagement and move away from the gathering head input gear case. If motor is not required to be removed it is not necessary to remove motor from the shovel.

15.

Disconnect any oil fill lines or pipes connected to the gear cases.

16.

Loosen the pot case attachment to the frame by removing the nine (9) 7/8” hex head cap screws from the four corners of the pot (see Figure 6.8). Removing these screws will also remove the four wedge blocks which secure the pot in position.

17.

Fit a lifting device securely to the top surface of the pot and the input gearcase and remove the pot from the gathering head frame.

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Reassembly of Gathering Head Gear Cases TOOLING REQUIRED - 3/8” in-hex - Ratchet and breaker bar - Heel Bar - 5/8” in-hex - ¾” in-hex - Chain breaker (where possible) - Porter-power with hollow ram for 1” threaded bar - Air lines and impact gun - 1” eye bolts x 2 - ¾” UNC jacking bolts x 3 - 1 1/8” socket - ½” drive extension - ¾” drive extension - 9/16” in-hex - 1” threaded bar long enough for hollow porta power ram

NOTE:

1.

Both the gathering head input and the CLA gear case has to be fitted as an assembly. They cannot be installed separately.

With the machine isolated as per mines isolation procedure and the cutter head safety stops in position to support the cutter head position the gear case assembly to allow the lifting equipment to lower into position.

WARNING: or death.

Failure to isolate machine as per mines procedures may cause serious injury

2.

Using lifting gear, lift and position gear cases above where gear cases fit.

3.

Lower gear cases into position.

4.

Line up mounting holes and start 5 – 7/8 x 2” long hex head cap screw with hardened steel washers. Figure 6.8.

NOTE:

Rev 1

Do not tighten bolts at this point.

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5.

Fit 4 wedge blocks and 7/8” x 2” long hex head cap screw with hardened steel washers and torque bolts to 646 ft lbs or 875Nm. Figure 6.8

6.

After torquing the wedge bolts then torque the mounting bolts to 646 ft lbs or 875Nm.

7.

Replace pot covers shown in figure 6.7 and torque hex head cap screw to 226 ft lbs or 306Nm.

8.

Replace top cover shown in figure 6.7 and torque countersunk socket head cap screw to 236 ft lbs or 320Nm.

9.

Replace CLA before connecting spline adaptor line up the centre of one arm to be between the centres of 2 arms on the opposite side.

10.

Connect splined adaptor and muff coupling see figure 6.7 replace footshaft cover.

11.

Reposition electric drive motor using a lever bar to slide motor into spigot of input gearcase.

12.

Start 8 ¾” motor. The motor bolts have an extended head 6 off 20” long and 2 off 10” long see figure 6.8 for position of bolts.

13.

Torque bolts to 392 ft lbs or 531Nm.

14.

Replace torque shaft as per torque shaft replacement procedure at start of this section.

15.

Check oil levels in both input and CLA gearcases and top up if necessary as per lubrication and servicing procedure in section 11.

16.

Repower machine as per mines repower procedure.

17.

Start machine and test conveyoring system.

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Removal of the Gathering Head from the Main Frame Weight of gathering head without drill rigs and shields = 9000 kg

NOTE:

To remove the shovel complete from the main frame, the shield and the roof bolting components can be removed from the gathering head for easier access to components.

NOTE:

BEFORE proceeding with the removal of the gathering head, A SAFE WORK METHOD STATEMENT is required from the drill rig OEM prior to the removal of any drilling units.

1.

Place the machine in a position where both sides in front of the crawlers are accessible.

2.

Lower gathering head until the dozer blade rests on the mine floor using wood packing blocks support the back of the gathering head (drawing required showing where to pack).

3.

Lower the cutting head frame and rest on gathering head frame.

4.

Remove all power from the machine and trip all circuit breakers to the "OFF" position.

WARNING:

5.

Clean off an area of the miner where parts can be set. Place clean rags or cardboard on this area, and keep dirt off the parts. Cover them if necessary.

NOTE:

6.

A competent Electrician is required at this point..

Electrician to disconnect and insulate left and right hand conveyor motor contactors and RTD circuit in the main flameproof enclosure. Disconnect and insulate load side wires of each component.

WARNING:

Rev 1

Isolate machine as per mines isolation procedures.

Failure to isolate machine as per mines procedures may cause serious injury or death.

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7.

Disconnect all water hydraulic and lubrication lines going to the gathering head conveyor drive motor, the gathering head gear cases and cylinders. Cap all hydraulic hoses disconnected from shovel and mainframe.

NOTE:

The electrical wiring and water lines going to the cutting head do not have to be disconnected.

BOLTER CONTROLS

ROOF BOLTER

CUTTING HEAD

GATHERING HEAD

SECTION THRU CUTTING CYLINDER LIFT PIN LOOKING TOWARDS FACE

Figure 6.10 8.

Disconnect and mark hydraulic and water hoses from mainframe to roof bolter controls and cap. Unbolt proximity switches from shields if fitted.

9.

Proceed to adhere to the Drill Rig OEM’s Safe Work Method Statement for the removal of the drilling units from this point forward until all drill rigs are removed.

10.

At this point the cutter head needs to be raised and the safety support pins positioned to support the cutter head. Power will be needed to raise the cutter head.

WARNING:

Rev 1

Ensure to inspect that the correct isolation has been carried out on the Cutter Head, Conveyor and Traction motor circuit breakers. Proceed to isolate the Cutter Head, Conveyor and Traction motors.

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11.

Apply power to machine.

12.

Raise the cutter head and install cutter head stops.

WARNING:

13.

Disconnect the conveyor chain (SEE CONVEYOR CHAIN REMOVAL).

WARNING

14.

The gathering head frame must be supported on the mine bottom with the dozer blade on mine floor and wood packers as shown in figure 6.12.

Support the rod end of the gathering head raise cylinders.

NOTE:

Rev 1

Isolate machine as per mines procedures.

The gathering head raise cylinders do not have to be removed from the main frame. If they are to remain in place, rotate them back away from the gathering head and securely wire or otherwise support them on the main frame.

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Figure 6.12

Rev 1

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MAINFRAME

GATHERING HEAD PIVOT PIN

MAINFRAME BUSHING

3/4" UNC x 2"LG HEX HEAD CAP SCREW (3 PER SIDE)

MAINFRAME BUSHING

PIVOT PIN RETAINER

PIVOT PIN RETAINER MAINFRAME BUSHING

GATHERING HEAD FRAME

LOWER CYLINDER PIN KEEPER PLATE

MAINFRAME BUSHING

LOWER CYLINDER PIN

SECTION A-A Figure 6.13 15.

Remove the upper cylinder pins from the gathering head raise cylinders.

16.

Remove the six 3/4" cap screws holding the main gathering head pivot pin retainer (See Figure 6.12 and 6.13) and remove the retainer.

17.

Using the hollow porter power and threaded rod pull the gathering head hinge pin out from the outboard side going in. If the pin does not come out, check to see that there is adequate, but not forcing, support under the rear of the gathering head.

18.

Remove isolation tag from traction circuit breaker and place in on position.

WARNING:

19.

Apply power to the miner.

WARNING:

Rev 1

Leave the cutter head and conveyor circuit breakers in off position.

Do not attempt to start the cutting head. Do not attempt to start the conveyor.

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NOTE

Prior to moving the miner, be sure that the lower section of the conveyor chain is free of the foot shaft so that, when the miner is trammed backward, the chain will pull free of the return deck of the gathering head.

20.

Raise the cutting head and remove safety stops.

21.

Lower cutter head to a position where it will clear the gathering head.

CAUTION:

The miner can now be backed slowly and carefully away form the gathering head assembly.

22.

Slowly tram the miner away from the gathering head until the gathering head is clear and the conveyor chain is free.

23.

Lower the cutting head to the floor.

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Installation of the Gathering Head TOOLING REQUIRED - Cincinnati chain breaker - Long screwdriver - General tools – hammers, chisels, pliers, shifters etc - 2 – crow bars - Porter power with 5 tonne ram 4” stroke Information

NOTE:

The gathering head will have to be positioned to allow the miner to be trammed onto the gathering head. The rear of the gathering head will need to be packed up the height of the main pivot bores on the main frame. If possible use same timber blocks used during disassembly.

Consideration when positioning gathering head to shield positioning and lifting points needs to be addressed if drill rigs and shield has been removed.

1.

Apply power to the miner and raise the cutting head so that it will be clear of the gathering head.

2.

Tram the miner to the gathering head frame, positioning it to align the pivots.

WARNING:

3.

Rev 1

BECAUSE THE MINER IS TRAMMING, THE CUTTING HEAD CANNOT BE BLOCKED UP. MAKE CERTAIN THAT ALL PERSONNEL STAY CLEAR OF THE CUTTING HEAD UNTIL THE MINER IS IN POSITION TO MATE WITH THE GATHERING HEAD.

When the gathering head pivots are closely aligned, lower cutting head onto the floor making sure the cutter head does not contact the gathering head. Timber blocking may be required under cutter head cutting drums.

WARNING:

Failure to securely block the cutting head could result in serious injury.

WARNING:

Isolate machine as per mines procedures.

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4.

Before attempting to install the pivot pins, make sure that the pins and their bushings are well-coated with grease to aid assembly.

5.

Install the RH and LH gathering head pivot pins. Be sure that the pivot bores in the gathering head frame and the main frame are aligned, and that you do not damage the end of the pivot bushing when starting the pin in.

6.

To align bores gathering head my need to be moved slightly. This can be done by using porter power ram under the shovel. Position either side behind packing supporting rear of shovel and use to raise. If shovel bore needs to be lowered remove some packing and lower with porter power.

7.

Place pivot pin to be started into bore see figure 6.13 and using porta power force home.

Repeat other side.

8.

Using porter power, enter each pivot pin in from the centre, until they are flush with the main frame pivot bushing and insert pivot pin retainer between the tow pins.

9.

Install the six (6) 3/4" cap screws to secure the retainer. Tighten the cap screws to 392 ft lbs or 531Nm.

10.

Align the gathering head frame clevises and both raise cylinders to accept the upper cylinder pins. Install the upper cylinder pins through the gathering head frame clevis and the eye of each cylinder.

NOTE:

The gathering head cylinder has a dry socket that allows the dry socket to be pulled out without hydraulic pressure. This can be done by hand. If not use lifting block to pull out.

11.

Replace cylinder pin retainers.

12.

Lubricate the cylinder pins and pivot pins.

NOTE:

Before proceeding with the installation of the gathering head, A Safe Work Methos Statement is required from the Drill Rig OEM prior to fitting the drill units.

13.

Proceed to adhere to Drill Rig OEM’s Safe Work Method Statement for the installation of the drill rigs from this point on until rigs are completely mounted to the mounting shield on the rear of the gathering head.

14.

Re connect the marked hydraulic and water hosing from the mainframe to the roof bolter controls and be thoughtful in the hose routing. Bolt the proximity switches to the shield if fitted.

15.

Connect the water lines and lubrication lines going to the gathering head motors including Bretby.

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16.

Connect the electrical leads to the motors and remount proximity switch for inside drill rigs tilt.

17.

Check oil levels in the gathering head pot cases and the gathering head input gear case.

18.

Check for proper greasing in the drive motors.

WARNING:

With the cutter head conveyor and traction circuit breakers in the off position apply power to the machine.

19.

Apply power to the machine.

20.

Raise cutter head and position safety stops.

WARNING:

Isolate machine as per mines procedures.

21.

Reassemble conveyor chain (refer to conveyor chain disassembly and assembly).

22.

Remove torque shaft from the left or right side conveyor motor.

23.

Reapply power to machine with the cutter head and traction circuit breakers in off position.

24.

Ensure the conveyor take up needle valve is closed. It is mounted on the RHS of the miner as per decals.

25.

Turn power on machine and check direction of motors that still has the torque shaft installed.

26.

Remove power from machine and isolate as per mines procedures.

27.

Replace torque shaft in motor not checked for direction and remove torque shaft from motor that has been tested and is running in the correct direction.

28.

Reapply power to machine with cutter head and traction circuit breakers in off position.

29.

Check direction off the second motor.

30.

When both motors are running in the correct direction raise the cutter head and remove cutter head safety stops.

31.

Clean up around and on machine.

32.

Test conveying systems

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CONVEYOR ASSEMBLY General Description The conveyor assembly is shown in Figure 7.1. The conveyor can be raised and lowered by hydraulic cylinders to facilitate loading. The assembly is attached to the main frame at a pair of raise pivots, and can be elevated by two hydraulic raise cylinders. The discharge section of the conveyor has a double-clevis swing pivot and can be swung 45o left or right to aid in manoeuvring around intersections or loading the haulage vehicle.

The tension on the conveyor chain is maintained by two hydraulic cylinders which have a constant 300PSI / 20 Bar supply when the pump/s are running.

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Conveyor Chain Removal TOOLING REQUIRED - Conveyor Chain Breaker - General Tools, hammers, chisels, shifters, pliers, etc - Long wire rope to pull conveyor chain around 30 metres long - Lever Bars A number of maintenance jobs on the miner require either breaking apart the conveyor chain or removing it completely. The following procedure will accomplish this.

1. Place the miner in a place under supported roof and where the top of the conveyor and both ends of the machine can be reached. Allow sufficient room at the back of the miner to pull the chain off the conveyor.

2. Raise the cutting head, and block it securely using safety support pins.

WARNING:

Failure to securely block the cutting head could result in serious injury.

3. Align the discharge conveyor straight with the intermediate conveyor, and lower the conveyor to its lowest position.

4. Remove all power from the machine and trip all circuit breakers to “OFF”.

WARNING:

Isolate machine as per Isolation Procedures.

5. Open the proper needle valve on the RH side of the machine which will release hydraulic oil volume from the constant tension take-up cylinders on the discharge conveyor. This will relax tension on the conveyor chain. Leave bleed off valve open.

CAUTION:

To avoid injury from flying debris of hardened steel, safety glasses (or face shield) for eye protection is required. Gloves should also be considered.

6. Use a pry bar to lift the chain off the conveyor deck several times to relieve tension in the chain.

7. Using a chain Breaker, disconnect the chain as per conveyor chain disassembly SECTION 6.

Disconnect the chain at the rear of the machine on the top decking.

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UNIVERSAL CONNECTOR FLIGHT PIN

RETAINING PIN CONNECTING PIN

SIDE STRAP

CHAIN FLIGHT

RETAINING PIN

Figure 7.2

NOTE:

For many jobs, such as maintenance on or removal of the Gathering Head, the conveyor chain needs only to be separated and not completely removed.

8. Pull the top half of the conveyor chain off the back of the machine.

NOTE:

To facilitate re-installation of the same chain or a new chain, attach a long puller cable to the end of the chain. To be pulled along the return deck.

When the conveyor chain is removed, this puller cable will travel with the forward end through the return deck to the back end of the conveyor, and will then be available to pull the new conveyor chain through the return deck and forward to the foot shaft.

9. Removing the gathering head foot shaft is not necessary, but be sure that the chain is disengaged from the foot shaft sprocket. Pull the other half of the conveyor chain rearward and out of the conveyor return deck.

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Conveyor Chain Installation WARNING:

Failure to isolate machine as per mines procedures may cause serious injury or death.

1. Make sure the cutting head is securely blocked, the machine power "OFF", and the conveyors straight and lowered.

WARNING:

Inadequate support of the cutting head can cause serious injury or the loss of life.

2. Lay the new chain, uncoiled and upside down, behind the conveyor, with the nearest end near the tail roller.

NOTE:

The conveyor chain does not have a correct or incorrect running direction, only a correct up and down side. The flat side of the flight chains must run on the deck.

3. Connect the pulling cable (see previous section, Steps 8 and 9) to the nearest end of the conveyor chain.

4. Pull the conveyor chain under the tail roller and through the return deck, stopping when the chain reaches the foot shaft.

5. Pull the conveyor chain up over the foot shaft sprocket and lay it in gathering pan.

6. With the pulling cable, keep pulling the chain and run it along the top conveyor deck to the back of the miner.

7. Pull or lift the other end of the conveyor chain off the mine floor and roll over the tail roller on the top deck.

8. Connect the chain using a connecting pin and two retaining pins (one in each end of the connecting pin). Bend the retaining pins opposite the direction of conveyor chain travel.

9. Clear the area of all tools.

CAUTION:

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10. Apply power to the miner, raise the cutting head, and remove the blocking.

11. Turn on the CLA motors to run the conveyor chain. Elevate the conveyor full up and down and swing the discharge conveyor full right and left and check that the chain is running smoothly.

12. Observe the chain as it comes off the foot shaft and ensure that there is no excessive slack, as indicated in Figure 2-4.3.

EXCESSIVE SLACK IN CONVEYOR CHAIN

Figure 7.3 Illustration of Excessive Conveyor Chain Slack 13. If such excess is observed, adjust the chain tension by adjusting the setting of the pressurereducing relief valve in the conveyor take-up circuit located in the main valve bank.

14. If the pressure is at the correct setting as indicated on gauge (300psi / 20 Bar), a chain link segment must be removed to shorten the chain.

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Removal of the Conveyor Assembly from the Miner Combined weight of the Intermediate and Discharge Conveyor = 7500kg

TOOLING REQUIRED - 2 – 3 tonne lifting blocks - 2 – Adjustable chains 2 metres long to support 3 tonne sockets 1 1/8” AF - Porter power with hollow ram for 1” threaded rod the length of the porter power plus 4” for nut and washers - Timber blocks

1. Using miner hydraulic power, raise and block the conveyor in an elevated position so as to provide access to the upper conveyor raise cylinder pins.

WARNING:

Inadequate support and securement of the conveyor can result in serious injury or loss of life.

2. Remove all power from the machine and trip all circuit breakers to the "OFF" position.

WARNING:

Failure to isolate machine as per mines procedures may cause serious injury or death.

3. With the conveyor still supported by the conveyor safety support pin, attach lifting devices to both the intermediate and discharge conveyor sections and tension them without raising the conveyor.

4. Relieve the pressure in the conveyor chain take-up circuit (see CONVEYOR CHAIN REMOVAL).

5. Use a pry bar to lift the chain off the conveyor deck several times to relieve tension in the chain.

6. Disconnect the conveyor chain and remove it from the machine.

7. Support the rod end of each conveyor raise cylinder. Remove the cotter pins from each upper cylinder pin and remove the cylinder pins (see Figure 7.4). Allow the cylinders to be lowered to the stabilizer or rear bumper.

8. Appropriately block or secure the conveyor assembly laterally to prevent it from swinging when the hydraulic lines are removed from the swing cylinders. On many miners, this drift may not occur, depending on the side slope of the mine floor and the amount of wear at the pivot area.

But the danger still exists. Obviously, the greater the slope of the mine floor, the higher the tendency of the conveyor to drift. In any case, ensure that it will not swing either way.

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CONVEYOR

Ø3/8" COTTER PIN LATERAL SWAY GUIDE

UPPER CYLINDER PIN 3/4" UNC x 2-1/2" HEX HEAD CAP SCREW

GUIDE PLATE 1" UNC x 3"LG HEX HEAD CAP SCREW

GUIDE DISC

1" UNC JAM NUT

CONVEYOR RAISE CYLINDERS

1" UNC x 2-1/2"LG SOCKET HEAD CAP SCREW

MAINFRAME

LOWER CYLINDER PIN

Figure 7.4 9. Be sure to disconnect the hydraulic hoses going from the side of the conveyor to the mainframe

WARNING:

Inadequate support and securement of the conveyor can result in serious injury or loss of life.

10. Remove the hydraulic lines going to the swing cylinder. Cap off the hose ends and cylinder ports using ¾” JIC caps. Cap the cylinder port off when the hose has been removed before disconnecting the next hose. Do both cylinders, one port at a time.

11. Disconnect lube lines going to the RH and LH pivot pins.

12. Disconnect water lines to water spray manifolds.

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LATERAL SWAY GUIDE PIVOT RETAINER

3/4" UNC x 2"LG HEX HEAD CAP SCREWS

GUIDE PLATE

INTERMEDIATE CONVEYOR MAINFRAME

CONVEYOR RAISE CYLINDER CYLINDER PIN CAP

1" UNC x 2-1/2"LG SOCKET HEAD CAP SCREW

Figure 7.5 13. Release any pressure that might exist between the lateral sway guides and the guide discs (Figure 7.5) by backing out the 1” square head set screw on each side.

PIVOT PIN RETAINER

MAINFRAME BUSHING CONVEYOR PIVOT PIN

CONVEYOR MAINFRAME BUSHING

MAINFRAME

CONVEYOR FRAME BUSHING

Figure 7.6

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14. Remove the six ¾” x 2” cap screws from the conveyor pivot pin retainer (see Figures 7.5 and 7.6) and remove the pivot pin retainer.

15. Push the conveyor pivot pins toward the centre until they are free.

NOTE:

If the pivot pin is tight, be sure the lifting devices are not binding the pivot. If it is not, then use the 1” tapped puller hole to aid removal of each pin.

16. With the lifting gear raise the forward end of conveyor to clear machine.

17. The miner can now be driven forward away from the conveyor.

18. Apply power to the miner.

WARNING:

Isolation of the conveyor motors and cutter head is required when driving the miner away from the conveyor.

19. Slowly drive the miner away from the conveyor.

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Installation of the Conveyor Assembly TOOLING REQUIRED - 2 – 3 tonne lifting blocks - 2 – Adjustable chains 2 metres long to support 3 tonne sockets - 1 - 1/8” AF - Porter power with hollow ram for 1” threaded rod the length of the porter power plus 4” for nut and washers - Wooden blocks 1. Attach a lifting device to the conveyor assembly and slowly maneuver onto the machine.

2. With the conveyor pivot in position, grease the conveyor pivot pins to facilitate their installation and drive them into the pivot bores.

3. Install the pivot pin retainer with six ¾” x 2” hex head cap screws. Uncap and reconnect the lube lines in each pivot pin.

4. Using the lifting device, pivot the conveyor into an elevated position and securely block the conveyor.

WARNING:

Inadequate blocking and securing the conveyor can result in serious injury or loss of life.

5. Uncap and reinstall the hydraulic lines going to the swing cylinders.

6. Attach the conveyor raise cylinders to the clevises on the underside of the conveyor by installing the upper conveyor raise cylinder pins.

7. Reconnect the conveyor chain (see CONVEYOR CHAIN INSTALLATION SECTION 6).

8. Adjust the guide discs to the lateral sway guides. See figure 7.4. Tighten adjusting bolt until disc touches mainframe and lock adjusting bolt. Do not put pressure on discs.

9. Clear all tools, parts and debris from the area.

10. Remove the lifting device.

WARNING:

Be sure all conveyor components are installed correctly and that the conveyor chain is properly engaged to the foot shaft sprocket before starting the miner.

11. Close take up cylinder needle valve and apply power to the machine. Ensure the take up cylinders tension the chain turn on the CLA motors to run the conveyor chain. Elevate the conveyor full up and down and swing the discharge conveyor full right and left and check that the chain is running smoothly.

WARNING:

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Be sure all conveyor components are installed correctly and that the conveyor chain is properly engaged to the foot shaft sprocket, before starting the miner.

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Removal of Discharge Conveyor Weight of discharge conveyor 3000 kg TOOLING REQUIRED - 2 – 1 tonne lifting devices - 4 – Adjustable lifting chains 1 metre long - General tools – hammers, chisels, shifter, pliers etc Information The discharge conveyor is the discharge end of the conveying system. From where the discharge section swivels laterally on the pivot to the end of the structure is called the discharge section.

1. Tram the machine to a place where the top and bottom of the conveyor can be reached, and there is enough room at the back for the removal of the conveyor chain and the discharge conveyor.

2. Raise the conveyor far enough to provide adequate work space under the swing pivot.

Securely block the intermediate conveyor section so the swing pivot remains accessible.

WARNING:

You will be working beneath the conveyor! Inadequate blockage can result in serious injury or loss of life.

3. Align the discharge conveyor straight with the centreline of the intermediate conveyor.

4. Remove power from the machine and trip all circuit breakers to the "OFF" position.

5. Relieve the pressure in the conveyor chain take-up circuit (see CONVEYOR CHAIN REMOVAL).

6. Attach the lifting devices to the discharge conveyor and tension it to support the weight. One device should support the rear and one positioned around swivel point.

7. With needle valve open as per step 5, use a pry bar to lift the chain off the conveyor deck several times to relieve tension in the chain.

8. Disconnect the conveyor chain using a chain breaker at a connecting pin close to the end of the discharge conveyor.

9. Disconnect the hydraulic lines from the discharge conveyor swing cylinders. Cap the lines and cylinder ports.

10. Remove the forward swing cylinder pin at the intermediate conveyor section.

11. Remove the ½” x 1-1/2” carriage bolts and ½” heavy hex elastic stop nuts that attach flexible sideboards to each side of the intermediate conveyor. See Figure 7.7

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SIDEBOARD RETAINER

CARRIAGE BOLTS

INTERMEDIATE CONVEYOR DISCHARGE CONVEYOR

FLEXIBLE SIDEBOARD

CARRIAGE BOLTS

Figure 7.7 12. Remove the four ¾” hex head cap screws (one 1-1/2” long, three 2” long) and their ¾” spring lock washers from each flexible sideboard guide assembly and remove them from the top of discharge conveyor on each side (see Figure 7.1).

13. Remove the flexible sideboards.

14. Remove the six ¾” x 2-1/2” Nylock socket head cap screws from the top pivot pin (see Figure 7.8) and remove the top pivot pin. Two ¾” tapped puller holes, protected by set screws and located on top and bottom of each pivot pin, are provided to aid in removing the pivot pin. As seen in Figure 7.8, a pivot retainer will remain in the top pivot bore. If not already released, this retainer can be tapped loose and removed from the area between the top and bottom conveyor decks.

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Ø3/4" DOWEL PIVOT PIN DISCHARGE CONVEYOR

3/4" UNC x 2-1/2"LG SOCKET HEAD CAP SCREWS (6 TOP & 6 BOTTOM)

INTERMEDIATE CONVEYOR

ADJUSTMENT SHIM 1" UNC x 4-1/2"LG SOCKET HEAD CAP SCREW

PIVOT RETAINER Ø1/2" ANTI-ROTATION DOWEL

Figure 7.8 15. Repeat this procedure for the bottom pivot pin and pivot retainer. If the bottom pin is not free to come off, check the tension on the lifting device to help free the pin. Remove the bottom pivot retainer.

16. The miner can now be driven forward away from the conveyor.

17. Reapply power to the miner.

WARNING:

Isolation of the conveyor and cutter motors is required when driving miner away from conveyor.

18. Slowly and carefully manoeuvre the discharge conveyor away from the intermediate conveyor section by moving machine forward.

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Installation of Discharge Conveyor TOOLING REQUIRED - 2 – 1 tonne lifting devices - 4 – Adjustable lifting chains 1 metre long - General tools – hammers, chisels, shifter, pliers etc Information The discharge conveyor needs to be supported by lifting blocks as per disassembly procedures at a height to allow the miner to be tracked on to the suspended conveyor.

1. With the intermediate conveyor securely supported by lifting devices as per disassembly procedure tram miner onto the discharge conveyor. Line up the swivel bores as close as possible using machine positioning.

WARNING:

Isolate machine as per mines isolation procedures.

2. Remove power from the machine and trip all circuit breakers to the “OFF” position.

WARNING:

Failure to securely block the intermediate conveyor or securely attach the lifting device to the discharge conveyor properly can result in serious injury or loss of life.

3. Check the top and bottom pivot pins and bushings for wear or damage, and replace them as necessary. Lubricate all pins and bushings with grease prior to installation.

4. Install the top pivot pin and pivot retainer, using six ¾” x 2-1/2” Nylock socket head cap screws.

Note that the pivot pin has an anti-rotation dowel which must be positioned in the slot in the top conveyor deck.

5. Similarly, install the bottom pivot pin and pivot retainer, using six ¾” x 2-1/2” Nylock socket head cap screws. The bottom pivot pin also has an anti-rotation dowel which must be positioned in the slot in the top conveyor deck.

6. Adjustment shims are provided (see Figure 7.7) in the event that the decks of the intermediate and discharge conveyors are misaligned due to wear or damage to the discharge conveyor.

7. Grease the four pivot surface lube points (two on each side) until grease is visible on the mating sections of the conveyor. This will lubricate the pivot pins and bushings as well as the large plates which slide on each other.

8. Using the lifting device, position the conveyor to align the swing cylinder clevises with both swing cylinder eyes. Lubricate the cylinder pins with grease and insert them, securing each with a new ¼” cotter pin/keeper plates.

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9. Uncap and reconnect the hydraulic lines to the cylinders. 2 swing cylinders and 2 take-up cylinders.

10. With the discharge conveyor straight, reconnect the conveyor chain (see CONVEYOR CHAIN INSTALLATION).

11. Install a flexible sideboard on each side of the conveyor, using three ½” x 1-1/2” carriage bolts with heavy hex elastic stop nuts on each sideboard.

12. Install the two flexible sideboard guides on each side of the discharge conveyor using two ¾” x 1-1/2” long hex head cap screws in the rear holes and six ¾” x 2” long hex head cap screws in the remaining holes.

13. Clear all tools, parts and debris from the area.

14. Remove isolation tags as per mines procedures and apply power to the machine.

15. Apply power to the machine.

16. Raise the conveyor and remove the blocking.

17. Operate the conveyor raise, lower, swing right and swing left and check for smooth operation.

18. Run the conveyor chain and check for correct operation of the take-up cylinders with chain running and swinging conveyor left to right.

Removal of Tail Roller Weight of Tail Roller 60 kg TOOLING REQUIRED - 1 Crow bar - 3/8” AF Allen Key - General tools – hammers, chisels, shifter, pliers etc - Chain Breaker

1. Place the machine to where the take-up roller can be comfortably reached and enough room is available for removal.

2. Align the discharge conveyor straight with the centreline of the intermediate conveyor.

3. Lower the conveyor to a comfortable work height, and support it securely.

WARNING:

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Failure to securely block the conveyor can result in serious injury or loss of life.

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Figure 7.9 4. Remove all power from the machine and trip all circuit breakers to the "OFF" position.

WARNING:

Failure to isolate machine as per mines procedures may cause injury or death.

5. Relieve the pressure in the conveyor chain take-up circuit as described in the CONVEYOR CHAIN REMOVAL section.

6. Use a pry bar to lift the chain off the conveyor deck several times to relieve tension in the chain.

7. Break the conveyor chain near the tail roller and clear the chain from the roller.

8. Remove the cover over each side of the tail roller by removing four 5/8” x 1-1/4” socket head cap screws from each cover (see Figure 7.9 & 7.10).

9. The tail roller may now be removed from the take-up slide.

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Figure 7.10 Re-Fitting of Tail Roller 1. With the machine still isolated as per removal procedure and the conveyor still fully lowered to bumper place tail roller in position.

2. Fit end caps and start socket head cap screw. See figure 7.10.

3. Torque ½ x 2 ¼” long socket head cap screws to 118 ft lbs or 160Nm. 4. Rejoin conveyor chain as per conveyor chain installation procedures at start of this section.

5. Close needle valve and lubricate roller as per maintenance procedure.

6. Remove isolation tags and re-power machine as per mines re-power procedure.

7. Start machine and check pressure reading at gauge next to needle valve.

8. Pressure gauge should read 300psi or 20bar.

9. Start conveyor and run conveying system.

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TRACTION SYSTEM General Description The RH and LH traction drive systems each consist of a D.C. tram drive motor, a tram drive gear case, a crawler chain, a chain take-up roller operated by a grease take-up cylinder.

RH PUMP DRIVE ASSEMBLY MAINFRAME BRAKE

CRAWLER FRAME

CRAWLER CHAIN

RH TRAM GEARCASE RH TRAM DC DRIVE MOTOR

GREASE TAKE-UP CYLINDER

TAKE-UP ROLLER

Figure 8.1

These components are mounted in a crawler frame which is an integral part of the main frame weldment. See Figures 8.1.

The LH crawler frame, contains the pump drive assembly which provides hydraulic pressure for the bolting rig circuitry when in bolting mode and the RH pump supplies hydraulic pressure to the mining and maintenance mode as well as the bolting component on the right side of the machine.

Operating the tram controls causes DC voltage to be supplied to the tram drive motors. The drive motor on each side of the miner powers an input planetary (see Figure 8.2) which is connected to a set of transfer gears on the inboard side of the motor. The transfer gears send power through the tram drive shaft into an output (crawler) planetary which drives the large 7T crawler chain drive sprocket and the crawler chain.

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Removal of the Tram Drive Gear Case Assembly (Complete with drive motor) Weight of Track Assembly 3000 kg

TOOLING REQUIRED - 2 adjustable lift chains 3 metres long each 2 tonne - Allan Keys ¾” AF ½” AF - ¾” drive in hex sockets ¾” ½” AF - ¾” drive extension bar - ¾” drive breaker bar and ratchet - Porter power with no. 6 Jic female hose end - Gauge 0 – 500psi 40bar - Timber Information Timber blocks to support the weight of the complete machine 80 tonnes. 4 points to be blocked the front and rear of each track approximately 20 tonnes on each stack. If only one assembly is to be removed it is only necessary to block the side to be changed out.

TRAM DRIVE SHAFT

TRANSFER GEARS INPUT PLANETARY ASSEMBLY

MAIN DRIVE SPROCKET BEARING

DUO CONE SEAL

TRAM DRIVE SPROCKET

GEAR CASE DC Drive Motor

DUO CONE SEAL

MAIN DRIVE SPROCKET BEARING

CRAWLER PLANETARY ASSEMBLY

Figure 8.2

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1. Place the miner to where the side of the machine being worked on has enough room available for removal of the crawler drive gear case and motor assembly. LHD needs to access the gear case at 90o to the machine.

NOTE:

The crawler drive gear case and motor can be removed as one unit the weight of the unit complete 3 tonnes.

2. Lower the conveyors to its down position, and raise the gathering head to the limit.

3. Lower the stabilizer shoe to its full travel, raising the rear of the miner off the bottom.

4. Lower the gathering head to the mine floor lower the cutting head all the way to raise the miner fully off the mine bottom. Be sure that the crawler frame is level by adjusting either the cutting head or stabilizer shoe.

CAUTION:

If the crawler frame is not level, re-installation of the gear case assembly will be more difficult.

5. Securely block the miner using timber blocks under both crawler chains but avoiding the area near the tram gear case to be removed.

WARNING:

Failure to properly block the machine as per mines procedures may cause injury or death.

6. Remove all power from the machine and trip all circuit breakers to the "OFF" position.

WARNING:

ISOLATE MACHINE AS PER MINES ISOLATION PROCEDURES.

NOTE:

Electrician to disconnect and insulate crawler drive motor contactor and RTD circuit in the main flameproof enclosure. Disconnect and insulate load side wires of left side or right side contactor.

7. Remove or disconnect all assemblies mounted in the area of the tram gear case. This will include such items as rub rails, the trailing cable connection box, lighting fixtures, water sprays and any other items which might get in the way of removal of the gear case assembly.

8. Remove all tram gear case covers.

9. Separate the crawler chain at a convenient point near the tram gear case (see CRAWLER CHAIN REMOVAL) and move the chain clear of the drive sprocket. NOTE: This may require the tram brakes to be released, if so pump off tram brakes using porta power as in crawler chain removal.

NOTE:

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This may require the tram brakes to be released, if so pump off tram brakes using porter power as in crawler chain removal.

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10. Disconnect all water from the track drive motor. Tag them for later identification. The main gear case and final planetary gear case may be drained if desired, but it is not necessary.

11. Disconnect the electrical leads from the motor and tag them for later identification.

12. Remove the four (4) 1" UNC set screws inserted in the jacking holes on each side of the gear case (See Figure 8.3).

13. Clean off the side of the gear case. Now remove the nine (9) 1" UNC cap screws out of the mounting plate (four (4) on the out by/sprocket side, and five (5) on the in by/motor side).

14. Remove four (4) wedge blocks shown in figure 8.3.

1” X 3-1/2” SOCKET HEAD CAP SCREW (1 PER SIDE)

1” X 3” SOCKET HEAD CAP SCREW (2 AT TOP OF MOTOR)

WEDGE BLOCKS 4 POSITIONS

1” THREADED JACKING HOLE (2 PER SIDE)

¾” X 4” SOCKET HEAD CAP SCREW (4 OUT BY)

1” X 6” SOCKET HEAD CAP SCREW (4 OUT BY 5 IN BY)

1” X 4” SOCKET HEAD CAP SCREW (2 AT BOTTOM OF MOTOR)

WEDGE BLOCK

Note: RH side shown, LH opposite

Figure 8.3

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15. Insert a 1" UNC x 6” cap screw into each of the four (4) jacking holes just uncovered. Using these cap screws, slowly jack the main case loose from the frame.

16. Position a loading device, such as a scoop, FBL or LHD bucket to the bottom edge of the main case. Connect a couple of adequate chains between the scoop and the back of the mounting plate 17. Wrap adjustable lifting chains around the mounting plate.

WARNING:

Over-stressing the chains could cause failure resulting in serious injury.

18. Slowly pull the track drive assembly from the mainframe.

NOTE:

The track brake unit is attached to the top of the gear case assembly.

See figure 8.4 when removing assembly disconnect brake hoses and cap. Assembly can be removed without removing brake assembly.

19. Slowly maneuver the gear case and motor assembly clear of the machine and onto the loading device.

20. Thoroughly clean out the keyways so that they are ready for later re-installation. Cover the crawler compartment to keep out dirt and debris.

NOTE:

The assembly will be supported by 2” square mounting keys. The full length of the gear case assembly which support the assembly when removing or installing.

BRAKE UNIT

BRAKE GEARCASE ASSEMBLY

TRACTION GEARCASE

SECTION A-A

Figure 8.4

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Installation of the Tram Drive Gear Case Assembly NOTE:

The crawler drive gear case and electric motor can be installed as one unit.

1. Ensure that the crawler frame mounting area is cleared of dirt and debris. Be especially sure that the keyways, and the bore in the inner face of the main frame, are clean. Apply a generous coating of MOLYKOTE G-N paste or EP2 grease to aid re-installation.

BEARING CARRIER (PLUG)

MOUNTING KEY

MOUNTING KEY

MOUNTING KEY

MOUNTING KEY

Figure 8.5

2. Coat the mounting keys on the gear case with MOLYKOTE G-N paste or EP2 grease. Also coat the bearing carrier on the inboard end of the main gear case (See Figure 8.5) with MOLYKOTE G-N paste or EP2 grease. This bearing carrier serves as a plug to fit into the bore in the main frame.

3. Slowly maneuver the gear case and motor into position next to the machine aligning the keys on the gear case with the keyways/slots on the crawler frame.

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CAUTION:

If the machine and gear case assembly are not both level and aligned with each other, installing the assembly into the frame will be more difficult.

4. With the runners aligned, slowly push assembly into the crawler frame, allowing the keys on the gear case to engage the keyways in the main frame. Be sure that the cap screw mounting holes line up. Also be sure that the mounting surfaces for the mounting plate are free of contaminants.

5. Fit the 4 wedge blocks and four (4) ¾” UNC x 4” long socket head cap screws and tighten enough to support the assembly.

6. Install the eight (8) 1” UNC x 6” socket head cap screws and the single 1” x 3-1/2” socket head cap screw, and washers, at the side of the assembly (see Figure 8.3), partially tightening each one in turn, and then repeating. If necessary, first use 1”-longer cap screws to start the assembly sliding into the frame before installing the regular 6” cap screws.

7. Torque wedge block hex head cap screws to 416 ft/lbs.

8. Pre-tighten each of the nine (9) 1” UNC cap screws. Be absolutely sure that the mounting plate is in against the main frame all the way.

9. Torque each of the cap screws sequentially to 1,010 ft-lb.

10. Remove the scoop device and lifting tool from the area.

11. Install the four 1" UNC set screws into the jacking holes on each side of the gear case.

12. Reconnect all water and lubrication lines to the gear case. Make sure the fittings are tight.

13. Reconnect the electrical leads to the motor. Make sure the leads are connected correctly.

14. Refill or top off the oil in the gear case. Also lubricate the electric motor.

15. Reconnect the crawler chain (see CRAWLER CHAIN INSTALLATION).

16. Adjust crawler chain with the take up roller as per section 11 chain adjustments.

17. Remove isolation tags from machine leaving cutter motors and conveyor motors tagged and isolated.

18. Apply power to the machine. Operate the tram lever on the side which was re-installed and check for smooth and proper operation.

19. Trip all circuit breakers to the OFF position as per mines procedures.

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20. Reconnect or re-install all assemblies mounted in the area of the tram gear case.

21. Clear the area of all tools, parts or other material.

22. Remove all blocks from the miner.

23. Switch all circuit breakers to the ON position.

24. Apply power to the miner and raise the stabilizer shoe and cutting head to lower the miner to the mine bottom.

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Removal of a Tram Drive Motor Information The tram drive motor can be removed without removing the tram gear case assembly.

TOOLING REQUIRED - ¾” Allan Key - ¾” In hex socket ¾” square drive - ¾” Square drive extension bar - ¾” Breaker bar and ratchet - 2 Lever bars - ¾” drive 1 ½” AF Socket 1. Place the miner to where the side of the machine being worked on has enough room available for removal of the crawler drive motor.

2. Lower the conveyors to its down position, and lower the gathering head to the mine bottom.

3. Lower the stabilizer shoe slightly just enough to take the weight of the machines rear.

WARNING:

ISOLATE MACHINE AS PER MINES ISOLATION PROCEDURES. REMOVE ALL POWER FROM THE MACHINE AND TRIP ALL CIRCUIT BREAKERS TOM THE OFF POSITION

4. Remove all power from the machine and trip all circuit breakers to the “OFF” position as per mines isolation procedure.

NOTE:

Before proceeding beyond this point, a competent electrician is required.

5.

Remove or disconnect all assemblies in the area of the tram motor, including rub rails, platforms, electrical enclosures, lighting fixtures, water sprays, or any other auxiliary components that would impair removal of the motor.

6.

Disconnect all wires and hoses going to the motor.

7.

Remove four (4) – 3/8” hex head cap screws and cover plate at end of motor see figure 8.6 and remove snap ring.

8.

Using 3/8” UNC hex head cap screw around 4” long and remove ‘o’ ring plug.

9.

Using ½ UNC hex head cap screws around 6” long and remove quill shaft.

10.

Remove the two 1" x 3” and two 1” x 4” socket head cap screws securing the motor to the gear case (see Figure 8.6).

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11.

Place slings around the front flange of the motor, being sure that they will be able to support the weight of the motor.

12.

Using wedges behind the ears/flanges of the motor slowly separate it from the gear case and edge it out.

13.

Pull the motor straight out and onto a loading device (e.g., scoop, FBL, LHD).

TRAM GEARBOX

3/8" UNC HEX SCREWS (4 OFF) COVER PLATE

SNAP RING

QUILL SHAFT

SHAFT PLUG O'RING

Figure 8.6

Rev 1

CAUTION:

Be careful not to damage any of the gland cover protrusions on the motor when removing it from the miner.

NOTE:

When the motor has been removed, it is normal for oil to run out of gear case. The gear case does not have an oil seal on the output shaft.

The motor seal retains the oil in the gear case.

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Installation of a Tram Motor 1. Clean the motor and the motor cavity thoroughly.

2. Install a new o-ring (lubricated) on the motor mounting flange (rear bell).

3. Put some oil around the bore of the input planetary (in the motor cavity), to help ease installation.

4. Manoeuvre the motor assembly slowly into the cavity and along its bottom. Go easy. Make sure not to damage any of the gland cover protrusions.

CAUTION:

Be careful not to damage the o-ring around the rear bell, or any of the gland cover protrusions.

5. Position the motor further into the cavity, using bars to jockey it into the bore of the input planetary inside.

NOTE:

Once the motor mounting spigot starts into the pilot bore, the motor should go in relatively easy.

6. Keep working the motor in until it seats and the flange ears are flush. If the ears are not flush (to within .020"), the motor is not seated properly.

7. Install the 1" UNC motor cap screws and washers, and slowly tighten them retighten to correct torque 1010 ft/lbs.

8. Replace Quill Shaft.

9. Replace ‘O’ ring Plug.

10. Replace Cover Plate.

11. Refill the tram gear case with oil to the proper level. Check the gear oil level using the sight gauge on the outer face of the final planetary drive.

12. Reconnect all wires and water hoses going to the motor.

13. Turn on power to the miner, and check the tram operation on that side to ensure proper and smooth operation of the tram system.

14. Remove all power from the miner again, and reconnect or re-install all assemblies in the area of the tram gear case that were removed.

15. Clear the area of all tools, parts or other material.

16. Restore power to the miner, and remove all blocking.

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Crawler Chain Removal TOOLING REQUIRED - General tools – Allan Keys, spanners, hammers, pliers etc - Long towing cable about 10 metres long - Hydraulic hand pump with no. 6 JIC female tale end - ¾” Drift 600 mm long

Equipment

NOTE:

Use a LHD to pull chain from miner and to install back into the miner.

1. Place the machine in a position where there is sufficient side room to work and enough space available to pull the chain off.

2. Lower the stabilizer shoe and the cutting head to raise the entire machine so the crawler chain may be removed. Securely block the miner chassis. The machine blocking cannot be in the way of the crawler chain. Block the chassis under the rear bumper and under the gathering head cylinder mainframe clevises (see Figure 8.6).

TIMBER PACKING

TIMBER PACKING

Figure 8.7

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WARNING:

Improper blocking of the miner chassis can cause serious injury or loss of life

3. Raise the gathering head to its maximum up position and securely block it.

4. Lower the cutting head to rest on the gathering head.

5. Lower the conveyor to its down position.

6. Remove all power from the machine and trip all circuit breakers to the "OFF" position.

WARNING:

ISOLATE MACHINE AS PER MINES ISOLATION PROCEDURES.

7. Bleed off grease in take-up cylinder behind the crawler chain idler roller. This is done by opening the vent side of the tee-fitting on the back end of the cylinder. Be sure that the cylinder collapses to relieve tension in the crawler chain. (Figure 8.8)

Figure 8.8

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NOTE:

The end of the chain just forward of where it will be separated should be blocked to minimise its fall when its disconnected. See figure 8.9.

Separation Point Chain Blocking Mine Bottom

Figure 8.9

3.8" FLAT HEAD RETAINING SCREW + SPACER & NUT

DUAL CONNECTING PINS

GUIDE SHOE

DRIVE SPROCKET HOLE GROUSER

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8. Disconnect the crawler chain assembly at a convenient location near the tram drive gear case.

•

Select the crawler link to be disassembled.

•

Remove the two (2) 3/8” countersunk flat head cap screws and Conelok nuts, one on each side of the crawler pad – see Figure 8.10.

•

Drive the two (2) crawler pins out of the crawler pad using a ¾” diameter bolt or rod.

CAUTION:

Personnel should stay clear of the chain during separation to avoid injury when the chain is disconnected.

9. Unblock the loose length of chain, lower it onto the mine bottom and attach a pull cable to the end of the chain.

10. Lay the pull cable to the rear of the miner and attach it to a vehicle or other method of traction.

11. Release brakes with an external hydraulic source. On the inside of the main valve bank remove no. 6 JIC fitting (3/8 hose) marked 88 rd. Cap fitting into valve bank. Connect disconnected hose to hand pump (porter power).

12. Pump the hand pump watching the brake release gauge and pump up to 500psi. The brakes will now be released.

NOTE:

The brakes are fully released at 256 PSI (18 bar). Do not exceed 500 PSI (35 bar). As long as pressure remains between these readings, the brakes will remain released

13.

Pull the cable until the crawler chain assembly is tensioned, then slowly pull the crawler chain until it has rotated the tram drive sprocket, gearing and motor and is free to slide off the crawler frame.

14.

Pull the remainder of .the crawler chain clear of the crawler frame and away from the machine.

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Crawler Chain Installation 1. The miner should placed in the same condition as for removing a crawler chain, that is, miner chassis raised and securely blocked, gathering head full up and blocked, cutting head resting on gathering head, and conveyor in its lowest position. All power should be removed from the machine and all circuit breakers switched to the "OFF" position.

WARNING:

ISOLATE MACHINE AS PER MINES ISOLATION PROCEDURES.

NOTE:

Ensure that the grease pressure in the crawler chain take-up cylinder is relieved (CRAWLER CHAIN REMOVAL, Step 7) and that the cylinder is fully collapsed.

2. Lay the crawler chain on the mine bottom at the rear of the miner and extending back from the miner. The grousers should be on the bottom side on the mine bottom. (See figure 8.11 for correct direction).

NOTE PROPER ORIENTATION OF GROUSERS WHEN VIEWED FROM TOP OF CRAWLER FRAME

Figure 8.11

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NOTE:

Be sure grousers are in the correct direction before installing the chain into the machine.

3.

Attach a pull cable to the miner end of the crawler chain.

4.

Feed the loose end of the pull cable around the take up roller and into the upper return deck for the crawler chain. Continue feeding the cable until it comes out of the opposite end of the return deck. Feed cable past he drive sprocket and attach to vehicle or other traction device.

5.

Release brake units via external hydraulic source as per crawler chain removal. Pump brakes between 265psi (18bar) to a maximum of 500psi (35bar). The brakes will remain released between these pressures.

6.

Slowly pull the crawler chain into position on the take up roller. Continue pulling the chain slowly as it moves into the upper crawler chain return deck. Pull the end of the chain until it reaches the drive sprocket.

7.

Feed the track chain around the drive sprocket lining up the sprocket teeth with the track chain.

CONNECTION POINT

CHAIN BLOCKING Figure 8.12

8.

Slowly pull the track chain until it reaches ground level. Remove pull slings.

9.

Pack up with timber blocks the rear of the track chain Figure 8.9 & 8.12.

10.

Remove cover and ‘o’ ring plug from end of drive motor. See Figure 8.6. Fit ½ hex head cap screws 6” long into end of quill shaft and lock with locknut.

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1-1/2" - 2" REF

GROUND LINE

APPROXIMATE SAG IN A NEW CRAWLER CHAIN ASSEMBLY

Figure 8.13

11. Using suitable spanner turn quill shaft in direction that will pull the track chain together for joining.

12. Fit connecting pins.

13. Install the two (2) 3/8” flat head cap screws and conelok nuts (one on each side of the pad).

14. Check to see that the vent on the take-up cylinder tee-fitting has been closed.

15. Using grease gun pump take up cylinder until sag on track chain is 1 ½” to 2” figure 8.13.

16. Install shims required to retain the take up roller in that position. Once shims are in place relieve the grease pressure in the take up cylinder by releasing no. 6 JIC cap next to nipple used for pumping. Refer chain adjustments in lubrication and servicing section.

NOTE:

In the case of a used or worn chain, if the take-up cylinder has reached its maximum travel and can no longer properly tension, the crawler chain, a link must be removed from the chain.

17.

Replace ‘o’ ring plug and end cap on drive motor.

18.

Clear the area of all tools – parts of other materials.

19.

Remove isolation tags as per mines procedures.

20.

Restore power to miner and remove all blocking.

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Crawler Take-Up Roller Removal TOOLING REQUIRED - General tools – Allan Keys, spanners, hammers, pliers etc - Length of ¾” Ø round bar 30” long 1. Position and prepare the miner.

WARNING:

Isolate machine as per mines isolation procedures.

2. Lower cutter head with shovel in float raising the front of the miner off the ground.

3. Pack the track drive chain with timber blocking as shown in 8.14.

4. Separate the crawler chain at the top of the take up roller (see Figure 8.14) or as high as possible without the platforms getting in the way.

5. Remove the take up assembly by placing a strap or chain around both sides of the idler roller and sliding it forward until it clears the frame.

CAUTION:

Blocks should be placed under the take-up assembly so that it does not fall from the take-up yoke. Personnel should stay clear of the unit when it is pulled from yoke.

6. If necessary, the hydraulic take-up cylinder can now be removed. Be sure to disconnect the grease line to the cylinder before removal.

MAINFRAME

FULLY COLAPSED TAKE-UP CYLINDER

SEPERATION POINT

CONNECTION POINT

GROUND LINE

TIMBER BLOCKING

Figure 8.14

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Crawler Take-Up Roller Installation TOOLING REQUIRED - General tools – Allan Keys, spanners, hammers, pliers etc - Length of ¾” Ø round bar 30” long

WARNING:

Isolate machine as per mines isolation procedures.

1. If the take-up cylinder has been removed, re-install it into its end mount. Block the cylinder until it is in a horizontal position.

2. Apply a thin coating of grease to the top and bottom take-up slide areas of the crawler frame.

3. Verify proper oil fill on the side of the take-up roller housing. Place the assembly on its side with the roller shaft horizontal. Remove both pipe plugs visible on the side of the roller. Pour gear oil into one hole until it runs out the other hole. Holes to be level with shaft.

4. Position the crawler take-up assembly in front of the slide area of the crawler frame.

5. Slide the assembly into the main frame, then rearward until it stops against the piston of the grease take-up cylinder.

CAUTION:

Ensure that the piston end of the take-up cylinder fits properly into the take-up plug in the roller assembly.

6.

Connect the grease line to the back end of the take-up cylinder.

7.

Reconnect the crawler chain.

8.

Clear the area of all tools, parts and debris.

9.

Apply grease to the take-up cylinder and check for proper chain sag (see Figure 8.13).

10.

Remove isolating tags as per mines procedures.

11.

Restore power to miner.

12.

Remove packing under track chain and raise the cutting head and gathering head.

13.

Check the machine operation.

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Stablising Shoe Assembly Stabiliser Cylinder Removal TOOLING REQUIRED - 1 Tonne lifting block - 1 Sling 1 tonne capacity 1 metre long - General tools – Allan Keys, spanners, hammer etc

STABILISER PIVOT PIN

STABILISER SHOE KEEPER PLATE

LOWER CYLINDER PIN

STABILISER PIVOT PIN

A

A

UPPER CYLINDER PIN STABILISER CYLINDER

1" UNC HEX HEAD CAP SCREWS (4 OFF) UPPER CYLINDER PIN

MAINFRAME STABILISER PIVOT

KEEPER PLATE

STABILISING SHOE 5/8" UNC HEX HEAD CAP SCREW

LOWER CYLINDER PIN

Figure 9.1

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1. Position the machine so that they back frame portion under the conveyor can be easily reached and ensure conveyer is supported by safety stop attached to machine.

2. Lower the stabilizer shoe so it is resting on the mine floor

WARNING: Isolate machine as per mines isolation procedures.

3. Remove pods, covers and guards from the right hand rear of mainframe to reveal cylinder.

Remove the hydraulic lines, and cap them. Remove all lube lines, and cap them.

4. Attach a lifting device to the cylinder and tension it. Remove hydraulic hoses to cylinder and plug and mark.

5. Remove the two (2) cap screws from the keeper plate (RH side) that secures the bottom cylinder pin to the stabilizing shoe and remove pin. See Figure 9.1.

6. Remove the four (4) 1” x 4” HHCS from the top of the cylinder mounting clevis. See Figure 9.1.

WARNING:

When the 4 – 1” x 4” hex head cap screws are removed, the cylinder end will fall unless supported.

7. Slowly manoeuvre the cylinder out of and away from the main frame by lifting through the cavity in which it is mounted.

8. When cylinder is suspended above the main frame.

9. Reapply power to machine as per mines isolation procedures.

10. Drive miner forward to allow cylinder to be lowered to mine floor.

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Stabiliser Cylinder Installation TOOLING REQUIRED - 1 Tonne lifting block - 1 Sling 1 tonne capacity 1 metre long - General tools – Allan Keys, spanners, hammer etc 1. Prior to installing the cylinder, it is a good idea to check the clevis bushings holding the cylinder onto the rear main frame and the stab shoe. Replace the bushings if they are worn.

Check that lubrication is getting to them.

2. Position stabilising cylinder fitted with the top bolt on clevis at rear of machine with lifting gear raise to a height that will allow the cylinder to clear the back of the miner.

3. Tram miner back to position cylinder over assembly area.

WARNING:

Isolate machine as per mines isolation procedures.

4. Lower the cylinder and manoeuvre the bottom clevis of cylinder into the stabshoe.

5. Fit pin and keeper plate.

6. With lifting device extend cylinder and manoeuvre top bolt on clevis into the place and install the 4 retaining bolts.

7. Remove the lifting device.

8. Remove the hydraulic cylinder port plugs and the hydraulic hose caps, and connect the hydraulic lines to the cylinder.

9. Check lubrication lines for any signs of damage. Be sure the fittings are passing grease. If the lines are ok, install them onto the fittings.

10. Check the operation of the stabilising shoe assembly.

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Stabiliser Shoe Removal Weight 700 kg TOOLING REQUIRED - 1 Tonne lifting block - 1 Sling 1 tonne capacity 1 metre long - General tools – Allan Keys, spanners, hammer etc - ¼” ID pipe threaded on end ¼” NPT Refer Figure 9.1 STABILISER PIVOT PIN

STABILISER SHOE KEEPER PLATE

LOWER CYLINDER PIN

STABILISER PIVOT PIN

A

A

UPPER CYLINDER PIN STABILISER CYLINDER

1" UNC HEX HEAD CAP SCREWS (4 OFF) UPPER CYLINDER PIN

MAINFRAME STABILISER PIVOT

KEEPER PLATE

STABILISING SHOE 5/8" UNC HEX HEAD CAP SCREW

WARNING:

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LOWER CYLINDER PIN

ISOLATE MACHINE AS PER MINES ISOLATION PROCEDURES.

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1. Remove stabiliser shoe cylinder (See prior Cylinder Removal).

2. Pack the front of the stabilizing shoe fabrication to stop shoe from falling to the floor when pin removed.

3. Remove the fasteners retaining the pivot pin keeper plates.

4. Remove the two (2) attachment pins. See figure 9.1.

5. Remove grease nipple and screw in ¼” ID pipe and pull pin towards centre of machine.

6. Reapply power to machine as per mines isolation procedures.

7. Drive miner forward slowly until stabilizer is outside the machine.

8. Shoe Installation 9. Install stabilizer shoe cylinder as per stabilizer cylinder installation.

10. Check operation of stabilizer shoe assembly.

11. Raise the conveyor and place safety stop in position.

12. Position stabilizer shoe at back of miner and pack up forward of shoe as per removal procedure.

13. Reverse miner over stabilizer shoe until shoe is in position where clevises are in line with clevises on mainframe.

WARNING:

Isolate machine as per mines isolation procedures.

14. Using porter power rams manoeuvre clevises together and insert pins. See figure 9.1 15. Fit pin retainers and torque 5/8 hex head cap screws to reattach stabilizer as per stabilizer cylinder installation.

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Cutterhead Raise and Lower Cylinder Weight of Cutter Head Cylinder 175 kg

TOOLING REQUIRED - General tools – Allan Keys, spanners, hammer etc - Sliding hammer 1” NPT for removing cylinder pins - 1 long sling about 6 metres long - 1 sling 1 tonne capacity 1.5 metres long - 1 tonne lifting block - Timber packing - Eimco - Hydraulic external power source

Figure 10.1

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Cutter Head Cylinder Removal TOOLING REQUIRED - General tools – Allan Keys, spanners, hammer etc - Sliding hammer 1” NPT for removing cylinder pins - 1 long sling about 6 metres long - 1 sling 1 tonne capacity 1.5 metres long - 1 tonne lifting block - Timber packing - LHD - Hydraulic external power source Machine needs to be positioned where the front of the miner can be reached. The cylinder can be removed using the gathering head as a work area.

1. Place the machine in a position where the auger raise cylinders can be reached and the top of the machine can be reached 2. Lower the gathering head and the conveyor to their lowest position 3. Lower Auger head onto manufactured safety head stops.

4. Remove all power from the machine 5. Trip all circuit breakers to the “OFF” position

WARNING:

Isolate machine as per mines isolation procedures.

6. Attach a lifting device to the auger raise cylinder being removed and disconnect the hydraulic lines, plugging the lines and capping the cylinder. Load locks may need to be removed in some instances.

7. Tension the lifting device enough to hold the cylinder in position while disconnecting 8. Remove the cylinder pin top end of the cylinder using 1” UNC sliding hammer 9. Place timber packing on top of the gathering head cylinder and lower cutter head cylinder onto packing and remove sling 10. Remove front cover between the tracks and remove the bottom cylinder pin 11. From the front of the machine using long sling attached to LHD slowly manoeuvre the cylinder out of the bottom clevis across the gathering head

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Cutter Head Cylinder Installation TOOLING REQUIRED - General tools – Allan Keys, spanners, hammer etc - Sliding hammer 1” NPT for removing cylinder pins - 1 long sling about 6 metres long - 1 sling 1 tonne capacity 1.5 metres long - 1 tonne lifting block - Timber packing - LHD - Hydraulic external power source

WARNING:

Isolate machine as per mines isolation procedures.

1. Position the cylinder using the LHD jib onto the gathering head with the rod end of the cylinder pointing into the machine with the gathering head and conveyor at their lowest position and all power off the machine 2. Using lifting gear used and positioned for removal, attach sling and slowly manoeuvre the cylinder in position on the frame, being sure all dirt and debris are cleaned out of the area for the auger raise cylinder 3. Install the cylinder pin into bottom end of the cylinder and mainframe clevis 4. Using external power source, extend the cylinder into the top clevis on cutter head frame and line up bores. Install the two cylinder pin keeper plates, one at each end of the cylinder. The load holding valve may need to be removed to do this. See Figure 10.1.

5. Install top cylinder pin.

6. Install keeper plates.

7. Remove the lifting device and attach the hydraulic lines to the cylinder.

8. Lubricate the cylinder pins using EP2 Grease and clean up area.

9. Replace all covers.

10. Turn power on the machine and remove head stops and check cylinder operation.

REFER FIGURE 10.1

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Gathering Head Raise and Lower Cylinder Weight 80 kg TOOLING REQUIRED - 1 tonne lifting block - 1 sling 1 tonne capacity 1.5 metres long - General tools Allen Key – spanners, hammer, chisel, etc - 1” bar 400 mm long punch bar

UPPER CYLINDER PIN PIN KEEPER PLATE

GATHERING HEAD RAISE CYLINDER

LOWER PIN KEEPER PLATE MAINFRAME

GATHERING HEAD RAISE CYLINDER UPPER CYLINDER PIN UPPER KEEPER PLATE

GATHERING HEAD FRAME

LOWER KEEPER PLATE

LOWER CYLINDER PIN

5/8" UNC FLAT HEAD CAP SCREWS

Figure 10.2

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Gathering Head Cylinder Removal TOOLING REQUIRED - 1 tonne lifting block - 1 sling 1 tonne capacity 1.5 metres long - General tools Allen Key – spanners, hammer, chisel, etc - 1” bar 400 mm long punch bar 1. Place the machine in a position where the gathering head cylinders and the top of the machine can be reached comfortably.

2. Lower the gathering head, and the conveyor to their lowest position.

3. Raise Auger head and locate onto manufactured safety stops.

4. Remove all power from the machine.

5. Trip all circuit breakers to the “OFF” position.

WARNING:

Isolate machine as per mines isolation procedures.

6. Attach a lifting device to the gathering head raise cylinder being removed. Disconnect and cap the hydraulic line going to the cylinder, cap the hydraulic port on the cylinder.

7. Position lifting block above cutter head cylinder and thread the sling down past the cutter head cylinder to the gathering head cylinder. Tension the lifting device enough to hold the cylinder in position while disconnecting.

8. With the cutter head safety stops in position supporting cutter head access is available to gathering head cylinders from the gathering head deck.

9. Remove the two cap screws that retain the keeper plate upper and lower. See Figure 10.2.

10. Remove the keeper plates upper and lower. See Figure 10.2.

11. Pull out or drive out (hammer and punch) the cylinder pins upper and lower. See Figure 10.2.

12. Slowly manoeuvre the cylinder out of the clevises and raise the cylinder using lifting equipment high enough to enable the cylinder to be pulled into the gathering head top deck plate.

13. Manoeuvre the cylinder across the gathering head.

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Gathering Head Cylinder Installation

TOOLING REQUIRED - 1 tonne lifting block - 1 sling 1 tonne capacity 1.5 metres long - General tools Allen Key – spanners, hammer, chisel, etc - 1” bar 400 mm long punch bar

WARNING:

Isolate machine as per mines isolation procedures.

1. With the gathering head and conveyor at their lowest position and all power off the machine, with the lifting device set up as per removal procedure.

2. Slowly manoeuvre the cylinder into position on gathering head deck, being sure all dirt and debris are cleaned out of the area for the gathering head cylinder.

3. Attach lifting gear and lift and position the cylinder into position to fit bottom cylinder pin. Fit bottom cylinder pin.

4. Using lifting gear, position cylinder clevis to gathering head clevis and line up holes. This cylinder has a dry socket that allows the rod to be pulled out without using external hydraulic power source.

5. Install top cylinder pin. Figure 10.2.

6. Install the two cylinder pin keeper plates, one on each end of the cylinder. Figure 10.2.

7. Use two cap screws on each keeper plate and tighten the cap screws. Figure 10.2.

8. Remove the lifting device and attach the hydraulic line to the cylinder.

9. Clean up area and tools.

10. Remove isolation tags as per mines procedures.

11. Turn power on the machine and remove head stops and check cylinder operation.

REFER FIGURE 10.2

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Conveyor Raise and Lower Cylinder Weight of Cylinder 150 kg TOOLING REQUIRED - Sisal rope 5/8 5 metres long - Allan Key ¾” AF - General tools – Allan Keys, spanner, hammer, chisel, etc - 1 tonne lifting block - 1 sling 1 ½ metres long 1 tonne capacity

CONVEYOR

Ø3/8" COTTER PIN LATERAL SWAY GUIDE

UPPER CYLINDER PIN 3/4" UNC x 2-1/2" HEX HEAD CAP SCREW

GUIDE PLATE 1" UNC x 3"LG HEX HEAD CAP SCREW

GUIDE DISC

1" UNC JAM NUT

CONVEYOR RAISE CYLINDERS

1" UNC x 2-1/2"LG SOCKET HEAD CAP SCREW

MAINFRAME

LOWER CYLINDER PIN

Figure 10.3

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Conveyor Raise Cylinder Removal TOOLING REQUIRED - Sisal rope 5/8 5 metres long - Allan Key ¾” AF - General tools – Allan Keys, spanner, hammer, chisel, etc - 1 tonne lifting block - 1 sling 1 ½ metres long 1 tonne capacity 1. Place the machine in a position where the conveyor raise cylinder can be easily reached from the side and top of the machine.

2. Lower the gathering head and auger head to their lowest position and raise the conveyor so that the conveyor stop can be fitted and block the conveyor at that point.

3. Remove all power from the machine.

4. Trip all circuit breakers to the “OFF” position.

WARNING:

Isolate machine as per mines isolation procedures.

5. Tie sisal rope around cylinder to remove above the largest or first stage of the cylinder rod.

6. Thread the other end of sisal rope around the conveyor raise and lower lateral guide plate several times and tie off. See figure 10.3.

7. Remove the cotter pin from the top cylinder pin, on the top of the cylinder and disconnect the hydraulic hoses.

8. Remove the cutter pin and washers from the top of the conveyor raise cylinder.

9. Remove top cylinder pin.

10. Untie sisal rope in step six and slowly lower conveyor raise cylinder onto the lowered stab shoe.

11. Remove the three (3) bolts attaching the bottom retaining bracket (on the mainframe) of the cylinder that is being removed and remove retaining plate.

12. The cylinder can now be pulled out from under the machines rear bumper.

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Conveyor Raise Cylinder Installation

TOOLING REQUIRED - Sisal rope 5/8 5 metres long - Allan Key ¾” AF - General tools – Allan Keys, spanner, hammer, chisel, etc - 1 tonne lifting block - 1 sling 1 ½ metres long 1 tonne capacity - External Hydraulic Power Source to Extend Cylinder

WARNING:

Isolate machine as per mines isolation procedures.

1. With the gathering head and auger head lowered and stabiliser shoe lowered to mine floor, the conveyor on its supplied safety stop and all power off the machine, manoeuvre the cylinder shell end first under the rear bumper of miner.

2. Attach lifting block to anchor point to allow sling to be threaded between the side of the conveyor and the mainframe.

3. Attach sling to shell end of cylinder and using lifting devices manoeuvre cylinder into position where bottom cylinder pin can be fitted.

4. Insert the bottom conveyor cylinder pin in the cylinder clevis. Figure 10.3.

5. With the area (on the mainframe) for the cylinder clean, slowly position the cylinder, with pin and bottom holding brackets, into position on the mine frame.

6. Install the cylinder holding bracket to the main frame with three (3) cap screws tightened to the proper torque 1010 ft/lbs.

7. Remove sling and rethread around the rod end clevis allowing enough clearance to position clevises.

8. Raise cylinder into top clevis and install top cylinder pin. Figure 10.3.

NOTE:

Use external hydraulic power source to extend cylinder.

9. Attach the hydraulic and grease lines to the cylinder and remove the lifting device 10. Replace cylinder pin keeper devices

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11. Remove isolation tags as per mines procedure 12. Apply power to the machine, raise the conveyor and remove the blocking 13. Check the operation of the conveyor and clean up the area REFER FIGURE 10.3

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Conveyor Swing Cylinder Weight of Cylinder 90 kg TOOLING REQUIRED - General tools – Allan Keys, spanner, hammer, chisel, etc - 250 kg lifting block - Sling 1 metre long to support 90 kg

LH SWING CYLINDER

DISCHARGE CONVEYOR

INTERMEDIATE CONVEYOR

RH SWING CYLINDER DISCHARGE CONVEYOR

DISCHARGE CONVEYOR

SWING CYLINDER

SWING CYLINDER

INTERMEDIATE CONVEYOR

CYLINDER PIN

INTERMEDIATE CONVEYOR

SWING CYLINDER

SPLIT PIN

SPACERS

SPACERS SPLIT PIN

CYLINDER PIN

Figure 10.4

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Conveyor Swing Cylinder Removal TOOLING REQUIRED - General tools – Allan Keys, spanner, hammer, chisel, etc - 250 kg lifting block - Sling 1 metre long to support 90 kg

1. Place the machine in a position where the swing cylinder can be reached with ease.

2. Lower the gathering head, auger head and conveyor to their lowest positions.

3. Remove all power from the machine.

4. Trip all circuit breakers to the “OFF” position.

WARNING:

Isolate machine as per mines isolation procedures.

5. Remove covers and attach a lifting device to the conveyor swing cylinder and apply enough tension to hold the cylinder in position when the pins are removed.

6. Disconnect the hydraulic lines from the cylinder. Cap the lines and plug the cylinder ports.

7. Remove the two conveyor swing cylinder pins (one from each end of the cylinder).

8. Slowly manoeuvre the cylinder out of the clevises and away from the machine.

9. Lower to the mine floor and remove the lifting device.

NOTE:

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Do not misplace spacers supporting the swing cylinder clevises. See figure 10.4

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Conveyor Swing Cylinder Installation TOOLING REQUIRED - General tools – Allan Keys, spanner, hammer, chisel, etc - 250 kg lifting block - Sling 1 metre long to support 90 kg 1. Attach a lifting device to the swing cylinder and slowly manoeuvre it into position on the swing conveyor. The rod end of the cylinder points to the rear of the machine.

2. Install the two conveyor swing cylinder clevis pins (one in each end of the cylinder) with the bottom spacers see figure 10.4.

3. Remove the plugs from the hydraulic ports on the cylinder and the caps from the hydraulic lines.

4. Connect the hydraulic lines to the cylinder.

5. Remove the lifting device and clean up the area.

6. Remove isolating tags as per mines procedures.

7. Apply power to the machine and check the operation of the swing cylinder.

REFER FIGURE 10.4

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Plow Cylinders TOOLING REQUIRED - General tools – Allan Keys, spanner, hammer, chisel, etc - Long screwdriver or pinch bar

PLOW CYLINDER

PLOW CYLINDER PIN

CYLINDER PIN

MACHINE CENTRELINE

PIN KEEPER PLATE

GATHERING HEAD

PIN KEEPER PLATE

OF GATHERING HEAD VIEWED FROM REAR RH SIDERH OFSIDE GATHERING HEAD VIEWED FROM REAR

Figure 10.5

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Plow Cylinder Removal TOOLING REQUIRED - General tools – Allan Keys, spanner, hammer, chisel, etc - Long screwdriver or pinch bar Information Plow cylinders do not required lifting devices as cylinder weight is 30 kg.

1. Place machine in a position where the plow cylinder can be reached comfortably.

2. Lower the gathering head to the mine floor.

3. Lower cutter head onto the gathering head.

4. Open plows out fully.

5. Remove all power from the machine.

6. Trip all circuit breakers to the “OFF” position.

WARNING:

Isolate machine as per mines isolation procedures.

7. Remove cover on top of the plow cylinder.

8. Disconnect all grease lines preventing cylinder removal.

9. Disconnect and cap the hydraulic lines going to the cylinder, while plugging the hydraulic ports on the cylinder.

10. Remove the keeper plate and retaining bolts from the gathering head cylinder pins.

11. Remove cylinder pins.

12. Remove the cylinder away from gathering head and plow.

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Plow Cylinder Installation TOOLING REQUIRED - General tools – Allan Keys, spanner, hammer, chisel, etc - Long screwdriver or pinch bar

WARNING:

Isolate machine as per mines isolation procedures.

1. Position the plow cylinder into position.

2. Install clevis pin and keeper plate on shell end of cylinder.

3. Push plow into gathering head and align opposite cylinder clevises.

4. Insert clevis pin and mount keeper plate.

5. Remove caps and reconnect hydraulic lines to the cylinder.

6. Connect all grease lines back to the grease manifolds and grease pins.

7. Clean up area.

8. Remove isolation tags as per mines procedures.

9. Apply power to the machine and check the operation of the plow cylinders.

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Conveyor Take-Up Cylinders Weight of Cylinder 40 kg

NOTE:

The take up cylinder is not retained by any clevis pins or mounting bolts. When cylinder has been forced into the retract position using lever bar the cylinder will be able to be manipulated out of the bore of the carriage and lowered from the assembly.

Figure 10.6

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Conveyor Take-up Cylinder Removal TOOLING REQUIRED - General tools – Allan Keys, spanner, hammer, chisel, etc 1. Place machine in a position where the take-up cylinders can be reached with ease.

2. Lower the gathering head and auger head to their lowest positions.

3. Block the conveyor at a suitable height with conveyor safety stand.

4. Remove all power from the machine.

5. Trip all circuit breakers to the “OFF” position.

WARNING: ISOLATE MACHINE AS PER MINES ISOLATION PROCEDURES.

6. Using needle valve provided bleed oil out of cylinder circuit (approx 20 Bar).

7. It is not necessary to separate the conveyor chain to remove cylinder.

8. Using long screwdriver or pinch bar force cylinder to retract removing all oil from cylinder.

9. Disconnect hydraulic lines from the cylinder. Cap the lines and plug the cylinder port.

WARNING: Be aware, cylinders will drop so ensure they are supported appropriately.

10. Slowly manoeuvre the cylinders away from the conveyor.

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Conveyor Take-up Cylinder Installation 1. Slowly manoeuvre the take-up cylinder into position.

2. Remove the plugs from the hydraulic ports on the cylinder and the caps from the hydraulic lines.

3. Connect the hydraulic lines to the cylinders.

4. Support cylinders at approximate height to re-align with the spindle sockets.

5. Press or jack conveyor tail drive assembly back onto the cylinders, ensuring that the cylinder has inserted into spindle sockets.

6. Remove support from beneath the cylinders.

7. Close needle valve.

8. Remove isolation tags as per mines procedures.

9. Apply power to the machine and check that the operation of the take-up cylinders has tensioned the conveyor chain and that 20 Bar is reading upon the gauge in the circuit mounted on the RH side of the discharge conveyor.

REFER FIGURE 10.6

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TRS Raise and Lower Cylinder Weight of TRS Cylinder 150 kg

Figure 10.7

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TRS Cylinder Removal TOOLING REQUIRED - General tools – Allan Keys, spanners, hammer etc - 1 long sling about 3 metres long - 1 sling 1 tonne capacity 1.5 metres long - 1 tonne lifting block - Timber packing - LHD - Hydraulic external power source Machine needs to be positioned where the front of the miner can be reached. The cylinder can be removed using the gathering head as a work area.

Place the machine in a position where the TRS raise cylinders can be reached and under an eye bolt.

1.

Lower the gathering head and the conveyor to their lowest position

2.

Lower Auger head to the floor

3.

Fully lower the TRS cylinder requiring removal as per figure 10.8.

Figure 10.8

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4.

Remove all power from the machine

5.

Trip all circuit breakers to the “OFF” position

WARNING:

Isolate machine as per mines isolation procedures.

6.

Remove roof pad item 3, mounting bolts - 4 off 5/8” bolts on the top side of the foot pad as per figure 10.8 and attach lifting device and remove from assembly and lower to the floor.

7.

Remove trunnion pad bolts - 4 off ½” bolts on the underside of blocks – item 5 as per figure 10.8. These bolts hold both top and bottom trunnion mounts together.

8.

Attach a lifting device to the trunnion blocks being removed and lower to the floor.

9.

Remove front lower top cover surrounding cylinder assembly by removing the ¾” bolts and remove covers. Refer to figure 10.7

10. Remove front surrounding cover of the cylinder assembly by removing 6 off ¾” bolts and remove cover.

11. Disconnect the hydraulic lines, plugging the lines and capping the cylinder. Load locks may need to be removed in some instances.

12. Attach a lifting device to the cylinder cross arm ensuring that the correct lifting techniques are being used and tension the lifting device enough to hold the cylinder in position while disconnecting.

13. Remove the cylinder mounting bolts at the bottom / base of the cylinder. These bolts are M16mm and by 4 off. See figure 10.9.

14. Remove cylinder assembly from the mount in the gathering head assembly and manoeuvre to the side of the machine.

15. Remove bolt from the top of the mast and slide cylinder from mast tubing.

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Figure 10.9

Servicing and Maintenance Prior to any work taking place on miner, full isolation is to be done as per Mine’s Remote Control Operations-Continuous Miner and Energy Control and Isolation Management Plan.

The above statement applies to any work on continuous miner including changing picks, sprays or any other work procedure.

WARNING:

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Full current isolation required as per mine Management Plan Energy Control and isolation.

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Top View Lubrication

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Left Hand Side Lubrication

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Right Hand Side Lubrication

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Lubrication Chart

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Lubrication – Gear Oil All gear cases are filled via an on board gear oil pump mounted on the LH Side.

WARNING:

Auger gear case and input boxes which are to be done by manual hand pump at lube point, this is a full current isolation activity

Fill via a handgun connected to the gear oil pump. Specifics for each of the gear cases are as follows: Tram Gear Cases Fill

Via external source - connect fill hose to RH or LH tram case fill hose connection located on top of the outer planetary housing.

Level Check

Via single sight glass in the final drive output planetary cover. Proper level is when the sight glass is completely full.

Drain

To completely drain the tram case, two (2) drain plugs have to be removed:

.

• •

½” magnetic drain plug on underneath side of the outer planetary. ¾” magnetic drain plug underneath front rear corner of Tram case for the reach gears. This plug is only accessible from underneath the machine.

Gear case fill plug Gear case sight glass level

Gear case drain points

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Cutter Head Gear Cases

WARNING:

Full current isolation required as per mine Managers Rules.

Fill

Via external source remove 1 1/2 “plug located on top of the cutting head banjo sections (L) (R).

Level Check

Via ½” pipe plug on front side of “banjo” section by core breaker. The RH and LH side of this gear case have separate oil sumps. Thus, there are check plugs for both sides of the gear case. Level is to be checked with the cutting drum resting on the ground from the same filling point.

Drain

Ensure to fit auger stops before attempting to drain! Via 1½” magnetic drain plug in bottom of each “banjo” section which the oil is put into.

Gear case level plugs

Gear case fill plug Gear case drain plug

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Cutter Head Input Gear Cases

WARNING:

Full current isolation required as per mine Managers Rules AND ENSURE TO FIT SAFETY SUPPORT PINS IF REQUIRED.

Fill

Via external source connect to oil fill point located at top of auger head mounting in the box like section. Remove 3” plug to access a ¾” plug and level dipstick on top of input case.

Level Check

By removing 3" pipe plug in cutting head gear case at the fill point in the box like section just in front of a “flat back” split line. Proper level is when the dipstick markings indicate that the box is full. Ensure to check these levels with the head resting on the floor. This gear case may overheat if it is overfilled.

Drain

Ensure to fit auger stops before attempting to drain! First, a 3” pipe plug must be removed from the under side of the box like section of the cutting head gear case just in front of the “flat back” split line. This will expose the ½” magnetic drain plug in the bottom of the cutting head input case.

Input gear cases fill point

Input gear case level point via internal dipstick

Input gear case drain points RH & LH

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Gathering Head (POT) Gear Cases Fill

Connect external source to CLA gear case fill point located on WITHIN THE SHOVEL. (See below).

Level Check

Via ¾” pipe plug protruding from the tee piece that holds the gear box breather. This is also mounted on the same manifold block as indicated below. The best way to ensure that this gear case is at the proper oil level is to do the following: • • •

make sure gathering blade is resting on the ground remove ¾ ” plug lubricate until oil runs out of level check hole

Due to the pot-like shape of this gear case, three (3) drain plugs have to be removed in order to completely drain it. The drain plugs are only accessible from underneath the gathering head.

Drain

Gear case level, fill and breather ports.

NOTE:

Rev 1

Gear case drain plugs

RH side manifold shown.

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Gathering Head Input Gear Cases Fill

Connecting external source to a lube line fitting located at the top of manifold block mounted at the rear of the roof bolting shield. (See below).

Level Check

Via ¾” pipe plug protruding from the tee piece that holds the gear box breather. This is also mounted on the same manifold block as indicated below. The best way to ensure that this gear case is at the proper oil level is to do the following: • • •

make sure gathering blade is resting on the ground remove ¾ ” plug Lubricate until oil runs out of level check hole.

Via 1½” magnetic drain plug on the under side of the gear case, this plug is only accessible by doing the following:

Drain

• • •

raise gathering head to it’s full height Use suitable packing to support the gathering head structure.

Crawl underneath gathering head frame.

Gear case drain plug

Input gear case fill, level and breather plug NOTE:

Rev 1

LH side manifold shown.

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Traction Idler Roller Fill

Position Idler Roller so that the ½” plugs are between 2 o’clock or 4 o’clock. Remove both plugs and fill with external source.

Level Check

Oil level is achieved when it runs out either hole.

Drain

Position ½” plugs at 12 o’clock and 6 o’clock and remove plugs to Drain roller.

½ drain and level plugs

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Greasing As per the Lubrication Chart page 7.

Tram Brakes The brakes are spring applied and hydraulically released. The units are hydraulically flushed back to tank through filtration mounted on the LH side above traction unit.

Filters

Brake circuit flushing filter

Left Hand Filters

LH Tank Breather

Hydraulic return Filter

Pressure Filter

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Right Hand Filters

Return Filter

Pressure Filter

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Chain Adjustments Crawler Track Chain Adjustment

WARNING:

Full current isolation required as per mine Managers Rules after machine is set off the ground.

To adjust the crawler track chain tension: Raise the auger head off the floor and in turn raise the gathering head from the floor. Following these steps lower the stab jack to the floor and allow the rear of machine to lift. Once rear is lifted, float the gathering head to the floor and lower auger head into the floor until the entire machine chassis is raised from floor. Isolate the machine. Apply grease pressure to the take-up assembly and tighten the track chain until there is between 1½ and 3 inches (38 & 75mm).

Install the shims required to retain the take-up roller in that position. Once shims are in place relieve the grease pressure in the take-up by releasing the 9/16” JIC cap to the side of the take up nipple manifold.

Grease take-up relieving JIC cap

Rev 1

Grease take-up nipple

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Conveyor Chain Adjustment The correct tension/pressure must be kept on the conveyor chain. The conveyor chain is tensioned hydraulically by two single acting cylinders mounted inside the discharge section of the conveyor. The cylinder circuit is auto adjusting with system pressure, when the machine pump is turned on and is set at 20 Bar (See Hydraulic Schematic). Periodic checks during servicing are required to ensure correct chain tension and pressure. The pressure gauge for this can be found on the right hand side of the machine. With the right side pump running raise the stabilizing cylinder.

CAUTION:

A chain too tight will ride the side of the conveyor pan and may break when loaded. A chain too loose will cause more wear and damage to the conveyor frame, or jam in the foot shaft area.

With the stabilizer fully retracted and pressure still on the stab raise check pressure gauge.

Pressure gauge should read 300psi – 20bar.

Release pressure to stabilizer cylinder and check pressure gauge. Pressure should still read 300psi – 20 bar.

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Tail roller

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Maintenance Mode There are (2) two power on operations available in Maintenance Mode on the miner.

1. Hydraulic Oil Power Fill 2. Gear Case Oil Power Fill

NOTE:

If running, stop pumps prior to either of the power fill mode procedures.

NOTE:

Prior to selecting Maintenance Mode, isolate the CUTTER, GATHERING HEAD & TRACTION circuit breakers and tag out as per mine isolation procedures. Interlocking in the radio system will stop pumps if all three circuit breakers are not in the off position.

Check and Fill Hydraulic Oil Reservoir The Hydraulic Reservoir upon the 30MB3 Miner contains 750 litres of 68 grade oil with the tank full. System capacity is 1000 Litres. Procedures for checking levels and filling are as follows: Low levels can be known in two ways. Either by a low oil level siren (and message on screen) or cutter head motors are disabled.

Oil level checks can be done via the sight glass manifolds mounted beside the traction gear cases as shown below. Right Hand side shown only. The oil level should be higher than the bottom sight glass and lower than the top sight glass.

Hydraulic oil level sight glasses

If oil levels are deemed to be low, source Hydraulic 68 grade oil and place at the left hand side of the machine, in bye of the electrical panel. Here there is the Hydraulic oil fill hose and a ball valve for visual oil fills requirements whilst filling only. See filling procedure below.

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Hydraulic Oil Power Fill The following procedure is to be followed to carryout hydraulic oil power fill tasks safely:1. Ensure Cutter, Gathering Head and Traction circuit breakers are isolated as per mines procedures.

2. Place selector valve handle in maintenance mode (lever in centre position).

3. Start machine.

NOTE:

Pump Motor will turn off if the Circuit breakers mentioned in point 1 are not open or in the off position.

4. Remove ¾” JIC cap from fill hose located forward of the left side main electrical control case and place in hydraulic oil drum. See photo below.

5. Open ball valve located forward of the electrical control case near oil fill hose.

6. Position oil fill valve into hydraulic oil fill. See below.

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7. Full the hydraulic tank until oil flows from the ball valve.

NOTE:

A continual flow is required as the line to the ball valve may have some residual oil left from past filling.

Hydraulic power fills hose

Hydraulic power fills oil level ball valve

8. When full place hydraulic full valve handle into neutral (centre) position.

9. Close oil level ball valve.

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Gear Case Oil Power Fill The following procedure is to be followed to carryout gear case oil power fill tasks safely: 1. Ensure Cutter, Gathering Head and Traction circuit breakers are in the off position and isolated as per mines procedures.

2. Place selector valve in maintenance mode.

3. Start machine.

NOTE:

Pump motor will turn off if the 3 circuit breakers as described in point 1 is not in the off/open position.

4. Remove ¾” JIC cap from suction hose located rear side of main electrical enclosure on left side of machine. Place in drum 460 gear oil. See photo below.

5. Position oil fill valve into gear oil fill see photo below.

6. Using lube gun top up gear cases as required.

7. Place Power Fill handles in neutral position when finished.

Power fills pump/motor assembly

Hydraulic and Gear Oil fill diversion valve

Rev 1

Gear oil fills hose

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Repair or Replace Water Sprays The water system on the miner provides for water cooling of electric motors and dust suppression during normal machine operations. The water used during normal machine operations, dust control, is firstly passed through the motor water jackets and second to the water sprays. The water spray circuit has been fitted with two 3 – way ball valves which are for changing the direction of the sprays as required by the mine. (Refer to water schematic).

Place the head in the horizontal plane with the shovel on the floor and conveyor boom down.

Open cutter circuit breaker on the main panel.

WARNING:

Full current isolation required as per mine Management plan – Energy Control and Isolation.

NOTE:

Refer to the Mine’s Remote Control Operations - Continuous Miner and Remote Control Operations – Continuous Miner.

Turn the water by-pass valve (located above reverse flush filter) on and walk around the machine checking for correct spray operation.

Turn water off once blocked sprays are located and lock out the ball valve with locking device fitted to handle.

Remove any spray not working correctly, then dismantle, clean and replace.

The miner is fitted with a bag type water filter that is located in the driver’s compartment.

Water flow meters

By pass ball valve

Reverse Flush Filter

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Machine Cutting Picks The cutting head on the 30MB3 Miner plays an integral part in the machines performance and its targets. It is highly important that the cutting picks are inspected during and before each shift and replaced as required. Procedure is as follows: 1

Place the head in the horizontal plane upon the manufactured head stops with the shovel on the floor and conveyor boom down.

2

Open cutter circuit breaker on the main panel.

3

WARNING:

Full current isolation required as per mine Managers Rules.

NOTE:

Refer to the Mine’s - Remote Control Operations Continuous Miner - Document – Energy Control and Isolation Management Plan are to be followed.

Replace picks as required and report and cracks or missing blocks immediately.

Cutter Head Picks

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HYDRAULIC COMPONENTS ASSEMBLY

Description The pump is a hydraulic piston demand pump driven by a 68 kW water-cooled AC motor, on the right side of the machine. The pump delivers 260L/min at 200 bar.

Pump direction is critical to its operation and must be correct for pump flow and pressure to be obtained. The pump must run in a clockwise direction when looking towards the drive end (splined end) of pump.

The hydraulic pump has 3 modes of operation.

1. Mining Mode 2. Maintenance Mode 3. Bolting Mode The hydraulic pump is required to be running first before all other functions will operate. e.g. The traction motors requires the pump contractor to be closed before power will be supplied to the traction system.

SUCTION HOSE MOUNT PLATE

3" BALL VALVE PRESSURE OUTLET SUCTION INLET

PUMP MOTOR

3/4" UNC x 2-1/2" LG HEX HEAD CAP SCREW

HYDRAULIC PUMP

SUCTION INLET

PUMP MOTOR 3/4" UNC x 1-1/2" LG HEX HEAD CAP SCREWS

HYDRAULIC PUMP MAINFRAME BASE PLATE

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Mechanical The drive of the Hydraulic pumps is direct driven via a splined shaft and therefore no drive couplings are required. The motor/pump assembly is mounted directly to an independent frame separate to the mainframe (but bolted to the mainframe) for ease of removal as a complete assembly. The option for the tradesman to swing the structure out to replace pump only is available as well.

Hydraulic Pump Removal TOOLING REQUIRED - 1 tonne lifting block - 1 tonne sling-chain 2 metres long - 1 15/16” socket ¾” square drive - 1 ratchet ¾” drive - 1 ¾” drive extension bar - 1 – ½” Allan Key or in hex socket with ratchet ½” drive - Wood packers to slide assembly out on 4” thick OK - Crow bar - Sisal rope 2 metres long - Clean rags Information The 30MB3 has 2 hydraulic pump/motor assemblies. The pump assemblies are located on each side of the machine between each track. See figure 12.1. The motor and pump are mounted onto a base mounting which allows the pump and motor to be removed as a complete unit.

1.

Place the miner to the side to be removed can be easily reached and there is enough side clearance to pull the pump motor assembly from between the tracks. Consideration to lifting anchors should be assessed when positioning machine.

2.

Lower the gathering head and discharge conveyor to their lowest height. Lower the cutter head to floor level.

3.

Remove all power from the machine and trip all circuit breakers to “OFF”.

WARNING:

4.

Remove all covers between the tracks on the side of the machine where pump motor is to be removed.

NOTE:

5.

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ISOLATE MACHINE AS PER MINES ISOLATION PROCEDURES. FAILURE TO DO SO CAN CAUSE SERIOUS INJURY OR DEATH.

Hose out between tracks if necessary.

Remove and disconnect all assemblies in the area of the motor pump assembly in the area including cover mountings – grease lines – water hoses – hydraulic hoses and any other auxiliary components that would impair removal of assembly. Mark all hoses and fittings to assist with reassembly. Do not remove suction hose from pump.

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SUCTION HOSE MOUNT PLATE

3" BALL VALVE PRESSURE OUTLET SUCTION INLET

PUMP MOTOR

3/4" UNC x 2-1/2" LG HEX HEAD CAP SCREW

HYDRAULIC PUMP

SUCTION INLET

PUMP MOTOR

HYDRAULIC PUMP

3/4" UNC x 1-1/2" LG HEX HEAD CAP SCREWS

MAINFRAME BASE PLATE

Figure 12.1 NOTE:

It is not necessary to disconnect the electric cables going into the pump motor if the electrical motor is not to be removed.

6.

Remove two (2) ¾” x 1 ½” long hex head cap screws from base plate Figure 12.1.

7.

Close 3” ball valve on suction line and remove hose clamp on outside suction elbow.

When assembly is being removed pry suction hose off elbow.

8.

The assembly is now in a position to be removed from between the tracks. Position wooden blocks beside the tracks to allow assembly to sit on the blocks.

9.

Wrap sling around pump and attach lifting block with sling onto rib bolt. Using lifting block to pull the assembly out. This can sometimes be achieved by using sisal rope and with assistance from others be pulled out by hand.

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10.

By positioning lifting gear over the pump support the weight of the pump.

11.

Remove four (4) ¾” x 2 ½” long hex head cap screws from base plate mounting supporting pump. Ref 12.1

12.

Pump is now free to be moved horizontally away from the electric drive motor. Move horizontally until spline disengages from the assembly.

13.

Remove rag from suction line and drain oil from hydraulic tank into clean oil drums until level is low enough to stop oil flowing.

14.

Keep oil for replacing into machine.

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Hydraulic Pump Installation TOOLING REQUIRED - 1 tonne lifting block - 1 tonne sling-chain 2 metres long - 1 15/16” socket ¾” square drive - 1 ratchet ¾” drive - 1 ¾” drive extension bar - 1 – ½” Allan Key or in hex socket with ratchet ½” drive - Wood packers to slide assembly out on 4” thick OK - Crow bar - Sisal rope 2 metres long - Clean rags - Silastic Preparation Check the electric motor coupling for warn spline and ensure spline insert is not loose in the elect motor driveshaft. Check tapped holes for corrosion of damaged threads.

WARNING:

ISOLATE MACHINE AS PER MINES ISOLATION PROCEDURES. FAILURE TO DO SO CAN CAUSE SERIOUS INJURY OR DEATH.

1.

With the miner position as per removal of hydraulic pump ensure all power is isolated from the machine.

2.

Using lifting gear position hydraulic pump to the motor shaft.

3.

Run a light ring of Silastic around the face of the pump and manoeuvre pump into splined shaft of the drive motor.

4.

Start four (4) off ¾” x 2 ½” long hex head cap screws into threaded holes on mounting plate and torque to 392 ft lbs 521 Nm.

5.

Using crow bar lever the assembly back into the line up the mounting holes. Do not start the mounting bolts.

6.

Position the suction hose assembly to the pump inlet and assemble the hose mounting clamp. Start the four (4) 5/8” 2 ¾” long socket head cap screws and tighten.

7.

Check and reline up the base mounting and start the two (2) ¾” x 1 ½” long hex head cap screws and torque to 392 ft lbs 531 Nm.

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8.

Replace hydraulic hoses – water hoses – grease lines cover mounting brackets.

WARNING:

SUCTION BALL VALVE MUST BE OPENED BEFORE STARTING PUMP MOTOR.

9.

The hydraulic tank will need to be checked for the correct level before re-powering the machine.

10.

If hydraulic tank level is deemed too low for the hydraulic oil fill pump to work. Using hand pump or air pump connects delivery hose to the ¾” JIC fitting on the LHS or RHS return filter. When oil is replaced into the hydraulic tank it must pass through the return filter.

11.

When oil has reached the correct level remove delivery hose and recap the return filter fitting.

12.

Remove isolation tags and re-power machine.

13.

Place the miner in mining mode so only the right side pump will start.

NOTE:

The priming of both pumps will be required after changing either pump.

14.

Start the right side pump and immediately turn off after starting. If there is air in the suction lines the pump will make a rattling noise.

15.

Repeat the above procedure until the noise abates and there is no evidence of air in the pump.

16.

Place the miner in bolting mode so both pumps will start. Start the pumps the right side will start first followed by the left side.

17.

Immediately stop the pumps when the left side pump starts. Repeat this procedure until the noise abates and there is no evidence of air in the pump.

18.

Isolate machine as per mines procedures.

19.

Replace covers between tracks and re-fit side platforms.

20.

Remove isolation tags.

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Removal and Replacement of Pump Drive Motor TOOLING REQUIRED - 1 tonne lifting block - 1 tonne sling-chain 2 metres long - 1 15/16” socket ¾” square drive - 1 ratchet ¾” drive - 1 ¾” drive extension bar - 1 – ½” Allan Key or in hex socket with ratchet ½” drive - Wood packers to slide assembly out on 4” thick OK - Crow bar - Sisal rope 2 metres long - Clean rags

NOTE: This procedure is identical to removing and replacing the hydraulic pump.

O'RING PUMP MOTOR

3/4" UNC x 2-1/2"LG SOCKET HEAD CAP SCREWS (8 OFF) ADAPTOR PLATE

HYDRAULIC PUMP

Figure 12.2

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Pump Drive Motor Removal WARNING:

ISOLATE MACHINE PROCEDURES.

AS

PER

MINES

ISOLATION

1.

Follow procedure for pump change out 1 to 10 including isolation procedures.

2.

Disconnect electric cables from motor and mark to assist on reassembly.

3.

By positioning lifting gear over the drive motor support the motor.

4.

Remove eight (8) – ¾” x 2 ½” long socket head cap screws from mounting face of motor. 2 off at each corner see Figure 12.2.

5.

Motor is now free to be moved horizontally away from the adaptor plate on the base plate.

NOTE:

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There is no need to remove hydraulic pump from base plate adaptor mounting.

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Pump Drive Motor Installation 1.

Using lifting gear position electric motor on base plate with mounting pointing towards the pump.

2.

Connect electric cables to motor and replace J box lid.

3.

Remove isolation tags from machine as per mines procedures and re-power machine.

4.

Start the pump motor. If right side pump motor has been refitted it is only necessary to have miner in mining mode. If left side has been refitted the miner will have to be in bolting mode.

5.

Check direction of motor. The correct rotation is clockwise looking from rear of electric motor.

6.

Isolate machine as per mines isolation procedures if incorrect rotation rewire to change rotation of motor.

7.

If correct rotation check ‘o’ ring is on motor mounting spigot (part no. 68668) and manoeuvre the motor onto the splined shaft of the pump.

8.

Start 8 – ¾” x 2 ½” long socket head caps screws at the corner of the drive motor and torque to 392 ft lbs 531Nm.

9.

Continue procedure from 5 off hydraulic pump installation including SWMS's.

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Hydraulics The hydraulic pump fitted to this miner is power controlled with pressure cut-off and load sensing.

The pump is of 190 cc/rev construction, with a maximum output of 260 l/min.

The maximum pressure is set to 200 bar (2900 psi), and the power control is set to 68 kW. Load sense lines from all modes that require a working supply above the standby settings of the pump come to a common manifold where a single signal is sensed by the pump ensuring hydraulic fluid supply to the required demand. This is called the load sense block. See Figure 12.3.

Each pump is protected by a pressure relief valve installed in the circuit in a manifold mounted on the inlet side of the Pressure Line Filter, and is set to 230 bar. This relief valve is an inclusion for safety as the system pressure is regulated by the pressure compensating function of the pump, where pump delivery will decrease toward zero whilst maintaining the maximum setting of the pump (I.e. 200 bar).

When the machine is in mining mode the pump will operate to supply hydraulic energy to 1.

Pressure filter and relief valve assembly.

2.

Mining/bolting and select diversion valve.

3.

Main valve bank.

When the machine is in bolting mode the pump will operate to supply hydraulic energy to.

1.

Both roof drill rigs.

2.

Both rib drill rigs.

3.

ATRS system (optional).

A diversion valve is positioned on each side of the machine. The valve can divert oil from the roof bolter to the rib bolter on each side of the machine. It is possible to operate the roof bolter on one side of the machine and the rib bolter on the opposite side of the machine.

NOTE:USE TOP CASE DRAIN PORT AND HOSE BACK TO TANK WITH 34 " HOSE WITHOUT RESTRICTIONS

T2 R

30 bar

200 bar

T1

X

MIN

MAX

M1

G A

S

Vg = 190 cc/rev Q = 260 l/min P = 200 bar P = 68 kW n = 1450 RPM

M

M

CLOCKWISE ROTATION

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Figure 12.3

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Hydraulic Pump The hydraulic pump is a variable displacement pump with load sense and horsepower limited.

The pump when viewed at the shaft end rotates in a clockwise direction.

The pump has 2 adjustable controls 1.

2.

Pressure cut off control – D Load sensing control – S

See Figure 12.4

Figure 12.4

The 3 adjustments must be correct to get maximum performance from the pumps.

The hydraulic system also has a main relief valve (See hydraulic schematic) located at the inlet of the pressure filters on each side of the machine. If the main relief valve is set to low the pump will dump over the relief valve and cause an increase in oil temperature. At the same time it will affect the operation of the machine. If the main relief valve is set to high the pump will not have a safety relief. Refer to HYDRAULIC SCHEMATIC in this section for relief valve setting.

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Power Cut Off Control – D Pressure cut off corresponds to a pressure control which adjusts and lowers the pump displacement when the pressure signal valve setting is reached. This function overrides power control. i.e. Below the pressure cut off setting the power control function is performed. If the ‘D’ is adjusted to low it will affect the pressure of the machine. If ‘D’ is adjusted to high it can cause component failure.

Load Sensing Control – S The load sensing control works as a flow controller controlled by load pressure and co-ordinates the pump displacement to the quantity required by the actuator. If the ‘S’ is adjusted to low it will not allow pump to deliver full flow. If the ‘S’ is adjusted to high it will cause increased oil temperature and erratic machine operation.

Valve Bank Information The main valve bank on the 30MB3 miner controls cylinder movements via 7 directional control spools.

1. Stabilizer Cylinder 2. Conveyor Swing Cylinders 3. Conveyor Raise Cylinders 4. Cutter Head Raise Cylinders 5. Cutter Head Extend Cylinders 6. Gathering Head Plow Extensions 7. Gathering Head Raise and Lower Cylinders The valve bank also supplies via a pressure reducing valve set at 20bar to the pilot circuit and conveyor chain tensioning cylinders. From the same supply oil is also directed through the tramming brakes for cooling when working steep grades. The 7 main valve bank spools are controlled by solenoid valves supplying oil to each end of each spool to move the spool when required. This oil supply is via a second pressure reducing valve set at 35bar.

At the end of the valve bank 2 stand alone solenoid valves supply oil to the pilot operated water valve and to release the tram brakes. The supply to the tram brakes has a pressure switch built into the valve bank to monitor the brake release pressure.

The inlet section the valve bank has a pressure relief valve set at 230bar. With the pump set at 200bar it is not possible to check the correct setting on the machine. (See adjustments for relief valve setting).

The seven spools have a different flow rate which is shown on the hydraulic schematic.

The flow rates are the maximum the spool will allow.

1.

2.

3.

4.

5.

6.

7.

Stabilizer Conveyor Swing Conveyor Raise Cutter Head Raise Drum Extension Gathering Head Plows Gathering Head Raise

145 litres per minute 32 litres per minute 145 litres per minute 145 litres per minute 32 litres per minute 32 litres per minute 145 litres per minute

Each spool has an adjustable stop that can be adjusted to restrict the spool movement.

This can be used to lessen the above flows by adjusting the stops in. (See hydraulic schematic).

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Adjustments Pilot Circuit The pilot oil is used for: 1. All Solenoids operating each spool 2. Solenoids operating water on/off and tramming brake release The adjusting valve can be adjusted by tightening the adjusting screw in to increase pressure or out to decrease pressure. By viewing the gauge on the machine labelled pilot pressure adjust the pressure reducing valve to 35bar and lock.

Conveyor Tension and Tramming Brake Coolant This pressure reducing valve controls pressure to the conveyor chain take up cylinders and the coolant flowing through the 2 trambrake units. To adjust view the gauge on the conveyor take up circuit and adjust to 20bar. Screw into increase pressure or screw out to decrease pressure.

Main Relief Valve (Main valve bank inlet) - OPTIONAL The main relief valve is set at 230bar. The output of the pump is 200bar which makes it difficult to set the relief valve. With the pump running and the stabilizer cylinder held in the raise position wind the adjusting screw out until the pressure begins to drop.

When the pressure begins to drop will be around 200bar the setting of the pump output. With the stabilizer cylinder still held in the raise position wind the adjusting screw in slowly. When the pressure stops increasing the relief valve will be at the pump setting. Wind the relief adjusting screw in ½ turn and lock.

Water Reticulation General (Ref: Water Schematic) The water to the machine is supplied from the mine water supply via a flexible water line attached to the machine.

A reverse flush filter or bag filter is positioned in the circuit after the supply isolation valve, and is located on the right hand rear of the machine.

The water system is used as a cooling medium for the electric motors DC transformer and cubicle. It is also used for dust suppression whilst mining.

If water supply to the cutting head is stopped whilst the cutter drums are rotating, flow switches (Item 3) shutdown the machine.

The circuit has been designed is such a way as to allow isolation of the water sprays whilst providing water recirculation to ensure cooling during relocation tramming.

A water pressure gauge is provided to register the supply water pressure reaching the machine.

The water used on the machine is supplied from the mine water.

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Circuit 1 (Right Side) Inlet at side of machine Reverse flush filter/Bag filter Flow meter Right side tram motor Flow switch Right side pump motor Supply to right side drilling rigs Solenoid operated hydraulic pilot operated water valves Right Hand Cutter Motor Flow Switch Circuit 2 (Left Side)

Flow meter Control Case, Transformer box, Left side tram motor, Flow Switch Left side pump motor, Supply to left side drill rigs, Solenoid operated hydraulic pilot operated water valve Left Hand Cutter Motor Flow Switch Water Dust Spray

Solenoid operated isolation valve, Item 5, controls water flow to: Auger motors LH and RH. Gathering head motors LH and RH. Spray manifolds in conveyor throat.

Spray manifolds across cutting heads, Gathering Head Sprays, incorporated into side shields.

Three way valves, item 11, can be changed to direct the head sprays, and hence the flow of air, to either the left of the machine or to the right.

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Tramming A mobile tramming unit can be attached to the miner when transporting the machine from one work area to another (relocation tramming). Quick disconnect couplings allow water to be circulated through: Electrical Control box, Traction Transformer box, LH & RH Traction motors, LH & RH Pump motors.

By connecting the inlet valve to the mobile tramming unit water supply and connecting the return to power tray coupling back to the power tray will allow the water to circulate through the electric motor and other electrical components for cooling.

Water Sprays The water system is fitted with hollow core sprays that assist with air flow. The sprays come in two (2) different sizes. The three (3) sprays at the back of the cutter head directing water spray into the conveyor system are ⅜” NPT thread. All the other sprays are ½ “NPT thread. The spray body is made of brass and has a stainless steel nozzle fitted to the body.

Spray Nozzles

Each spray is fitted with a gauze strainer to prevent blockage of the spray nozzle.

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Gauze Strainer

O-Ring

SS Nozzle

To clean the strainer and spray, remove the spray and dismantle, by removing the ‘O’ ring retaining the strainer. Remove strainer and clean. The stainless steel nozzle can also be removed if the body requires cleaning.

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Flow Switches The flow switches Item 4 in water schematic is used to monitor water flow through the machine.

As explained previous the cutter head motor will stop if no water is flowing through the flow switches monitoring water flow coming out of the motors.

There is also two flow switches monitoring water flow through the traction and pump motors.

Both water flow switches are set at 5 litres per minute. The software system can inhibit or activate the flow switches.

When activated the machine can be trammed, without water, with only the pumps operating. If a hydraulic function except for the brake release solenoid is operated for more than 10 seconds the machine will stop the pump motors. The same applies for the cutter head or conveyor motors if started.

Pumps There are a number of safety and machine protection interlocks that will stop the machine pumps or prevent it from starting: •

Transmitter must be logged on

•

Machine Emergency Stop or Lanyard is operated

•

Electronic Module fault

•

Lost radio signal

•

Left or right pump overload (4 minute reset)

•

Left or right over-temperature (RTD) fault

•

Incorrect Transmitter frequency

•

In “Maintenance Mode”, either of the (3) circuit breakers not open

•

Incorrect Combination of mode pressure switches.

NOTE:

Rev 1

Turning off power to the miner or control circuits will not reset the 4 minute overload reset timers. If power is removed during an overload reset time period, the reset timer will restart at the time remaining when power was removed.

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Traction There are a number of safety and machine protection interlocks that prevent tramming.

•

Pumps - these have to be running.

•

Earth leakage detected in traction circuit.

•

Traction transformer over-temperature (RTD) has tripped.

•

Either left or right traction motors have overloaded (Reset time is 4 minutes).

•

A shutdown in SCR traction drives electronics.

•

Deadman pressure - the brake solenoid has not operated or the pressure switch is closed.

This has to be energised to allow tramming.

•

Traction circuit breakers tripped.

•

Traction transformer Overload trip. (Reset time is 4 minutes).

If any of these conditions are not satisfied, a corresponding message will be displayed.

NOTE:

Rev 1

Turning off power to the miner or control circuits will not reset the 4 minute overload reset timers. If power is removed during an overload reset time period, the reset timer will restart at the time remaining when power was removed.

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Cutters There are a number of safety and machine protection interlocks that prevent the cutters from being started, or stop them if they are already operating: • • • • • • • • •

Pumps - these have to be running.

Either left or right cutter motor has overloaded (i.e. the motor current is too high). Reset time is 4 minutes.

Either left or right cutter motor over-temperature (RTD) has tripped.

Water spray for cutter head has failed (low flow) or has been turned off.

Tramming SPEED 2 or SPEED 3 has been selected whilst in reverse.

Low oil level High oil temperature.

Variation above 50% between current of each cutter motor.

The machine has to be in mining mode.

NOTE:

Turning off power to the miner or control circuits will not reset the 4 minute overload reset timers. If power is removed during an overload reset time period, the reset timer will restart at the time remaining when power was removed.

Conveyor There are a number of safety and machine protection interlocks that prevent the conveyor from being started, or stop it when it has already been started.

• • • • • • •

Pumps - these have to be running.

Gathering Heads reverse has to be stopped, to start the gathering heads in forward.

Gathering Heads forward has to be stopped, to start the gathering heads in reverse.

Either left or right gathering head motor is overloaded (i.e. the motor current is too high).

Either left or right gathering head motor over-temperature (RTD) has tripped.

Variation of 50% in motor currents.

The machine has to be in Mining mode.

NOTE:

Rev 1

Turning off power to the miner or control circuits will not reset the 4 minute overload reset timers. If power is removed during an overload reset time period, the reset timer will restart at the time remaining when power was removed.

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Event Monitor

The Event Monitor is Page 99 on the display screen menu and this screen includes:• • • • •

Event logging of current and previous fault history up to 100 events, at which time the oldest log will then be dropped off replaced with most current event.

Indicates the number of events logged at the bottom of the screen Current or uncleared faults are shown in red and have flashing warning triangle Indicates time and date event occurred and time and date event was cleared To erase Fault Log you need to be at the High Level Password and operate both the [SHIFT] and [REMOTE] Keys.

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Fault Log inside Event Monitor

Ensure the pump has been stopped prior to accessing the fault guide.

The option pictured above can be accessed from the event log by selecting the event you want information on by using [SHIFT] and CONV DWN. Operate [SHIFT] and CONV RIGHT to bring the above screen up which is the fault guide.

To return back to the Event Log, press, [SHIFT] and then PAGE.

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Main Control Case Indicators A panel of LEDs are visible through the viewing window in the Main Control Case. The LEDs indicate the following:1.

2.

3.

4.

110V Control – (Green – healthy) Control supply is ON Radio 24V – (Amber – healthy) 24V supply to Radio system is ON E/Stops Healthy – (Green – healthy) Machine Emergency Stops are all out Traction E/L Trip – (Red – Tripped) this will appear on power up, after a Traction E/L Test or if there is an earth fault on the traction circuit.

5. Pendant Mode – (Green – on) Indicates that pendant mode is selected. Radio is not able to be used in this mode.

6. Pump Overload – (Red – Tripped) Indicates that the manual pump overload had tripped. This will only operated when pendant mode is selected.

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Water Troubleshooting Guide PROBLEM: Lack of water reaching miner - water sprays Water Troubleshooting Chart for Drill Rigs in Drill Rig Section

WATER ISIS WATER FROM REEL CONNECTED TO CONNECTED MINER? TO MINER?

CONNECT HOSE AND OPEN WATER VALVE

NO

YES NO

WATER ISIS WATER PRESSURE

NO

PRESSURE AT SUPPLY SOURCE AT HOSE REEL

CORRECT WATER PRESSURE AT MINER? 100 PSI MINIMUM.

MECHANICAL SKILLS REQUIRED

YES

NO WATER FLOW ISISWATERFLOW PASSING PASSINGINLET THROUGH THROUGH BAG INLET FILTER? FILTER.CHECK FLOW AT CHECK FLOW AT WASHDOWN HOSES? WASH DOWN HOSES

NO REPLACE CLEAN FILTER FILTERBAG

MECHANICAL SKILLS REQUIRED

YES

IS WATER PASSING THROUGH PILOT OPERATED WATER VALVES?

NO

REFER HYDRAULIC SHEET

YES

ARE MINER WATER SPRAYS OPERATING

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NO

MECHANICAL SKILLS REQUIRED

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Service NSW Service Centre Bucyrus Australia 20 Kullara close Beresfield NSW 2322 Australia Queensland Service Centre Bucyrus Australia 33-37 Michelmore st Mackay Queensland 4740 Australia

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