Storage and transport
Installation
Points to observe prior to installation
Who is allowed to carry out installation?
Installation is only allowed to be carried out by personnel having received adequate training to perform this task.
Work on:
the safety components (pressure relief valves, fire extinguishing equipment etc.)
the electrical equipment (control units, signaling devices, etc.)
And
the hydraulic equipment (cylinders, directional control valves, hoses etc.)
should only be carried out by DBT America service engineers or by specially trained personnel.
Which tools are required for installation?
special tools
No special tools are required to put the Continuous Miner ® into service.
The receptacles come with a special wrench for connecting and disconnecting receptacles.
In addition, various items of auxiliary equipment and machines may be required at the point of installation.
These include i.e.:
¢ Blocking
¢ Hammer
¢ Screwdriver
¢ Retaining ring pliers
¢ Pliers
¢ Wire cutters
¢ Pry bar
¢ Chisel
¢ Punch
¢ Rose gun
¢ Welding equipment
¢ Chain falls
¢ Slide hammer (provided by DBT America) with the following adapters:
¢ 1”-8
¢ 5/8”-11
¢ 3/8”-16
¢ An adjustable wrench
¢ 7/16” wrench
¢ 3/4” wrench
¢ 1 1/8” wrench
¢ 1 1/2” wrench
¢ 7/16” socket wrench
¢ 9/16” socket wrench
¢ 3/4” socket wrench
¢ 15/16” socket wrench
¢ 1 1/8” socket wrench
¢ 1 1/2” socket wrench
¢ 1 7/8” socket wrench
¢ 15/16” torque wrench
¢ 1 1/2” torque wrench with 20-to-1 multiplier
¢ 1 7/8” torque wrench with 20-to-1 multiplier
¢ 7/8” torque wrench with 20-to-1 multiplier
¢ 3/8” Allen wrench
¢ 5/16” Allen wrench
¢ 5/8” Allen wrench
¢ 3/4” Allen wrench
¢ 7/8” Allen wrench
¢ 3/8” hex torque wrench
general safety rules
Before attempting any repairs, a DANGER sign must be attached to the appropriate circuit at the power distribution box. It is mandatory, under United States Federal Law, that the trailing cable be uncoupled and locked-out from the power source to provide visual evidence that the miner is de-energized
A scheduled preventative, maintenance, lubrication, and inspection system should be followed
Only qualified and authorized personnel should be permitted to maintain, repair, adjust and inspect the miner.
Before beginning any maintenance on the miner, perform the following procedures:
1. Visually disconnect the miner from the power source.
2. Block any and all elevated assemblies before working under them Make sure that the blocking can support the weight of the assembly without slipping or failing.
3. Relieve all hydraulic pressures.
4. Position all levers and controls in NEUTRAL or OFF
5. Work on the miner only in an area where the roof is properly supported.
6. Test the air for methane before beginning any maintenance work
Perform all procedures in accordance with accepted practices and applicable regulations.
The following general safety precautions should be observed:
¢ Any operation to check performance of the miner must be conducted in an area with sufficient safe clearance.
¢ Methane monitoring of the air must occur before and during all maintenance
¢ Avoid fire hazards and have fire protection equipment present whether working above or below ground.
¢ Do not use open pans of fuel or flammable cleaning fluid for cleaning parts.
¢ Control mechanisms, lights, overload devices, guards, and safety devices must be inspected regularly and maintained in safe operating condition.
¢ All parts of component assemblies and frame members must be carefully and regularly inspected and maintained in safe operating condition
¢ The original approved safe operating features of the miner must be maintained.
¢ Operation, warning, and maintenance instruction plates, tags or decals must be maintained in a legible condition. general maintenance safety
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¢ Modifications and additions that affect safe operation must not be performed without prior written approval from DBT America. Warning, operations, and maintenance instruction plates, tags, or decals must be changed accordingly.
¢ The hydraulic system should be regularly inspected and maintained in conformance with accepted practices. Cylinders, valves, and other similar parts should be checked to ensure that “drift” has not developed to the extent that it could create a hazard
¢ Motors, controllers, switches, protective devices, electrical conductors, and connections should be inspected and maintained in conformance with accepted practices and applicable regulations. Special attention should be paid to the condition of electrical insulation
¢ The miner should be kept as clean as possible to minimize fire hazards and to help in the detection of loose or defective parts.
¢ Care should be taken to ensure that all replacement parts are interchangeable with the original parts and are of quality equal to that provided in the original equipment.
¢ When performing maintenance, do not wear rings, watches, loose shirt sleeves, worn or tattered gloves, loose jackets, neck ties, or other apparel that could become entangled in the miner.
¢ Always wear the proper, approved safety clothing.
¢ Maintenance personnel must know how to properly operate the miner in order to perform test and inspection procedures.
¢ The miner must be maintained in “Permissible” condition, where applicable
¢ When working on or operating a miner from the Operator’s Platform area, do not reach out of the cab with your foot.
¢ Never touch a rotating or moving assembly or component.
¢ Be careful to avoid pinch points while operating or maintaining the miner.
¢ Be careful when working around high-pressure hydraulics. The high-pressure jet of fluid from a pinhole leak in a hydraulic hose can penetrate through skin and into the tissue below, causing serious problems such as blood poisoning.
lubricate every shift inspect daily
¢ Cutter head shear cylinder
¢ Cutter head shear cylinder pin (left and right)
¢ Cutter head shear cylinder to frame pin (left and right)
¢ Cutter head pivot pin (left and right)
¢ Conveyor roller
¢ Trailing cable for breaks or cracks in the cable cover
¢ Lighting systems for damage
¢ Conveyor flights for excessive wear or damage, and replace as necessary
¢ Cutter head mining bits for wear or damage, and replace as necessary
¢ Scrubber spray nozzles for blockage
¢ Check the lubrication levels of all the following components and fill as necessary:
¢ Gear cases (drum drive, gathering head, tram primary planetary, tram secondary planetary, tram idler)
¢ Tram drive (left and right)
¢ Drum drive (front and back, left and right)
¢ Front roller (left and right, tram idler)
¢ Lubricant levels of the oil reservoir
¢ Hydraulic fluid levels
¢ Gathering head lift cylinder
¢ Gathering head hinge pin
¢ Gathering head foot shaft
¢ Conveyor chain take-up pin
¢ Conveyor chain take-up locknut
¢ Conveyor swivel pin (upper and lower)
¢ Conveyor swing cylinder jack pins (front and rear)
¢ Conveyor-to-tractor frame pin
¢ Tractor frame stabilizer shoe pins (left and right)
¢ Clean and remove accumulated sludge:
¢ Scrubber filter screens
¢ Scubber inlet duct work
¢ Mist eliminator and sump
¢ All seals for leakage
¢ Gear case breathers (primary, gathering head) for airflow obstructions
¢ Entire front end for damage, and tighten all hardware
¢ Tram track for missing parts, wear, or damage
¢ All sprockets and idlers for wear or damage
¢ Hydraulic lines for wear and damage
¢ Drive sprocket shear pin bushings for wear/ damage
check daily
¢ Electrical system for damage, malfunctioning components, and loose or corroded connections
¢ The methane monitor is maintained according to manufacturers and regulatory specifications.
¢ Trailing cable connection at the power center of r permissibility according to Federal Regulations ( Part 75, Title 30 ).
¢ All lubrication fittings and plugs for proper installation as well as damage
¢ All bolts and capscrews, and tighten as necessary
¢ All chain tensions, and adjust as necessary
¢ Drum drive clutch, and adjust as necessary
¢ Tram track tension, and adjust track take-up cylinder as needed
¢ Required hydraulic pressures, and make corrections to the hydraulic system by readjusting the appropriate relief valves
¢ Gathering head hinge pins for excessive movement, and adjust as necessary
¢ Conveyor tension springs for proper expansion and contraction during conveyor operation, and adjust as necessary.
replace when necessary electric motor maintenance every month
¢ Return filter element
¢ Pilot circuit primary oil filter
¢ Clean all debris from motor frames
¢ Clean all heat exchangers
¢ Inspect motor bearings for lubricant leakage
¢ Check temperatures of bearings and frames
¢ Start motor and confirm that it accelerates to operating speed in an appropriate time
¢ Listen to the running motor for any unusual noises
Drain and Fill lubricant in all gear cases (drum drive, gathering head, tram primary planetary, tram secondary planetary). Take oil sample prior to draining. Send Sample to DBT America for analysis. To gather the oil Sample for analysis please follow the following steps outlined on the following page.
This process applies to the CLA Gear case and Pot Lube Check Presently, the lube checks require the removal of the check plugs, which are beside the fill port, and observation of the gear’s lube flow from the check port. It has been found that this does not insure the true gear lube level. To assure the proper gear lube level apply the following procedure.
1. Remove all plugs.
2. Using a rose gun or lube bucket force gear lube in the fill port until lube flows from the check port.
The diagram below gives a description of the location of the ports for both the upper and lower ports.
Inspect CLA’s for excessive wear and damage, and replace as necessary
¢ Cutter gear case mounting is secure, and tighten as necessary ¢ CLAs for looseness, and tighten as necessary
Lubricate scrubber fan motor.
¢ Clean motors thoroughly
¢ Inspect couplings, belts, belt guards, mounting frame bolts, end-shield bolts, and mechanical fastenings for mechanical soundness and tightness
¢ Check end play of rotor shaft
¢ Operate motors at normal load and temperature
¢ Measure and record motor insulation resistance and temperature
¢ The DC tram motors require regular preventive maintenance. Inspect the commutator, cable rigging, and brushes. The commutator should be dark brown with no signs of burning. Check for brush wear and spring tension. replace all of the brushes when replacement is necessary
Replace oil reservoir breather.
Lubricate the right and left cutterhead motor bearings (front and rear).
¢ Clean motor thoroughly
¢ Lubricate ball bearings, if required. Record the date the motor was lubricated.
¢ Inspect all gaskets, particularly lubricant seals, and replace as needed
¢ Check operating speed.
¢ Inspect and tighten all electrical connections
¢ Inspect fans for loose or damaged blades
¢ Run motor and examine drive for smooth operation and lack of excessive Vibration.
¢ Check current readings and compare with normal value on motor nameplate and previously recorded values
¢ Check motor mounts, end-shields, couplings, and shaft keys for looseness.
¢ Inspect all covers, belt guards, and other guards for damage, and tighten until securely fastened.
Drain, flush, and refill the entire hydraulic system
¢ Inspect all windings and insulation
¢ Clean and repair insulation as needed
¢ Measure resistance and record
¢ Check for and remove any magnetic particles
Notes on installation
Serious damage can be caused to the continuous miner ® as a result of incorrect installation. The unit should therefore only be installed under the instruction of specialists from DBT America.
The sequence of operations during installation must be adapted to the individual conditions prevailing at the site. Before starting the work a detailed list of steps to be taken with respect to transport and assembly should be prepared and a corresponding plan established.
The sequence of operations during installation must be adapted to the individual conditions prevailing at the site. Before starting the work a detailed list of steps to be taken with respect to transport and assembly should be prepared and a corresponding plan established
superbolt installation and specifications
tightening procedures
IMPORTANT
¢ Thread Diameter 1 1/4”
¢ Jackbolt Diameter 5/16”
¢ Jackbolt Socket Size 1/4”
¢ Required Jackbolt Torque 35 (in./lb.)
Read all these instructions completely before you begin.
This procedure is typical for the majority of SUPERBOLT products. Specific installation procedures that are shipped with all products may supersede this general procedure. Use the appropriate instructions shipped with the product you are installing. Contact SUPERBOLT, Inc. at (412) 279-1149 with any questions.
Air or electric power wrenches of the appropriate size may be used for running up jackbolts. Attempt to tighten as consistently as possible and remove the power wrench frequently; do not tighten all at once. Use a standard torque wrench to verify final torque values.
1. SUPERBOLT products are designed for use with hardened surface washers. Slide the washer onto the bolt or stud first.
2. VIEW A - Check the base of the tensioner(s) and verify that all jackbolts are flush with the bottom of the tennsioner body.
3. VIEW A - Clear any dirt or chips from the threads of the bolt or stud and from the main internal thread of the tensioner
4. VIEW A - Spin the tensioner body down on the main thread of the bolt or stud by hand. The tensioner body should be in light contact with the hardened washer.
5. Determine the target jackbolt torque value for the desired preload, either from the installation sheets shipped with the product or the catalog tables, or by calling SUPERBOLT, Inc. The jackbolt torque value stamped on the tensioner is a standard value for that part, and may not be appropriate for your specific application. Since jackbolt torque is directly proportional to the tension load, you can easily figure other values as required (e.g., 1/2 preload = 1/2 jackbolt torque).
6. Start by snugging the jackbolts to 10% of the target jackbolt torque value from step 5. This seats the thread and eliminates clearances. The star pattern shown in VIEW B should be used for this initial tightening sequence.
7. VIEW B - Tighten the jackbolts in the star pattern to 50% of the target jackbolt torque value.
8. VIEW C - Change to a circular pattern and torque the jackbolts to 75% of the target jackbolt value.
9. VIEW C - Continue one more pass in the above circular pattern with 10% more torque than that of the target jackbolt torque value.
10. VIEW C - Long bolts will stretch, so by the time you get back to the first jackbolt, it will be loose again
11. VIEW C - Set the torque wrench for the final torque value and continue to repeat the circular pattern until all jackbolts are torqued to the same value. do not exceed the torque value stamped on the tensioner without specific approval from SUPERBOLT, Inc.
loosening procedures
Jackbolts should be loosened with care For longer bolts and studs, this procedure is even more important. Loosening can be accomplished quickly, but do not rush to completely loosen individual jackbolts. Remember that the intent is to slowly release the preload force. All jackbolts should be loosened uniformly, and usually there is no need to remove any jackbolt from the tensioner body during loosening.
1. Turn the first jackbolt counter-clockwise until it feels loose (no more than one half turn). The idea is just to unload each jackbolt, not to completely loosen it.
2. Move in a circular pattern to the next jackbolt and repeat step 1.
3. Continue repeating until all jackbolts have been unloaded.
4. By the time you get back to the first jackbolt, it will be tight again. Repeat the process moving in a circular pattern.
5. Usually after two or three passes, the tensioner can be spun off the bolt or stud by hand Long bolts or studs that stretch more may require extra passes.
6. Before reusing any tensioner, the jackbolts should be removed in the appropriate manner. The body and jackbolts should be cleaned and re-lubricated with SUPERBOLT approved lubricant to ensure proper jackbolt torque vs. preload performance upon reinstallation.
The torque-preload relationship of SUPERBOLT tensioners depends on the tension body and jackbolt materials, heat treatment, plating, lubricants and many other factors. SUPERBOLT engineers have performed extensive tests to determine the best lubricants for the various materials utilized by SUPERBOLT, Inc. Two custom lubricants, JL-G and JL-M, are offered by SUPERBOLT, Inc.
¢ JL-G is a lubricant paste made from selected flaky graphite and prime mineral oil It has a relatively uniform friction factor of 0.130 under widely varying conditions. JL-G is used in the assembly of most SUPERBOLT products.
¢ A number of commercially available graphite - or nickel - based lubricant compounds such as Fel-Pro C102 or Fel-Pro N5000 can be used for re-lubrication in the field. Copper bearing compounds have not performed well as jackbolt lubricants.
JL-M is a lubricant paste made from molybdenum-disulifide powder and pure mineral oil. It has a friction factor of 0.045 to 0 070. Tests have shown that when jackbolts are tightened the first time, the friction of JL-M is approximately 0.070. Each subsequent tightening reduces the friction factor lower until at the fourth tightening it levels out at approximately 0 050. SUPERBOLT, Inc. uses an average friction factor of 0.055 for torque calculations. It must be emphasized that the tensioners must be tightened several times to stabilize at the low values. After many repeat tightenings, the friction factor can be as low as 0.045. Due to these variations in friction factor, molybased lubricants are used instead of graphite-based lubricants only in the following cases.
1. On very large jackbolts when the torque required for a specific preload would be too high; or,
2. Where space restrictions prohibit the use of sufficiently large torque wrenches.
In some cases, SUPERBOLT tensioners are “broken in” at the factory to lower the friction factor for field installation.
Fel-Pro C-870 molybdenum-disulfide paste has performed similarly to JL-M. Other molybdenum pastes and greases tested had much high friction factors. Testing for friction factor is recommended for all critical installations where lubricant and/or bolt and nut materials are unknown.
Safety features
The operator must become familiar with all the safety features and their location on the machine prior to installation or operation. Safety features include:
The machine is equipped with panic strips. The panic strip(s) are used to break the control circuit only in emergency situations, stopping all motors. Striking with a small amount of force will actuate either panic strip.
The machine was shipped from the factory with a protective canopy. Ensure that the canopy is in place and secure at all times to protect the operator from fall debris.
The machine is equipped with fire suppression (remote) actuators. This particular suppression system is pneumatically actuated and extinguishes with dry chemicals. To actuate the system from either of the actuators, pull the safety pin and strike downward on the plunger. Immediately after the plunger is struck, dry chemical will be dispensed throughout the machine. The fire suppression system must be completely recharged with dry chemicals and expellants after it has been actuated.
If either of the fire suppression actuators is actuated, the system must be completely recharged with dry chemicals and expellants.
The machine is equipped with guards and covers to reduce the possibility of personnel coming in contact with rotating or moving parts. All guards and covers must be installed and securely fastened during operation.
Do not operate the machine any of the guards or covers removed. You or other personnel could be seriously injured from moving or rotating parts.
The machine is equipped with a circuit breaker reset. The circuit breaker reset may be used to shutdown the machine in emergency situations.
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Operation
This chapter contains important information on the operation of various components of the miner. It also includes instructions on the replacement of wear parts. Read this chapter carefully and thoroughly In particular, observe the safety instructions in chapter 2 “Your safety”.
The cutter head assembly for each Dash Series miner model is unique. Therefore the procedures in this section are identified by miner modelDash Zero, Dash One, Dash Two, and Dash Three.
Lower the gathering head and the cutter head to the floor. Position the conveyor tail section level with the floor. Remove and lock-out the electrical power ti the miner.
1. Disconnect the power cables and water hoses from the cutter motors - follow the procedure in CUTTER MOTOR. Be sure to tape up the power cables since electrical power will be connected to the miner.
2. Disconnect the water hoses to the dust suppression sprays.
3. VIEW A -Remove both boom pivot pins - follow that procedure.
4. Disconnect electrical power to the miner.
5. Extend the shear cylinders to push the boom pivots out of their tractor frame clevises.
6. Block the shear cylinders to keep them stationary during their pin removal.
Provide support and lift to the cutter boom assembly.
Never work under any raised assembly without proper blocking.
7. Remove the shear cylinder boom clevis pins - follow the procedure in SHEAR CYLINDER.
8. Connect electrical power to the miner.
9. Retract the shear cylinders to pull their bearings free from the boom clevises. Disconnect electrical power.
10. VIEW B -Raise the rear of the boom assembly until it is above the top edge of the gathering head backboard. Reconnect electrical power.
11. Slowly tram the miner backwards until the cutter boom pivot points clear the front of the gathering head.
12. To install the boom assembly - reverse the above procedure.
Dash Zero, Dash One, Dash Two Removal / Installation.
Lower the gathering head and the cutter head to the floor, position the conveyor tail section with the floor. Remove and lock-out the electrical power to the miner.
1. VIEW A -Remove the capscrew and lock washer that secures the front rub rail to the tractor frame and open the front rub rail.
2. VIEW B -Remove the front idler take-up jack bracket -follow the FRONT IDLER TAKE-UP JACK procedure in SECTION 5, TRACTOR FRAME.
3. VIEW C -Remove the pivot pin retaining plate and its support block.
4. Connect electrical power to the miner.
5. VIEW C -Insert the slide hammer’s 1”-8 NC adapter into the end of the pivot pin
Pressure from the cutter boom onto the pivot pin can make its removal very difficult. The shear cylinders can be used to find the boom position that puts the least pressure on the pin.
When the pivot pin pull point is found, block the cutter boom to prevent it from dropping or moving when the pivot pin is removed.
6. VIEW D -Attach the slide hammer to its adapter and pull the boom pivot pin.
7. To install a boom pivot pin - reverse the above procedure.
Lower the gathering head and the cutter head to the floor. Position the conveyor tail section level with the floor. Remove and lock-out the electrical power to the miner.
1. VIEW A -Remove covers or scrubber duct work to access the boom pivot.
2. VIEW B -Remove the pivot pin grease line and retaining plate.
3. VIEW B -Insert the slide hammer’s 1”-8 adapter into the end of the pivot pin.
4. Connect electrical power to the miner.
Pressure from the cutter boom onto the pivot pin can make its removal very difficult. The shear cylinders can be used to find the boom position that puts the least pressure on the pin.
When the pivot pin pull point is found, block the cutter boom to prevent it from dropping or moving when the pivot pin is removed.
5. VIEW B -Attach the slide hammer to its adapter and pull the boom pivot pin.
6. To install a boom pivot pin - reverse the above procedure.
Position the conveyor tail level with the floor. Lower the gathering head to the floor. Raise and block the cutter head assembly. Remove and lock-out the electrical power to the miner.
Never work under any raised assembly without proper blocking.
Remove necessary covers to access the clutch at the rear of the cutter motor.
1. VIEW A -Remove the eight capscrews and lockwashers that secures the clutch cover to the motor frame.
2. VIEW A -Remove the clutch cover to expose the clutch assembly.
3. VIEW A -Remove the retaining ring that secures the motor shaft inside the clutch assembly.
4. VIEW A -Pull the motor shaft from the motor and clutch assembly. Store the motor shaft in a clean place.
5. VIEW B -Remove the sixteen locknuts on the out side of the pressure plate.
6. VIEW B -Remove the pressure plate and the out put hub assembly ( with seal and bearing ) from the clutch.
7. VIEW C -Remove the retaining ring found on the exterior of the keeper plate.
8. VIEW C -Remove the three capscrews and serrated washers that secures the keeper plate to the input hub.
9. VIEW C -Remove the keeper plate and disc spring to reveal the motor shaft secured by a retaining ring.
The remaining clutch assembly is very heavy Verify the weight can be supported.
10. VIEW D -Remove the retaining ring from the motor shaft. The input assembly of the clutch is unattached and can be slipped off the motor shaft.
11. VIEW D -Remove the final retaining ring from the motor shaft.
12. To install the Drum Drive Torque Limiting Clutch - reverse the above procedure.
Position the conveyor tail level with the floor. Lower the gathering head to the floor. Raise and block the cutter head assembly Remove and lock-out the electrical power to the miner.
Never work under any raised assembly without proper blocking.
1. VIEW A -Remove brackets and covers to access the drum drive motor.
2. VIEW B -Remove the capscrews and lock washers that secure the cover for the drive shear shaft. Remove the cover and o-ring.
3. VIEW B -Remove the retaining ring, the plug and the o-ring. Pull the drive shaft out of engagement with the gear case. Replace the shaft cover. Keep the shear shaft in a clean place.
4. VIEW C -Remove the capscrews on the motor junction box cover and remove the cover and o-ring.
5. VIEW D -Mark the motor and power cable leads and disconnect the leads.
6. VIEW E -Remove the stuffing box clamp and slide the power cables out of the motor junction box.
7. Disconnect the cooling water hoses from the motor. Plug the motor and hose ends to keep them clean.
The drum drive motor is very heavy. Verify its weight can be supported.
8. VIEW A -Remove the four bolts which mount the drum drive motor to the gear case.
9. VIEW A -Slide the motor out of the gear case
10. To install a drum drive motor - reverse the above procedure. Be sure to isolate and jog the new motor to check for correct rotation Note: Reuse top and bottom water manifolds.
1. VIEW A -Remove brackets and covers to access the drum drive motor.
2. Remove the torque limiting clutch assembly - follow that procedure.
3. VIEW B -Remove the four capscrews and lock washers on the motor junction box cover and remove the cover and o-ring.
4. VIEW C -Mark the motor and power cable leads and disconnect the leads.
5. VIEW C -Remove the stuffing box clamp and slide the power cables out of the motor junction box. Replace the junction box cover and o-ring.
6. Disconnect the cooling water hoses from the motor. Plug the motor and hose ends to keep them clean. -
7. VIEW D -Remove the caps from the Superbolts and remove the four Superbolts that secure the drum drive motor to the boomfollow the procedure in SUPERBOLT
8. To install a drum drive motor - reverse the above procedure. Be sure to isolate and jog the new motor to check for correct rotation
Position the conveyor tail level with the floor. Lower the gathering head to the floor. Raise and block the cutter head assembly. Remove and lock-out the electrical power to the miner.
Never work under any raised assembly without proper blocking. The drum drive motor is very heavy Verify its weight can be supported.
1. Advance the conveyor chain so that a conveyor flight does not block the shear cylinder piston end pin access plate in the conveyor bed.
2. VIEW A -Remove covers to access both ends of the shear cylinder.
3. VIEW B -At the Cutter boom clevis remove two capscrews and lock washers and remove the retaining plate.
4. VIEW B -Using the slide hammer with a 1”-8 adapter pull the pin from the clevis bushing.
5. Connect electrical power to the miner.
Stand clear of the blocked cutter head assembly during contraction of the shear cylinders.
6. Slowly contract the shear cylinder until the rod comes free from its cutter boom clevis.
Remove and lout-out the electrical power ti the miner.
7. Raise and lower the shear cylinder control lever to release any pressure from the shear cylinder.
8. VIEW C -At the tractor frame clevis, remove the two capscrews and lock washers that secure the pin retaining plate to the frame. Remove the retaining plate.
The shear cylinder is very heavy. Verify its weight can be supported.
9. VIEW C -Using the slide hammer with a 1”-8 adapter pull the pin from the clevis busing.
10. Mark for reconnection then disconnect and cap the hoses to the shear cylinder.
11. The shear cylinder can now be removed
12. To install a shear cylinder - reverse the above procedure.
shear cylinder dash-3
1. VIEW A -Access both ends of the shear cylinder.
2. VIEW B -At the Cutter boom clevis remove two capscrews and lock washers and remove the retaining plate.
3. VIEW B -Using the slide hammer with a 1”-8 adapter pull the pin from the clevis bushing.
4. Connect electrical power to the miner.
DANGER
cutter drums dash-0
The shear cylinder is very heavy Verify its weight can be supported. Remove and lock-out the electrical power to the miner.
5. Slowly contract the shear cylinder until the piston end comes free from its cutter boom clevis.
6. Raise and lower the shear cylinder control lever to release any pressure from the shear cylinder.
7. Mark the hoses for reconnection then disconnect and cap them.
8. VIEW B -At the tractor frame clevis, remove the two capscrews and lock washers that secures the pin retaining plate to the frame. Remove the retaining plate.
9. VIEW B -Using the slide hammer with a 1”-8 adapter pull the pin from the clevis bushing
10. The shear cylinder can now be removed
11. To install a shear cylinder - reverse the above procedure.
1. Manually rotate the cutter head drums slowly until the center drum connecting flanges are parallel to the mine floor. .
2. Before you do any disassembly, familiarize yourself with the position of the cutter drum alignment marks / arrows.
DANGER
center cutter drums
The cutter drums are extremely heavy Verify its weight can be supported. Remove and lock-out the electrical power to the miner.
1. VIEW A -At the split line of the two halves remove the weld straps using a cutting torch.
2. VIEW A -Remove the twelve capscrews and retainer plates holding the center drum flanges together. Store the capscrews and retainer plates for reinstallation.
3. Attach lifting chains or other lifting device to the top half cutter drum.
4. Break the seal between the center drum’s halves with a pry bar.
5. Lift the upper half of the center drum and move it away from the miner.
6. Connect electrical power to the miner.
7. Raise the cutter head assembly slowly until it is completely clear of the lower half of the center drum and tram the miner away from the drum halves.
8. To Install the center cutter drum - reverse the above procedure. Remember to torque the twelve capscrews to 1700 lb.-ft. alternating front to back starting from one end and working toward the other.
Verify the lifting device is capable of listing the drum’s weight. Use care when handling the cutter drum.
Follow welding safety instructions.
1. Drain the gear case oil before starting to remove the drums.
2. VIEW F -Remove the long capscrews and nuts on the two studs which secure the end drum to the cutter drum drive assembly.
3. Remove plug and center drum input shaft.
4. VIEW D -Remove the drum sliding it off of the hub.
5. Remove the key and store for reinstallation.
6. To install the end drum - reverse the above procedure.
7. Be sure the match timing arrows are aligned
8. VIEW F -Torque the capscrews to 350 lb.-ft.
The end cutter drums are very heavy. Verify the supports can support its weight.
1. The end cutter drum must be removed. Follow that procedure.
2. VIEW E -Using a cutting torch remove the straps tack welded to the strut capscrews.
3. VIEW E -Remove the eight strut capscrews.
4. VIEW F -Remove the remaining nuts on the two studs
5. Slide the strut and hub assembly from the gear case over the two studs.
6. VIEW B -Remove the capscrews from the main cutter drum
7. VIEW C -The cutter drum can now be removed from the output shaft by sliding it off the hub and two dowel pins.
8. To install the main cutter drum reverse the above procedure. Apply red loctite and torque the capscrews to 350 lb.-ft.
The main cutter drums are very heavy. Verify the supports can support its weight.
cutter drum installation / removal dash-1
1. Manually rotate the cutter head drums slowly until the center drum connecting flanges are parallel to the mine floor.
2. Before you do any disassembly, familiarize yourself with the position of the cutter drum alignment marks / arrows.
CAUTION
center cutter drum
Position the conveyor tail section level with the floor. Lower the gathering head until it is level with the floor. Raise and block up the cutter head assembly. Allow for removal of the cutter drums.
Never work under any raised assembly without proper blocking.
Remove and lock-out the electrical power to the miner.
The cutter drums are extremely heavy. Verify its weight can be properly supported and use extreme case when handling.
1. VIEW A -At the split line of the two halves remove the weld straps with hammer and chisel.
2. VIEW A -Remove the sixteen capscrews and retainer plates holding the center drum flanges together. Store the capscrews and retainer plates for reinstallation.
3. Attach lifting chains or other lifting device to the top half cutter drum.
4. Break the seal between the center drum’s halves with a pry bar.
5. Lift the upper half of the center drum and move it away from the miner.
6. Connect electrical power to the miner.
7. Raise the cutter head assembly slowly until it is completely clear of the lower half of the center drum and tram the miner away from the drum halves.
8. To Install the center cutter drum - reverse the above procedure. Remember to torque the sixteen capscrews to 1900 lb.-ft. alternating front to back starting from one end and working toward the other.
end cutter drums
1. Drain the gear case oil before staring to remove the drums.
2. Remove the lock-ring tack welded to the capscrews using a cutting torch.
3. VIEW F -Remove the long capscrews and nuts on the two studs which secure the end drum to the cutter drum drive assembly.
4. Remove plug and center drum input shaft.
5. VIEW D -Remove the drum sliding it off of the hub.
6. Remove the key and store for reinstallation.
7. To install the end drum - reverse the above procedure.
8. Be sure the match timing arrows are aligned
9. VIEW F -Torque the capscrews to 900 lb.-ft. Tack weld the lockring.
The end cutter drums are very heavy Verify their weight can be supported. Follow welding safety procedures.
1. The end cutter drum must be removed. Follow that procedure.
2. VIEW E -Using a cutting torch remove the retainer tack welded to the strut capscrews.
3. VIEW E -Remove the eight strut capscrews.
4. VIEW F -Remove the remaining nuts on the two studs
5. Slide the strut and hub assembly from the gear case over the two studs.
6. VIEW B -Remove the capscrews from the main cutter.
7. VIEW C -The cutter can now be removed from the output shaft by sliding it off the hub and two dowel pins.
8. To install the main cutter drum reverse the above procedure. Torque capscrews to 500 lb.-ft. If never size is used reduce the torque value to 300 lb.-ft. ( If loctite is used reduce the torque value to 425 lb.-ft. )
9. Tack weld the lock-ring and capscrew retainer.
The strut and hub assemblies are very heavy Be prepared to supports its weight.
The main cutter drum is extremely heavy. Verify its weight can be supported.
1. Manually rotate the cutter head drums slowly until the center drum connecting flanges are parallel to the mine floor.
2. VIEW C - Before you do any disassembly, familiarize yourself with the position of the cutter drum alignment marks / arrows.
3. VIEW A -At the capscrews remove the weld straps with hammer and chisel.
4. VIEW C -Remove the twenty capscrews and retainers holding the center drum flanges together. Store the capscrews and connecting plates for reinstallation.
5. VIEW B -Attach lifting chains or other lifting device to the top half cutter drum.
7.
Verify the lifting device is capable of lifting the drum;s weight. Use care when handling the cutter drum. cutter drums dash-2
6. Break the seal between the center drum’s halves with a pry bar.
8. VIEW B -Lift the upper half of the center drum and move it away from the miner.
9. VIEW C -Remove the center drum alignment keys from the keyway if the cuttting drums are key driven ( not square drive ). Store for reinstallation.
10. Connect electrical power to the miner.
11. Raise the cutter head assembly slowly until it is completely clear of the lower half of the center drum and tram the miner away from the drum halves.
12. To Install the center cutter drum - reverse the above procedure. Remember to torque the twenty capscrews to 1850 lb.-ft. alternating front to back starting from one end and working toward the other.
Position the conveyor tail section level with the floor. Lower the gathering head until it reaches the floor. Raise and block the cutter head assembly. Allow space for the removal of the cutter head.
Never work under any raised assembly without proper blocking.
Remove and lock-out the electrical power to the miner. Follow welding safety procedures.
The cutter drums are extremely heavy. Verify the supports willhandle its weight.
end cutter drums
1. VIEW D -Remove the weld straps between capscrews using a cutting torch.
2. VIEW D -Remove the twelve capscrews which secure the end drum to the cutter drum drive assembly.
3. VIEW D -Remove the drum from the miner.
4. To install the end drum - reverse the above procedure.
5. VIEW C -Be sure the match timing arrows are aligned.
6. VIEW D -Torque the twelve capscrews to 1200 lb.-ft. Tack weld the straps.
The end cutter drums are very heavy. Verify the supports can handle its weight. Follow welding safety procedures.
Position the conveyor tail section level with the floor. Lower the gathering head until it reaches the floor. Raise and block the cutter head assembly. Allow for removal of the cutter drums.
Never work under any raised assembly without proper blocking.
Remove and lock-out the electrical power to the miner.
1. Manually rotate the cutter head drums slowly until the center drum connecting flanges are parallel to the mine floor.
2. VIEW C -Before you do any disassembly, familiarize yourself with the position of the cutter drum alignment marks / arrows.
The cutter drums are extremely heavy. Use extreme care when handling.
center cutter drum
1. VIEW A -At the capscrews remove the weld straps using a cutting torch.
2. VIEW C -Remove the eighteen capscrews holding the center drum flanges together. Store the capscrews for reinstallation.
3. VIEW B -Attach lifting chains or other lifting device to the top half cutter drum.
4. Break the seal between the center drum’s halves with a pry bar.
5. VIEW B -Lift the upper half of the center drum and move it away from the miner.
6. VIEW C -Remove the center drum alignment keys from the key way if the cuttting drums are key driven ( not square drive ). Store for reinstallation.
7. Connect electrical power to the miner.
8. Raise the cutterhead assembly slowly until it is completely clear of the lower half of the center drum and tram the miner away from the drum halves.
9. To Install the center cutter drum - reverse the above procedure. Remember to torque the eighteen capscrews to 1850 lb.-ft. alternating front to back starting from one end and working toward the other.
Follow welding safety procedures.
Verify the lifting device is capable of lifting the drum’s weight. Use case when handling the cutter drum.
1. VIEW D -Remove the weld straps between capscrews using a cutting torch.
2. VIEW D -Remove the twelve capscrews which secure the end drum to the cutter drum drive assembly.
3. VIEW D -Remove the drum from the miner.
4. To install the end drum - reverse the above procedure.
5. VIEW C -Be sure the timing arrows are aligned.
6. VIEW D -Torque the twelve capscrews to 1200 lb.-ft. Tack weld the strap across the capscrews.
Follow welding safety procedures.
The end cutter drums are very heavy Verify the supports can handle its weight.
case dash-0 installation / removal
1. Remove the cutter drums - follow that procedure.
2. Remove the covers and water spray manifolds, hosing, and remove cutter motor power leads attached to the gear case.
3. Securely block the cutter drum drive gear case to support it when it becomes separated from the boom.
4. VIEW A -Remove the two capscrews which adjust the special key.
5. Remove the strapping from the capscrews securing the gearcase to the boom using a cutting torch.
6. VIEW D -Remove the fourteen hex head capscrews that secure the cutter drum drive gear case to the cutter drum.
7. Remove the cutter motor.
8. Connect electrical power to the miner.
9. Slowly tram the miner in reverse away from the blocked gear case.
10. VIEW B -Remove the special key and store for installation.
11. To install a gear case - reverse the above procedure. Torque the fourteen capscrews to 1700 lb.-ft.
Position the conveyor tail section level with the floor. Lower the gathering head to the floor. Raise and block-up the cutter head assembly Allow for removal of the cutter drums
Never work under any raised assembly without proper blocking.
Remove and lock-out the electrical power to the miner.
The gear case is very heavy Verify the supports can handle its weight.
Stand clear of the gear case and the miner when tramming.
Follow welding safety procedures.
Follow welding safety procedures. gear case dash-1
1. Remove the cutter drums - follow that procedure.
2. Remove the covers and water sprays attached to the gear case. Note: Same as Dash Zero.
3. Securely block the cutter drum drive gear case to support it when it becomes separated from the boom.
4. VIEW B -Remove the strapping from the capscrews securing the gear case to the boom using a cutting torch.
5. VIEW B -Remove the sixteen hex head capscrews that secure the cutter drum drive gear case to the cutter drum.
6. Remove cutter motor.
7. Connect electrical power to the miner.
8. Slowly tram the miner in reverse away from the blocked gear case.
9. VIEW B -Remove the two keys and store for installation.
10. To install a gear case - reverse the above procedure. Torque the sixteen capscrews to 1900 lb.-ft.
Position the conveyor tail section level with the floor. Lower the gathering head to the floor. Raise and block-up the cutter head assembly. Allow for removal of the cutter drums.
Never work under any raised assembly without proper blocking.
Remove and lock-out the electrical power to the miner.
The gear case is very heavy. Verify the supports can handle its weight. .
Stand clear of the gear case and the miner when tramming.
1. Remove the center cutter drum and the end cutter drum - follow that procedure.
2. VIEW A - On the rear of the cutter drum drive motor, locate the clutch housing and the motor shaft access cover plate.
3. VIEW A - Remove the four capscrews that secure the motor shaft access cover plate to the clutch housing. Remove the access cover plate to expose the end of the motor drive shaft.
4. VIEW A - Remove the retaining ring that secures the motor shaft in the clutch assembly.
5. VIEW A - Pull the motor shaft from the motor and clutch assembly.
6. Store the motor shaft in a clean, safe place.
7. To protect the clutch from damage and dirt, replace the access cover plate. .
8. Securely block the cutter drum drive gear case to support it when it becomes separated from the boom.
9. VIEW B -Remove the strapping from the twenty-one capscrews securing the gear case to the boom using a cutting torch.
10. VIEW C - Remove the twenty-one 1 1/4” hex head capscrews that secure the cutter drum drive gear case to the cutter boom
11. Connect electric power to the miner.
12. Slowly tram the miner in reverse away from the blocked gear case.
13. Remove the three face keys and save for installation.
14. To install a gear case -reverse the above procedure except for the following steps.
15. VIEW D -Insert four 1 1/4” dowel guides into the cutter boom face, spacing them equally over the boom face.
16. VIEW D -Mark the holes on the exterior of the gear case mounting brace that correspond to the positions of the guides on the boom face.
17. VIEW D -Apply RTV silicon sealer to the gear case center alignment key and install the key into the boom face. Also install the gear case’s two larger side alignment keys into the boom face.
18. VIEW C -Torque the twenty-one capscrews to 1850 lb.-ft. beginning with the inner capscrews and working to the outside. Remember to fill the gear case with approved lubricant
Position the conveyor tail section level with the floor. Lower the gathering head to the floor. Raise and block-up the cutter head assembly. Allow for removal of the cutter drums. Remove and lock-out the electrical power to the miner.
The gear case is very heavy. Verify the supports can handle its weight. Stand clear of the gear case and the miner when tramming
Never work under any raised assembly without proper blocking.
Follow welding safety procedures.
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cutter boom dash-2, 3 gear case
gathering head ass’y installation / removal
See figure—14 & 15
CAUTION
The gathering head assembly has two Continuous Loading Arms ( CLA ) which rotate to load the cut material on to the conveyor Two electric motors drive the CLA gear cases and the conveyor foot shaft. The electric motors are called either “gathering head” or “conveyor” motors.
1. View A - Place blocking under the rear of the gathering head to stabilize its position during and after the removal of the pivot pins and disconnection of the lift cylinders.
2. Remove the electric motor cable and cooling water lines from the gathering head. Disconnect these from the motor. Refer to the motor removal procedure
3. View B - Access the gathering head pivot point by removing the forward tram rub rail.
4. View C - Remove the two 3/4” capscrews and lock washers that secure the pin retaining plate to the tractor frame.
5. View C - Remove the two 1” capscrews and lock washers that secure the pin retaining plate to the pivot pin.
6. View D - Using the slide hammer with a 1”-8 adapter remove the pivot pin.
7. Repeat steps 3 through 7 for the opposite side.
8. Disconnect both lift cylinders from the gathering head by pulling the piston end pins. Refer to the lift cylinder replacement procedure.
9. Lower the gathering head control lever at the valve bank The weight of the lift cylinder pistons should cause the piston ends to come free from the gathering head
10. Connect electrical power to the miner.
11. View E - Lift the cutter head off of the blocking and slowly tram the miner in reverse until the cutter head clears the backboard of the gathering head.
12. To install the gathering head - reverse the removal procedure.
Lower the conveyor tail until it is level with the floor. Lower the gathering head until it rests on the floor. Raise and block up the cutter head assembly. Remove and lock-out electrical power to the miner. Be sure to tape up the motor cable leads. There will be electric power on the miner before the motors are reconnected.
CAUTION
DANGER
Check the blocking of the gathering head assembly so it w ill not drop w hen the pivot pins are removed and the lift cylinders are disconnected W hen separating the gathering head from the tractor frame, insure that the disconnected ends of the conveyor chain slide out of the gathering head.
Never work under any raised assembly without proper blocking.
See figure 16
1. View A - Remove the three 1” capscrews and lock washers where the arms meet the CLA hub.
2. View A - Remove the six 1” capscrews and lock washers located in the center of the CLA hub. The CLA should now be free and able to be removed.
3. View B - Remove the four CLA alignment keys from the exposed gathering head gear case turntable. Store the keys in a safe place.
4. View C - On installation of the CLA, mark the outer bolt hole on the CLA that is directly adjacent to a key cut-out. Place a 1” wooden dowel in the outer bolt hole of the gear case turntable that is directly adjacent to a key cut-out. Place the four keys into their cut-outs on the gear case turntable.
5. View D - Place the CLA on the gear case turntable so that the dowel extends through the marked CLA hole. Adjust as necessary to fit the turntable keys into the CLA cut-outs.
6. View D - Remove the wooden dowel and install the nine lock washers and capscrews. If hog rings are used, they should be installed so that their sharp points prevent the capscrew from loosening per View E.
7. After CLA installation, inspect the positions of the CLAs to insure that the arms will not collide during rotation
Lower the conveyor tail until it is level with the floor. Lower the gathering head to the floor. Raise and block up the cutter head assembly. Remove and lock-out electrical power to the miner.
Never work under any raised assembly without proper blocking.
gathering head motor installation / removal
1. View A - Remove the side cover secured by two capscrews and lock washers. The end of the motor will be exposed.
2. View B - Remove the 2” pipe plug on the end of the motor. Using a screwdriver remove the retaining ring that secures the shaft end plug inside the motor housing.
3. View B -Pull the drive shaft out using a slide hammer with a 3/8”-16 adapter. Store the drive shaft, shaft end plug and the retaining ring in a safe place. Replace the pipe plug in the end of the motor.
4. View D - Disconnect and plug the water connections.
5. View E - Remove the four 3/4” socket head capscrews that secure the motor to the gear case adapter plate. The motor can now be pulled out to get to the junction box. Note the seal between the motor and the gear case
6. View C -Disconnect the electrical cables in the junction box. Mark the cable motor leads so they can be reconnected correctly Remove the stuffing box clamp and pull the cable out of the motor.
7. To install a motor - reverse the above removal procedure. Use a new seal between the motor and the gear case.
8. A newly installed motor must be run independent of the other motor to insure proper rotation. This can be done by isolating the other motor in the controller case
Verify electrical power to the miner is disconnected and lockedout.
1. View A -Slowly advance the conveyor chain until a connecting link appears at the gathering head foot shaft area.
2. Loosen the conveyor chain tension as much as possible. ( See Conveyor Chain Adjustment Procedure.)
3. View A - Remove the conveyor chain connecting link.
4. View B -Remove the eight 3/4” capscrews and lock washers securing the footshaft cover to the gathering head.
5. View C -Remove the four 1/2” capscrews from each of the two collars and remove the collars from the footshaft.
6. View D -Slide the two couplings from the ends of the footshaft toward the center sprocket on the footshaft.
7. View E - The footshaft can now be removed.
8. To install the footshaft - reverse the above removal procedure.
9. Be sure to readjust the conveyor chain tension.
Never work under any raised assembly without proper blocking.
Verify power to the miner is disconnected and lock-out.
gear case installation / removal
1. Completely drain the gear case lubricant by removing the two 3/4” plugs located on the underside of the gear case. Replace the drain plugs.
2. Reconnect electrical power and lower the gathering head assembly to the floor.
3. Remove the CLA ( Follow that procedure.)
4. Remove the drive motor. ( Follow that procedure. )
5. Remove the footshaft. (Follow that procedure.)
6. View A - Remove capscrews and the upper and lower deck covers.
7. View B -Disconnect the four lubrication hoses from the gear case. Tag the hoses so they can be reconnected properly Plug both ends to keep dirt out.
8. View C - Remove the twelve capscrews that secure the gear case pot and mounting wedges to its mounting plate.
9. The gear case can now be removed.
10. To install a gear case -Reverse the removal procedure. Use a new gear case-to-motor seal.
11. Fill the gear case. Attach a rose gun to the lower port located next to the gathering head side cover and fill the gear case to the proper level with gear lubricant. The gear case is full when steady oil flow is observed from the breather plug in the top port. Check for leaks.
Lower the conveyor tail until it is level with the floor. Raise and block up the cutter head assembly. Raise and block up the gathering head assembly. Remove and lock-out electrical power to the miner.
Never work under any raised assembly without proper blocking.
The cutter head assembly should still be blocked up.
1. View A - Remove two capscrews and the Piston Pin Retaining Bar.
2. View A -Use the slide hammer with a 5/8”-11 adaptor to pull the Piston Pin from the clevis bushings.
3. Lower the gathering head control lever at the valve bank The weight of the lift cylinder piston should cause the piston end to come free of its clevis.
4. Move the gathering head lift cylinder control lever up and down to release any pressure from the lift cylinder.
5. View C - Remove the hydraulic hose from the lift cylinder’s hydraulic fitting. Plug the hose end to keep it clean.
6. View D -Remove the two capscrews that secure the Pin Retaining Plate to the tractor frame. Remove the Pin Retaining Plate.
7. View D - Use the slide hammer with a 5/8”-11 adapter to pull the rod end pin from the frame cleves bushing.
8. The lift cylinder can now be removed.
9. To install the lift cylinder - reverse removal procedure.
Lower the conveyor tail until it is level with the floor. Raise and block up the cutter head assembly Raise and block up the gathering head assembly. Remove and lock-out electrical power to the miner.
Never work under any raised assembly without proper blocking. Stand clear of the blocked cutter head and gathering head assemblies.
Be prepared to support the cylinder when it becomes free.
The maintenance procedures for the tractor frame assemblies are basically the same for all of the Dash Series miners.
The installed tram case includes the tram motor, the tram primary planetary gear, the tram reach gear set, the tram secondary planetary gear, and the tram sprocket. Removal of the tram case is a major undertaking involving the removal of crawler track pads from the tram case. Depending upon the maintenance required removal / installation procedures are given for each major component.
For detail disassembly and assembly and to identify parts of the tram gear case refer to the assembly drawing in the parts book for that miner.
1. VIEW A - Remove the tram rub rail after pulling the two tram rub rail pins.
2. VIEW B - Remove the four hex head capscrews and lock washers that hold the input shaft access cover to the motor frame. Remove the input shaft access cover and o-ring.
3. VIEW B - Remove the retaining ring, shaft plug & o-ring and pull out the motor input shaft. Replace the input shaft access cover.
4. VIEW C - Disconnect the cooling water hoses from the motor. Plug the hoses and fittings to keep them clean.
5. VIEW D - Remove the four capscrews that hold the tram motor bracket to the tram case. Remove the tram motor bracket.
6. VIEW D -Slide the tram motor out from the tram case until the electrical connection and hand hole cover are accessible. Remove the eight capscrews that hold the hand hole cover to the motor frame. Remove the hand hole cover and o-ring.
7. VIEW D - Mark the wire connections and disconnect the power cables. Remove the two capscrews that hold the stuffing boxes half moon clamp to the junction box. Slide the stuffing box out of the junction box. On the Dash Zero remove the scrubber duct mounting bracket also
8. VIEW E -Slide the tram motor out from the tram case onto blocking. Take care not to damage the motor adapter plate seal.
9. To install the tram motor - reverse the above removal procedure Note: Slide the input shaft through the tram motor (VIEW B) and into the tram planetary primary gear -The input shaft end without the threaded hole should be inserted first. It may take some adjusting to get the splined end of the shaft to fit into the gear spline. Be sure to install a new motor-to-adapter seal.
LOWER THE GATHERING HEAD AND CUTTER HEAD TO THE FLOOR. POSITION THE CONVEYOR TAIL SECTION LEVEL WITH THE FLOOR. REMOVE AND LOCK OUT ELECTRICAL POW ER TO THE MINER. DO NOT RECONNECT ELECTRICAL POWER TO THE MINER WHILE THE TRAM MOTOR POWER CABLE IS DISCONNECTED.
Installation
1. VIEW A - Remove the tram motor. ( Follow that procedure ) The tram primary planetary gear is located behind the tram motor.
2. VIEW B - Remove the sixteen capscrews that secures the motor adapter plate and the primary gear ring to the tram case.
3. Remove the motor adapter plate from the gear case.
4. Carefully slide the primary planetary carrier assembly out of the primary gear ring and remove the assembly from the tram case.
5. Carefully slide the primary gear ring out of the tram case.
6. Installation of the primary planetary gear set - Reverse the above procedure using the following installation steps.
7. VIEW B - Insert alignment dowels inserted into four (4) of the sixteen (16) capscrew holes in the tram case.
8. VIEW B -Mark the mounting holes of the primary planetary gear ring that correspond to the holes in which the alignment dowels were placed.
9. VIEW B - Carefully insert the primary planetary gear assembly into the gear ring. Be sure that the extension of the sun gear faces out from the center of the miner and that the internal gear teeth of the primary carrier are seated securely onto the tram drive pinion gear. Orient the adapter plate with the adapter dowels along the bottom edge.
10. VIEW B - Install and tighten the sixteen 3/4” capscrews to 230 lb.-ft. Remove the alignment dowels as you proceed.
Lower the gathering head and the cutter head to the floor. Lower the conveyor tail section. Remove and lock-out electrical power to the miner. Recommended
1. VIEW A - Remove the tram rub rail after pulling the two pins.
2. VIEW B - Remove the 3/4” plug from the bottom of the secondary planetary gear cove and drain the lubricate from the gear case. Replace the plug.
3. VIEW C - Remove the 16 capscrews that hold the secondary planetary gear cover to the tram case.
4. Remove the secondary planetary gear thrust washer from the planetary gear cover.
5. VIEW D -Slide the secondary planetary gear ring off the secondary planetary gear assembly.
6. VIEW D -Install eight 3/4” - 10x2 1/2” hex head capscrews into the sprocket bearing carrier to hold it on the tram case.
7. VIEW E - Pull the secondary tram gear shaft from the gear and sprocket.
8. VIEW F -Carefully slide the secondary planetary assembly out of the sprocket bearing carrier.
9. VIEW G - Installing the secondary planetary assembly is basically the reverse of the above procedure, except for the following.
10. Slide the secondary tram drive shaft with the thread hole end to the outside into the tram drive sprocket and reach gear set. The shaft may require some adjustment to introduce the splined end into the reach gear.
11. Insert four alignment dowels into the holes in the sprocket bearing carrier.
12. To facilitate ring gear insertion, mark the mounting holes of the secondary planetary ring gear that corresponds to the holes in which the alignment dowels were placed.
13. Carefully slide the secondary planetary ring gear onto the four alignment dowels so that the dowels appear through the marked holes. The planetary should slide smoothly into the ring gear teeth.
14. Place a new thrust washer into the secondary planetary cover. The side of the thrust washer with the inscribed circles should face away from the drive shaft.
15. To facilitate the gear cover replacement, mark the mounting holes of the secondary planetary gear cover that corresponds to the holes in which the alignment dowels are placed. NOTE: The flat edge of the cover located adjacent to the 3/4” lubrication fitting is the top of the cover.
16. Slide the secondary planetary gear case cover onto the alignment dowels so that the dowels appear through the marked holes.
17. Using the 5/8” torque wrench, install and torque all sixteen capscrews to 220 ft.-lb., removing the alignment dowels as you proceed.
18. Fill the secondary planetary gear case to the proper level with the recommended lubricant. Allow the lubricant level to stabilize and recheck it several times before operation.
Lower the gathering head and the cutter head to the floor. Lower the conveyor tail section Be prepared to support the heavy weight of the secondary planetary ring gear when removing it from the secondary planetary assembly Be prepared to support the heavy weight of the secondary planetary gear assembly when removing it from the sprocket bearing carrier in the tram case.
tram case installation / removal
See figure—5 & 6
1. VIEW A - Place blocking under the cutter head assembly and raise the front of the miner and use the stabilizer jack to raise the rear of the miner. Place blocking in multiple locations under both crawler tracks. When the miner is lowered, the weight of the miner rests on the tram track blocking. Leave the blocking under the cutter head; the crawlers will be raised off their blocking later.
2. VIEW B - Remove the tram rub rail after removing the two tram rub rail pins.
3. VIEW B - Open the front rub rail after removing the capscrew holding it in place.
4. VIEW C - Use a grease gun to extend the take-up jack to remove the pusher plate pressure and remove the idler adjustment shims,
5. VIEW C - Open the pressure release valve on the take-up jack to allow the cylinder to contract. This will loosen the tension on the crawler chain.
6. VIEW D -Disconnect the tram crawler pads near the track entry opening by removing the two roll pins that hold the crawler pins in the crawler pads.
7. VIEW D - Attach heavy wires to the end of the crawler track link that passes through the tram case and over the tram sprocket.
8. If the tram drive is operational reconnect electrical power to the miner.
9. VIEW E -Slowly operate the tram motor forward to rotate the sprocket so that the end of the tram track that passes through the case and rolls off the sprocket.
10. VIEW E -Pull the tram track from the front of the miner ( near the idler ) so that the free end of the tram track is pulled clear of the tram case exit opening.
11. VIEW F -Remove the two 1-1/4”x 3-3/4” lg. Superbolts from the sprocket side of the tram case and the two 1-1/4”x 3-3/4” Superbolts from the motor side of the tram case. Follow the SUPERBOLT installation / removal procedures.
12. VIEW F - Remove the two 1-1/4”x 5” Superbolts from the sprocket side of the tram case and the two 1-1/4”x5” Superbolts from the motor side of the tram case. Remove the two capscrews from the sprocket side of the tram case.
13. Follow the TRAM MOTOR removal procedure to disconnect the tram motor power cable and cooling water hoses.
14. VIEW G -Slide the tram case out from the tractor frame onto blocking. Pull the tram track guide wires out of the tram case exit opening and secure the wires to the tractor frame.
15. To install the tram case - reverse the above procedure.
16. VIEW H - Check the tram track tension when the crawlers are off the floor. The track sag should be between 2-1/2” and 3-1/2”. If the tram track is not at the proper tension follow the adjustment procedure in TRAM TRACK.
DANGER
CAUTION
Never work under any raised assembly without proper blocking.
stabilizing cylinder installation / removal See figure—7
Remove and lock-out electrical power to the miner. Stand clear of the miner w hen using the tram motor to remove the tram track from the sprocket. The assembled tram case is very heavy Be prepared to support the tram case before removing it from the tractor frame.
1. VIEW A - Place blocking under the conveyor tail section. Place blocking under the cutter head assembly Lower the gathering head onto blocking. Lower the conveyor tail section onto blocking.
2. VIEW A - Pressure down the cutter head to raise the front of the miner. Pressure down the stabilizer to raise the rear of the miner. Place blocking in multiple locations under both tracks. Add blocking under the tractor frame.
3. VIEW A -Raise the cutter head and the stabilizer until the weight of the miner is on the blocked up tracks and tractor frame.
4. Remove the blocking from under the stabilizer shoe.
5. VIEW B -Reference for horizontal mounted stabilizer cylinder on Dash One, Dash Two, and Dash Three miners. VIEW CReference for vertical mounted stabilizer on Dash Zero miners.
6. VIEW B / C - With the stabilizer shoe resting on the ground, remove the capscrews securing pins at the cylinders rod end clevis.
7. VIEW B / C - Remove the rod end pin using a hammer and punch.
8. Connect electrical power to the miner.
9. Contract the stabilizer cylinder. The rod end bearing of the cylinder should remove itself from its clevis.
10. Raise and lower the stabilizer cylinder lever to release any pressure from the stabilizer shoe lift circuit.
11. Disconnect the hydraulic hoses from the stabilizer cylinder. Mark the hoses and plug them to keep them clean.
12. Remove and cap the hydraulic fittings from the cylinder.
13. VIEW B / C - Remove the cotter pins or capscrews used to secure the cylinder pin at the tractor frame clevis.
14. VIEW B / C - Remove the cylinder pin at the tractor frame using a hammer and punch.
15. To install a stabilizer cylinder - reverse the above procedure.
16. VIEW D - If both stabilizer cylinders have been removed, The stabilizer shoe can be removed by removing the two pivot pins at the tractor frame.
CAUTION
Never work under any raised assembly without proper blocking.
Remove and lock-out electrical power to the miner. Be prepared to support the heavy stabilizer cylinder.
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