CAT Bucyrus Gleithobel plow® GH 1600-3 Operating Manual - PDF DOWNLOAD

Operating manual Gleithobel plow® GH 1600-3 Translation of the original operating manual

Doc. No.: 6050 015 000 BA 00

Bucyrus Europe GmbH Industriestr. 1 D-44534 Lünen

Phone: +49 (0) 23 06 / 709 - 0 Email: info@de.bucyrus.com Fax: +49 (0) 23 06 / 709 - 1421 Web: www.bucyrus.com

Translation of the original operating manual.

Amendments and alterations to this publication are not subject to notification. Bucyrus reserves all rights to this publication.

Its content is protected by copyright law. No part of this publication may be reproduced or transferred in any way or form without the prior written approval of Bucyrus.

Bucyrus assumes no liability for direct or indirect consequences of misprints.

We reserve the right to introduce modifications as a result of technical development without prior notice.

Bucyrus Europe GmbH, Lünen 2010E

Contents

Contents 1. About this manual Before starting work . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3

Persons for whom the operating manual is intended . . . .

Purpose of this operating manual . . . . . . . . . . . . . . . . . . . .

Characters and symbols used . . . . . . . . . . . . . . . . . . . . . . .

1.3 1.4 1.4

Bucyrus Europe GmbH, Lünen 2010

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2. Your safety Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation and repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3 2.4

Operating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4

Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Unauthorized use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Prerequisites for operation . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4 2.4 2.4 2.5

Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.6

3. Storage and transport Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3

Storage of the equipment . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3

Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4

Before transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

How to transport the plow . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4 3.4

4. Installation

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What you need to observe prior to installation . . . . .

4.3

Who is allowed to carry out the installation? . . . . . . . . . . .

Which tools are required for installation? . . . . . . . . . . . . . .

Notes on installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3 4.3 4.3

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.5

Gleithobel plow® GH 1600-3 . . . . . . . . . . . . . . . . . . . . . . . .

4.5

How to install the Gleithobel plow . . . . . . . . . . . . . . . . .

4.6

Gleithobel plow body GH 1600-3 . . . . . . . . . . . . . . . . . . . . .

Thrust rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main bodies, right and left . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dogbone connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjusting mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bit turret . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gleithobel plow upper parts . . . . . . . . . . . . . . . . . . . . . . . . .

Bit holders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pulling sledge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.6 4.7 4.7 4.9 4.10 4.11 4.13 4.16 4.17 4.18

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Contents Chain attachments and connections . . . . . . . . . . . . . . . . . .

Fitting the plow on the conveyor . . . . . . . . . . . . . . . . . . . . .

4.19 4.20

Plow bit lacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.21 Selecting plow bits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lacing example, DBT 2003 bit system . . . . . . . . . . . . . . . .

The DBT 2003 bit system . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing a plug-in bit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing the plug-in bit . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DBT 2003 Apex bit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DBT 2003 roof bit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DBT 2003 slot-fitting bits . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DBT 2003 bottom bit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.21 4.22 4.23 4.23 4.24 4.25 4.26 4.26 4.26

5.3

Setting the bottom bits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Setting the bit turret . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cut depth of the plow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3 5.5 5.6

When faults occur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.7

Identifying the cause of faults . . . . . . . . . . . . . . . . . . . . . . . .

Geological faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Excessive inclination of the plow guide . . . . . . . . . . . . . . . .

5.7 5.7 5.8

How to maintain the Gleithobel plow . . . . . . . . . . . . . .

5.9

Maintenance assembly drawing . . . . . . . . . . . . . . . . . . . . . .

Maintenance checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance checklist details . . . . . . . . . . . . . . . . . . . . . . . .

5.10 5.11 5.13

Replacing wear elements . . . . . . . . . . . . . . . . . . . . . . . . . 5.19 How to replace guide pieces in the upper area . . . . . . . . .

Replacing the pulling sledge and articulated skids . . . . . .

5.19 5.19

6. Technical data Gleithobel plow® GH 1600-3 . . . . . . . . . . . . . . . . . . . . . .

6.3

Main dimensions, weights and bit system . . . . . . . . . . . . . .

6.3

Technical description . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.4

Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.6

Screws/bolts with ISO metric thread . . . . . . . . . . . . . . . . . .

6.6

Permissible media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.7

Lubricating greases and pastes . . . . . . . . . . . . . . . . . . . . . .

6.7

Gleithobel plow identification . . . . . . . . . . . . . . . . . . . . .

6.9

7. For your information Standards and directives . . . . . . . . . . . . . . . . . . . . . . . . .

7.3

Referenced standards and directives . . . . . . . . . . . . . . . . .

7.3

Gleithobel plow® GH 1600-3

Bucyrus Europe GmbH, Lünen 2010

Steering the Gleithobel plow . . . . . . . . . . . . . . . . . . . . .

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5. Operation

1

About this manual

Before starting work

About this manual This chapter contains important information that makes it easier for you to use this manual. It provides you with information about the structure of the manual and the symbols and characters used in it.

Before starting work applicable operating manual

type of plow

Take care to ensure that the operating manual available to you applies to the type of plow used. Failure to do so can result in a safety hazard to yourself and others.

Make sure that the data for the plow corresponds to the data given in the operating manual.

This operating manual is for the plow type: Gleithobel plow® GH 1600-3 ID no.: 6050 015 000 00 XX*) It may only be used for plows of this type.

Bucyrus Europe GmbH, Lünen 2010

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category according to Atex directive

The plow is a device of Group I, Category M2 according to the European Directive 94/9/EC. The operating manual must be available at all times to all persons working on or with the plow.

It should always be available at the place of operation, if possible.

new operating manual

Request a new operating manual immediately if the current operating manual is no longer complete or has become illegible.

Persons for whom the operating manual is intended This operating manual is intended for those persons who work with or on the plow.

All persons working with the plow, must read this operating manual.

This includes persons who: J are in charge of transport, J perform installation / removal work, J operate the plow, J correct malfunctions, J perform daily routine work, J perform maintenance work, J perform repair work.

Supervisory personnel who: J initiate the activities mentioned above and/or J supervise the activities mentioned above.

*) placeholder for variant code

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1.3

Before starting work Purpose of this operating manual efficiency

This operating manual is intended to help you work efficiently and safely with our product. It contains important information on all activities relating to the plow.

Read this operating manual completely and at your leisure. Pay special attention to the safety instructions.

Try to memorize the appearance and meaning of the safety and instruction symbols.

service

Should you have any questions, please contact our service department. Our service address can be found in the chapter entitled “For your information”.

safety

Read the chapter entitled “Your safety” closely. This chapter contains important information indicating possible hazards.

Observe this information and follow the instructions.

Characters and symbols used The following characters and symbols are used for safety instructions and important information in the operating manual.

Danger!

Passages in the text marked with this symbol indicate an imminent danger. Possible consequences are very serious injury or even death.

Warning!

These points contain information on hazardous situations.

Possible consequences are very serious injury or even death.

Caution!

This symbol draws your attention to dangerous situations.

Possible consequences are light to moderately serious injuries and machine damage.

Notice!

Points in the text marked with this symbol draw your attention to harmful situations. Possible consequences are damage to the plow or damage within its immediate vicinity.

Important!

Passages in the text marked with this symbol contain useful tips and information intended to make work easier for you.

They do not warn about harmful or hazardous situations.

J Items in lists are marked with bullets.

– Items in sub-lists are marked with a long dash at the start of the line.

. Text passages indicated in this way describe individual work steps. Follow these instructions step-by-step. This will help you carry out your work faster and, more importantly, more safely.

1.4

Gleithobel plow® GH 1600-3

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Memorize the symbols and their meanings.

2

Your safety

Personnel

Your safety This chapter provides you with important information for your safety.

Pay special attention to this chapter. The safety instructions and rules of procedure will help you to avoid hazardous situations and perform the necessary work as safely as possible. state-of-the-art technology

The plow has been manufactured in accordance with the latest technology and generally accepted safety standards and regulations.

You and others can nevertheless still be exposed to dangerous situations, e.g. as a result of environmental influences, machine damage or operating errors.

Do not make any modifications or carry out conversions which could impair the safety of the plow. All modifications and conversions must be approved by Bucyrus.

Only use original spare parts from Bucyrus. Note that using parts from other manufacturers will void the guarantee.

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The European directives/standards listed in this operating manual must be applied when the plow is used within the member states of the European Union.

If the device is used outside the EU, the directives and standards which apply in those countries must be observed.

In addition to this operating manual make sure to also observe the respective legal provisions and regulations for accident prevention in your country.

Observe the safety and accident prevention regulations: J of the mining company, J of the mines inspectorate and J of the mining supervisory authorities. additional operating manuals

Please also read the operating manuals of the components required for operation, e.g. gearboxes, E-motors, etc. carefully and thoroughly. Clarify any questions before starting work.

Personnel Operation The plow may only be operated by trained personnel. training

The plow may only be operated by qualified personnel who can provide proof of having been trained on the control system installed.

Reading the operating manual, especially the chapter on safety, must constitute a part of this training.

Personnel must possess sufficient knowledge of the J mechanical system and J the control technology

and be able to demonstrate this.

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2.3

Operating conditions Installation and repairs As a fundamental rule, installation and repair work may only be carried out by personnel who have been adequately trained for these particular requirements.

Installation or repair work on the safety components shall only be performed by Bucyrus service technicians or by specially trained personnel of the mining company.

Operating conditions Intended use The plow was designed and manufactured for mining minerals only, particularly hard coal in longwall mining.

Use the plow only as intended.

Intended use: J mining coal and J loading coal into the face conveyor.

Unauthorized use

Ambient conditions Appropriate measures must be taken by the operator to combat the potential hazards in mines due to firedamp or the ignition of dust (see DIN EN1710).

These include: J sufficient and continuous ventilation and J plow water curtain/water spraying system.

The M2 equipment must be switched off if the firedamp concentration in the free cross section of the continuously ventilated areas of the face exceeds a certain percentage of the lower explosion limit (LEL) defined by national legislation.

It may only be restarted by authorized persons.

The atmosphere in the mine should be monitored at hazardous points to allow the power supply of all devices to be switched off, except those which are relevant for safety and suitable for use in explosive atmospheres.

The M2 equipment must be stopped immediately and secured against restarting (locked out) if firedamp protection facilities are found to be damaged.

Where ever it is necessary to support ventilation, the face must be equipped with means to dilute flammable gases in areas where cutting tools are used.

It must only be possible to operate the M2 equipment when the water spraying system is switched on.

The water pressure and the water flow rate of the water spraying system must be monitored. The M2 equipment must be switched off if the values fall below the limit values. The limit values depend on operational conditions such as the length of the face, number of nozzles etc.

2.4

Gleithobel plow® GH 1600-3

Bucyrus Europe GmbH, Lünen 2010

Bucyrus will not accept any liability for damage resulting from any such unauthorized use.

E

Applications not expressly listed as intended use represent unauthorized use and are not permitted with the plow.

Operating conditions Prerequisites for operation Putting the plow into operation is prohibited until it has been determined that the machine into which this plow is installed complies with the European Directive 94/9/EC and the standard DIN EN1710.

As the equipment supplied is only part of an overall system, the operator is responsible for meeting the necessary safety requirements or installing the required safety systems for the devices/components not included in the scope of supply of this equipment and/or other devices/components required for operation. These shall be identified according to the legal provisions applicable at the time they are placed on the market.

The M2 equipment/plow may only be operated when the safety requirements according to DIN EN 1552 have been met. These include: J equipment for preventing unauthorized starting, J startup warning systems, J water spraying systems,

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J safe shutdown command systems, Bucyrus Europe GmbH, Lünen 2010

J emergency-stop systems, J dust extraction systems, J noise protection, J warnings, etc.

Electrical equipment required to operate the plow shall be identified according to the legal provisions that apply at the time it is placed on the market.

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2.5

Safety instructions Safety instructions Basic principles general

Always work with utmost concentration.

Familiarize yourself with your working environment.

protective clothing and equipment

Always wear personal protective clothing and equipment. This also includes ear protectors since the noise emitted by the conveyor or plow may at times exceed 85 dB(A) (e.g. when the conveyor is being emptied).

Inform your colleagues of: J your exact location, J the work you are carrying out, J the amount of time you will probably require.

protective device

Only start the plow if it is in a technically perfect condition and all safety equipment, e.g. EMERGENCY STOP devices, start-up warnings, etc. is correctly installed.

notice signs EMERGENCY STOP

Observe the notice signs on the plow.

Press the EMERGENCY STOP switch immediately in the event of faults or irregularities in operation. Inform your supervisor of any peculiarity, so that necessary action can be taken immediately.

Also press the EMERGENCY STOP switch if safety equipment such as firedamp protection systems fails.

protection against being switched back on again

Secure the plow and the conveyor from being switched back on again while carrying out: J maintenance work, J inspection work, J repair work, J or when safety equipment fails such as:

– firedamp protection cordon off working area

moving parts

danger of explosion

Cordon off your working area over a wide range for monorail and floor conveying devices.

Never reach into or enter areas between machine components which can move.

Make sure to ensure that the mining area is sufficiently sprayed and ventilated as sparks or hot cutting tools may ignite explosive atmospheres and dust.

Make sure to comply with the intervals specified for maintenance and inspections of the plow, as hot surfaces may ignite explosive atmospheres and dust.

2.6

Gleithobel plow® GH 1600-3

Bucyrus Europe GmbH, Lünen 2010

Observe the acoustic and optical start-up warnings.

E

Keep the signaling and lighting systems in proper working order.

Safety instructions Storage and transport Observe the specified storage periods and the storage instructions.

Never store materials or components in your working area.

Inform the persons concerned about the intended transport route and the probable duration of transport. transport safety device

Make sure that the transport safety devices have been correctly installed.

Secure all moving parts so that they are stationary.

Never stay under unsecured components or suspended loads.

lifting points

Attach the lifting gear only to the lifting points provided for that purpose. Observe the different load limits of the lifting points. Also observe the instructions on the transport sheets.

Only use means of attachment which are in a good condition and have been designed for the loads concerned.

Bucyrus Europe GmbH, Lünen 2010

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Only use transport straps to attach round parts or the lifting points intended for this purpose. Never use chains or steel cables for this purpose.

Do not damage the finished or polished surfaces of shafts, sealing surfaces, etc. floor conveying devices

When using floor conveying devices for transport make sure that the center of gravity is as low as possible.

Installation and startup

inclined face

Use chains to secure all individual parts on inclined faces, e.g. on the supports.

environmental acceptability

When working with oils, greases and other chemical substances, observe the safety regulations that apply to the product.

Dispose of auxiliary equipment which has been soiled with oil, grease or other chemical substances in an environmentally sound manner.

Operation Operate the control system only if you have comprehensive knowledge of the operating elements and their method of operation. You need to have been instructed on the control system concerned.

Make sure that there are no persons in the working area of the plow before switching the plow on.

Clean the operating plate at regular intervals. Make sure that the operating symbols are clearly recognizable This measure avoids faulty operation and any resulting accidents.

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2.7

Safety instructions Maintenance and repairs Make sure you observe the prescribed maintenance and inspection intervals.

Inform the supervisory personnel and the face crew about maintenance and repair work. Provide them with information on the intended work and its probable duration. securing

Secure your working area over a wide range, in order to avoid endangering other persons.

Before all work, secure the plow and the conveyor against starting unintentionally and without authorization.

work in the mining area

You may only carry out work in the mining area if J the plow and conveyor have been shut down and secured

against being switched back on again, J the roof has been secured against falling rock,

Stop and lock out the plow and conveyor and secure them against restarting before replacing any defective components.

Remove any defective components from the face immediately to avoid hindering the face crew. This measure also prevents the unintentional reinstallation of these components elsewhere.

Pass on these components for servicing without delay.

original parts

Only use spare parts which meet the technical requirements. This is only ensured with original Bucyrus spare parts.

Please refer to the spare parts lists for the order numbers.

Secure the components to be replaced against slipping on inclined faces by using chains or lifting gear, for example.

To lift the conveyor, only use: J the intended lifting points, J lifting tackle of adequate load-carrying capacity.

Reset the shields to which you intend to attach lifting tackle. Check the setting pressure again. Under no circumstances should the canopy be disengaged from the roof. It must always be in full contact over the entire length. protective devices

2.8

Refit any removed protective devices immediately after completing work and check that they are working properly.

Gleithobel plow® GH 1600-3

Bucyrus Europe GmbH, Lünen 2010

replacing components

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J the coal face has been supported to prevent it from collapsing.

3

Storage and transport

Storage

Storage and transport This chapter contains important information on the correct storage and safe transport of the plow.

Following the instructions and notes will increase the life cycle and service life of the plow. You will be able to carry out transport work more safely and quickly.

Reading this chapter thoroughly will help you make your day-to-day work easier.

Storage Storage of the equipment corrosion protection

Components with temporary corrosion protection are protected for about six months.

avoid direct exposure to sunlight

Protect the equipment from direct exposure to sunlight.

Only store the electrical equipment, electronic components, spare parts made of rubber or plastic such as seals and hoses as well as hydraulic fluids in closed rooms at 15 °C to 25 °C.

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moisture and dirt

Protect all parts of the equipment stored outdoors from moisture and dirt, for example using tarpaulins.

The mounting surfaces of hydraulic components must be protected from corrosion and sealed with blind plates. Protect the hydraulic plug-type connectors and the electrical connectors with the appropriate caps and plugs.

short-term storage

For short-term storage (approx. 4 weeks) of equipment outdoors, but at temperatures above freezing, electrical components do not need to be removed. These components must be specially protected against high temperatures, dirt and moisture.

long-term storage

For long-term storage (more than 4 weeks), the equipment must not be stored outdoors. It needs to be stored in a dry, well-ventilated room.

After a storage period of approximately two years, an inspection must be performed to determine whether the measures taken and the method of storage have prevented damage.

This inspection can be carried out by Bucyrus upon request.

natural aging

Even with proper storage, seals and hoses are subject to natural aging. Do not use these components if they have been stored for more than two years.

Important!

Make sure during storage that any new supplies are stored separately from existing stocks in such a way that on removal, old stocks are always taken first.

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3.3

Transport Transport Before transport freezing temperature

Transporting equipment at temperatures between –21 °C and –40 °C is only permitted if certain measures were already taken for these conditions during the design and production. Nevertheless, the individual parts and devices of this equipment must not be subjected to sudden loads at such low temperatures and may only be loaded statically or quasi-statically.

Electrical and electronic components must be removed for overseas transport or prolonged storage outdoors, unless these components or the complete equipment are protected against harmful environmental influences by suitable packaging.

The electrical cables remain in the equipment. They must be protected carefully against transport damage and the connectors must be protected against dirt.

How to transport the plow For transport and installation, the plow and its main components are equipped with lifting eyes. In some cases, you will need to screw these lifting eyes into the holes provided before transport and remove them again immediately after transport.

Warning!

For lifting, only use lifting eyes which meet the respective technical and legal regulations. Observe the max. permissible load capacities of the lifting eyes and keep a sufficient distance away from suspended loads.

You could be seriously injured or even killed by falling loads.

Only use suitable load handling devices.

Danger!

To transport loads, always use all points of attachment provided. Components may come loose due to incorrectly or insufficiently attached loads. Falling components can cause serious injury or even death.

3.4

Gleithobel plow® GH 1600-3

Bucyrus Europe GmbH, Lünen 2010

electrical and electronic components

E

During transport of this equipment with floor conveying devices at such low temperatures, measures must also be taken to ensure that the parts and devices are not subjected to sudden loads.

At very low temperatures and on roads in poor condition, the vehicle speed must therefore be limited to maximum 25 km/h for truck transport.

Transport Fig. 1:

Correct transport of machine parts WRONG

Bucyrus Europe GmbH, Lünen 2010

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CORRECT

Transporting the complete plow.

To lift and transport the complete plow, only lifting eyes with a minimum load capacity of 8000 kg may be used. Only these lifting eyes are designed for the max. total weight of the complete Gleithobel plow.

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3.5

Transport Tab. 1: Complete Gleithobel plow - Dimensions and weights Length L2 [mm]

Length L3 (mm)

Width W [mm]

Height H [mm]

Weight

[mm]

Length L1 [mm]

1145 - 1445

5796

17019

4251

1022

1445

11264

Plow height

Fig. 2:

[kg]

GH Gleithobel plow, GH 1600-3 b

b

L3 b

a

b

c L1 L2 a

Bucyrus Europe GmbH, Lünen 2010

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a

a b

H

W L1 length of plow L2 length of plow with pulling sledge L3 length at center of bit turret W width H height

a lifting eye (load capacity = 8000 kg) 1) b lifting eye (load capacity = 3000 kg) 1) c transport safety device (pulling sledge) 2)

1) Replace with screw pin before startup.

2) Remove before startup.

3.6

Gleithobel plow® GH 1600-3

Transport Warning!

When lifting the plow, the articulated skids may slide off the guide pins of the plow body!

Falling components can cause serious injury and death. Before lifting the plow, secure the articulated skid by pushing an approximately 150 mm long pin (Ø10 mm) into the hole on the articulated skid and the guide pin.

Fig. 3:

Securing the articulated skid 1

2

4 1 plow body 2 guide pin

E Bucyrus Europe GmbH, Lünen 2010

4

3

3

4

3 hole for locking pin 4 articulated skid

Transporting the main components

3

5

For transport, the main components are equipped with lifting eyes or load rings. Depending on the weight of the individual parts to be transported, lifting eyes may be used here with a maximum load capacity of 3000 kg, 5000 kg or 8000 kg for lifting. In some cases you will have to insert the lifting eyes into the holes provided before transport and remove them again immediately after transport.

Danger!

Falling components can cause serious injury or even death.

Observe the safe working load of the lifting eyes and keep a safe distance away from suspended loads.

Warning!

Recoiling chain ends and falling components could result in serious injury to you and others or even death. To transport the pulling sledge, only use suitable means of transport, such as the transport baskets of the floor conveying devices.

Tab. 2: Main components - Dimensions and weights

Doc. no.: 6050 015 000 BA 00

Description

Length [mm]

Width [mm]

Height [mm]

Weight [kg]

Gleithobel plow body GH 1600-3

3259

790

852

3508

Main body, 1600-3, right

1443

900

1026

2001

Main body, 1600-3, left

1443

900

1026

2001

Gleithobel plow upper part, right

819

691

944

605

Gleithobel plow upper part, left

819

691

883

605

Pulling sledge

17014

463

265

1220

Bit turret

574

364

795

357

Adjusting mechanism

379

260

195

93

VPSV / 01

3.7

Transport Fig. 4:

Gleithobel plow body, GH 1600-3 a

c b

b L

W

L = 3259 mm

a lifting eye (load capacity = 8000 kg) 1) b articulated skid 2) c thrust rod 2)

W = 776 mm H = 797 mm

Fig. 5:

Main body 1600-3, right W

a

H

L b L = 900 mm W = 1443 mm H = 1026 mm

a lifting eye (load capacity = 8000 kg) 1) b articulated skid 2)

The left-hand main body has a symmetrical design.

1) Replace with screw pin before startup.

2) Transport separately.

3.8

Gleithobel plow® GH 1600-3

Bucyrus Europe GmbH, Lünen 2010

E

H

Transport Fig. 6:

Gleithobel plow upper part, right W

L

a

H

E

L = 772 mm W = 633 mm H = 871 mm

a lifting eye (load capacity = 3000 kg) 1)

Bucyrus Europe GmbH, Lünen 2010

The left-hand GH upper part has a symmetrical design.

Fig. 7:

Bit turret W

L a

H

L = 574 mm W = 292 mm H = 795 mm

a lifting eye (load capacity = 3000 kg) 1)

1) Replace with screw pin before startup.

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3.9

Transport Fig. 8:

Pulling sledge rigid L1 L2

W

a

H H a Lifting eye

Bucyrus Europe GmbH, Lünen 2010

E

L = 17014 mm W = 463 mm H = 265 mm

3.10

Gleithobel plow® GH 1600-3

4

Installation

What you need to observe prior to installation

Installation What you need to observe prior to installation Who is allowed to carry out the installation?

Installation work may only be carried out by persons who have been adequately trained for these particular requirements.

Work on: J the safety components (pressure relief valves, extinguishers,

etc.), J the electrical systems (controls, signaling devices, etc.) and J the hydraulic system (cylinders, directional control valves,

hoses etc.) may only be carried out by service engineers from Bucyrus or by specially trained personnel.

Which tools are required for installation?

Bucyrus Europe GmbH, Lünen 2010

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tool box

You require a number of tools in order to be able to install the Gleithobel plow properly.

We recommend that you deposit the tool box supplied at the drive.

Furthermore, various items of auxiliary equipment and machines are required at the installation points, These include: J lifting tackle with an adequate load capacity J straps (e.g. for attaching round components) J means of attachment with sufficient load capacity J impact wrenches incl. accessories J drill incl. accessories

Notes on installation Caution!

Please take care to observe the respective separate operating manuals (e.g. for the conveyor gearboxes, motors, chain tensioner etc.). installation plan

installing the plow on the conveyor

tightening torques for screws and bolts

instructions for handling - connection points

Doc. no.: 6050 015 000 BA 00

The sequence of operations during installation must be adapted accordingly to the individual conditions prevailing at the site. Before starting work, a detailed list of all steps to be taken with respect to transport and assembly should be compiled as well as a corresponding installation plan.

How to install the plow on the conveyor depends on the corresponding conveyor. Observe the separate conveyor operating manual. The procedure is described there.

For tightening torques not specified for the installation of the components, please refer to the list in chapter 6. Please also observe the tightening torques specified in the spare parts lists provided.

Pins, holes, screws and securing elements must be lubricated with A1 grease (see chapter 6, section entitled “Greases and lubricating pastes”) prior to installation.

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4.3

What you need to observe prior to installation lifting eye

There are tapped holes bores at several points of the Gleithobel plow that are protected by screw pins during normal operation. The positions of these tapped holes can be viewed in the figures of the main subassemblies of the plow. These figures can be found in chapter 3, from page 3.8 or in the corresponding spare parts catalog. These tapped holes are only for attaching lifting eyes for transporting the plow or individual components.

Tab. 3: Tapped holes for lifting eyes Screw pin DIN 914

Lifting eye

with hex socket

Type

M24 M30

M24x30 / WAF 12 M30x35 / WAF 14

TAWGK3 TAWGK5

3000 5000

M30

M30x35 / WAF 14

TAWGK8

8000

Warning!

Persons could be seriously injured or even killed by recoiling chain ends. Chains under tension can break and lifting eyes can be destroyed or torn out of their threads due to overloading.

Therefore, never use the lifting eyes and their tapped holes to attach pulling shackles, etc.

The tapped holes for lifting eyes and the lifting eyes may only be used to lift and support loads. They may only be loaded statically and only with the permitted weight (see identification stamped on the lifting eye).

4.4

Gleithobel plow® GH 1600-3

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Load capacity in kg

Bucyrus Europe GmbH, Lünen 2010

Tapped hole

Overview Overview Gleithobel plow® GH 1600-3 The main components of the plow are listed below.

Tab. 4: Main components - Dimensions and weights Quantity Length [mm]

Description

Height [mm]

Weight [kg]

Gleithobel plow body GH 1600-3

1

3259

790

852

3508

Main body, 1600-3, right

1

1443

900

1026

2001

Main body, 1600-3, left

1

1443

900

1026

2001

Gleithobel plow upper part, right

1

819

691

944

605

Gleithobel plow upper part, left

1

819

691

883

605

Pulling sledge

1

17014

463

265

1220

Bit turret

2

574

364

795

357

Adjusting mechanism

2

379

260

195

93

GH Gleithobel plow, GH 1600-3, plow height 1145 - 1445 mm

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Fig. 9:

Width [mm]

Bucyrus Europe GmbH, Lünen 2010

25 2

10

25

1 11

3

18

a or b 41

41

a or b

41

1 GH Gleithobel plow body 2 main body 1600-3, right 3 main body 1600-3, left 10 Gleithobel plow upper part, right 11 Gleithobel plow upper part, left

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18 pulling sledge 25 bit turret 41 adjusting mechanism a switching solenoid b filler piece

4.5

How to install the Gleithobel plow How to install the Gleithobel plow Gleithobel plow body GH 1600-3 The base component of the Gleithobel plow is the symmetrically designed Gleithobel plow body. It is mounted on the Gleithobel plow guide that can be moved in longitudinal direction. The Gleithobel plow upper parts for the plow bits, the pulling sledge for the plow chain and the two main bodies with the bit turrets are attached to the Gleithobel plow body.

The wear parts (11) are arranged at the top. They grip the upper guide and guide the Gleithobel plow in longitudinal direction. The articulated skids (32, 33) are arranged so that they can move. They grip the lower end guide and are supported by the plow guide.

Wear pieces and articulated skids can be replaced.

The guides on the Gleithobel plow body are arranged so that they can move over saddles and troughs. The maximum permissible angle deviation per pan connection is approx. 6 degrees.

Fig. 10: Gleithobel plow body, GH 1600-3

36

Bucyrus Europe GmbH, Lünen 2010

37 11

10 31 12

30 13

11

11

33

7, 40, 41

1 Gleithobel plow body, GH 1600-3 7 protective cap 10 thrust rod 11 wear part 12 retaining flap, right 13 retaining flap, left

32

30 control shaft, right

37 filler piece, left

31 control shaft, left

40 socket DN 10

32 articulated skid, right

41 staple DN 10

33 articulated skid, left

44 lifting eye (load capacity = 8000 kg) 1)

36 filler piece, right

49 screw pin M 30x35-12.9

1) After installation, replace the lifting eye (44) with screw pin (49).

4.6

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1

44, 49

Gleithobel plow® GH 1600-3

How to install the Gleithobel plow rinser connections

There is a system of holes in the Gleithobel plow body via which briquetted fine coal can be flushed out of the lower guide area. For this, the rinser connections (A) arranged on the outside must be used for the guide area.

Fig. 11: Rinser connections in the Gleithobel plow body 7

7

A

b 7 protective cap

B water outlet

A rinser connections DN 10 (socket 3/4” DN 10, staple, sealing ring 27x32)

Bucyrus Europe GmbH, Lünen 2010

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Notice!

After rinsing the connections must then be sealed again with the protective caps provided.

Thrust rod The thrust rod (Fig. 10, item 10) is mounted centrally in the Gleithobel plow body. It swivels the trailing Gleithobel plow upper part out of the cut, while the advancing Gleithobel plow upper part cuts.

Install the thrust rod, before installing the main bodies, right and left, and the Gleithobel plow upper parts.

Important!

Once the plow has been completely installed, to install / remove the thrust rod, you must release the main body on the right or left from the Gleithobel plow body, and temporarily remove the Gleithobel plow upper part and a filler piece (Fig. 10, item 36 or 37).

Control shaft Gleithobel plow level control

The position of the upper parts of the Gleithobel plow is changed using the control shafts (Fig. 10, items 30, 31). The upper parts of the Gleithobel plow cut the lower area of the seam. They are attached as moving parts to the main body of the Gleithobel plow and can be locked in various cutting positions (see section entitled “Setting the bottom bits”, page 5.4).

To install the control shaft, proceed as follows:

. Before installation, grease the surface of the control shaft and the extension well with a lubricating paste free from molybdenum disulfide (see chapter 6, section entitled “Greases and lubricating pastes”).

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How to install the Gleithobel plow . Check whether: – the lubricating nipple (c) is installed in the control shaft – the spring dowel pin (b) is on the extension (a) – the dirt strippers (45, 46) are in the corresponding annular grooves in the sleeve (f).

. Push the extension (a) so far into the sleeve on the plow body part until you can place the control shaft on it.

. Place the control shaft snugly on the extension. . Check whether the bottom side of the cover plate (71) is mounted with the hex. nut (65).

. Push the control shaft upward until you can guide the hex. head screw (51) through the bore on the plow body and the control shaft.

. Screw the hex. head screw (51) into the hex. nut (65) held by

. Grease the control shaft via the lubricating nipple (c, d).

Fig. 12: Control shaft e d 46

Control shaft in detail

f

a

a b

51 45

65 71 31 c

31 control shaft, left, WAF 36 45 dirt stripper 46 dirt stripper 51 hex. head screw M 20x 200-10.9 65 hex. nut V M 20-8 71 cover plate

4.8

a extension b spring dowel pin c lubricating nipple, control shaft, bottom d lubricating nipple, control shaft, top e lubricating nipple, pivot pin f sleeve (transparent illustration)

Gleithobel plow® GH 1600-3

Bucyrus Europe GmbH, Lünen 2010

Important!

The hex. nut is held in place by the cover plate in the recess of the plow body. Blows to the head of the hex. head screw could, for instance when inserting a screw, lead to the nut and the cover falling off and going astray. The Gleithobel plow body must be taken off its guide for reinstallation.

E

the cover plate (71) and tighten it with the required torque.

How to install the Gleithobel plow Main bodies, right and left The two main bodies, right and left, are connected to the plow body laterally via dogbone connections (5, 12).

The main bodies are equipped with swivel-mounted bit holders (9, 10).

The swivel angle is limited by a chain link (14).

The main body is equipped with a plug-in bit turret. The bit turret can be extended and retracted via an adjusting mechanism, thus adjusting the cutting height of the plow's seam height. plow limit stop

In the right and left main bodies, there are recesses in the vicinity of the upper guide for holding a switching solenoid or a filler piece (7). There is another switching solenoid and a filler piece in the pulling shackle.

The switching solenoid is required to control the plow drive and to determine the position of the plow in the face. For this, the pulses are required that are emitted by sensors in the Gleithobel plow guide when the switching solenoid is guided past them.

rinsing device

To backflush the bit turret guide, the main body is equipped with a water port (DN 10) (11).

Remove the plug under the adjusting mechanism and backflush the adjusting plate and the bit turret guide with water.

Bucyrus Europe GmbH, Lünen 2010

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Notice!

After backflushing, the port must be reasealed with the appropriate plug.

Fig. 13: Main body, left

a

8, 29, 30 11, 33, 34, 35, 55

10

26, 27

1

2

9 12 7

4

14

3

6 1 main body, left 2 wear part 3 articulated skid, right 4 articulated skid, left 5 dogbone retainer 6 cover 7 filler piece 1) 8 anti-rotation lock 9 intermediate flap

5

10 end flap 11 plug 12 dogbone 14 chain link 26 hex. nut V M 20-8 27 hex. head screw M 20x75-8.8 28 screw pin M30x35 29 spring washer 30 hex. head screw M24x45-8.8

31 hex. head screw M 24x70-10.9 32 hex. nut V M 24-10 33 sealing ring 34 socket 3/4” 35 staple 36 lifting eye (max. load capacity = 8000 kg) 2) 55 o-ring

1) The switching solenoid is installed in the right-hand main body here.

2) After installing it, replace the lifting eye (36) with screw pin (28).

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4.9

How to install the Gleithobel plow Dogbone connection The Gleithobel plow body and the two main bodies, right and left, are connected via dogbones.

The dogbone connections consist of the following components: J dogbone (1) J securing piece (2) J filler piece (3) J centering bolt M 24x2x58-10.9 (4) J collar nut, self-locking M 24x2 (5) Fig. 14: Dogbone connection 2

3

1 4, 5

plow body (a).

. Insert the securing piece (2) in the dogbone pocket of the main body (b) and push it on to the dogbone extension.

. Insert the centering bolt (4) into the recess of the securing piece.

. Push the filler piece (3) and the nut (5) onto the centering bolt. . Tighten the connection with a tightening torque of 215 Nm. Fig. 15: Installing the dogbone connection b a

1

4.10

4 2

1 dogbone 2 securing piece 3 filler piece 4 centering bolt M 24x2x58-10.9

3

5 5 collar nut M 24x2 a Gleithobel plow body b main body

Gleithobel plow® GH 1600-3

Bucyrus Europe GmbH, Lünen 2010

. Insert the dogbone (1) in the dogbone pocket of the Gleithobel

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For installation, please proceed as follows:

How to install the Gleithobel plow Adjusting mechanism The adjusting mechanism enables the adjustment of the bit turret to be varied infinitely via a worm gear.

The total adjustment range is 300 mm. Ten revolutions are equivalent to a stroke of 25 mm.

For the adjustment, you must first undo the screws (31) and remove the anti-rotation lock (8). Commercially available spanners or inserts with a width-across-flats of 36 can be used for the hex head on the worm gear.

Carry out a function test every day.

Important!

The bit turret can retract automatically due to the movement of the machine. This means that the required cutting horizon cannot be maintained.

After adjusting the bit turret, the anti-rotation lock must be reinstalled.

Bucyrus Europe GmbH, Lünen 2010

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Important!

The screws of the anti-rotation lock can only be tightened properly when the sheet is lying horizontally. When adjusting the bit turret, make sure the hexagon of the adjusting mechanism is in the correct position.

The adjusting mechanism is equipped with permanent lubrication (0.2 kg A2 roller bearing grease, see chapter 6, section entitled “Lubrication greases and pastes”). The worm gear must be lubricated (a) every week.

Fig. 16: Adjusting mechanism

29, 30

8 1

6

31, 32

a

1 main body, left 6 cover 8 anti-rotation lock 29 spring washer

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30 hex. head screw M24x45-8.8 31 hex. head screw M 24x70-10.9 32 hex. nut V M 24-10 a lubricating nipple

4.11

How to install the Gleithobel plow The adjusting mechanism is installed in the main body on the gob side. Please proceed as follows:

. Lubricate the surface of the adjusting plate (b) with a lubricating paste free from molybdenum disulfide - e.g.: gleitmo 810 (see “Lubricating greases and pastes”).

. Remove the eyebolts (c). . Insert the hex. head screws (31) into the appropriate holes in the main body (1).

. Push the adjusting mechanism (a) into the main body. . Fit the cover (6) and fasten the nuts (32) with the corresponding torque.

. Install the anti-rotation lock with the spring washers (29) and the screws (30).

. Press in 0.2 kg A2 roller bearing grease (see “Lubricating

c

4.12

b

c

32

6

1 main body 6 cover 8 anti-rotation lock 29 spring washer 30 hex. head screw M24x45-8.8 31 hex. head screw M 24x70-10.9

8

29, 30

32 hex. nut V M 24-10 a lubricating nipple a adjusting mechanism b adjusting wheel c eyebolt d hex. head screw, WAF 36

Gleithobel plow® GH 1600-3

Bucyrus Europe GmbH, Lünen 2010

Fig. 17: Installing the adjusting mechanism a 1 31 d

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greases and pastes”) via the lubricating nipple (Fig. 16, item a).

How to install the Gleithobel plow Bit turret The bit turret can be adjusted in height with the adjusting mechanism in the vertical T-guide the main body. Here, the adjusting plate of the adjusting mechanism engages in the adjustment grooves on the rear side of the bit turret (a). The adjusting range is 300 mm.

For the installation, you must move the bit turret with the height adjustment mechanism to the desired position.

For plow work the bit turret is swivel-mounted to a limited extent on its guide piece.

Fig. 18: Bit turret

7, 8

a 1 E

5, 6

2

Bucyrus Europe GmbH, Lünen 2010

4 3

1 bit holder 2 guide piece, long 3 threaded bush 4 securing piece 5 hex. head screw M 16x45-8.8

6 hex. nut M 16-8 7 screw pin M 24x30-12.9 8 lifting eye (load capacity = 3000 kg) 1) a adjustment grooves

To install the bit turret, please proceed as follows:

. Place the bit turret (1) with the recess on the peg (a). . Lift the bit holder (1) so that the upper part grips the guide piece (2).

Fig. 19: Pushing in the bit holder

1

2

a

1 bit holder 2 guide piece

a peg

1) After the installation, the lifting eye (8) must be replaced with the screw pin (7).

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4.13

How to install the Gleithobel plow . To secure it, screw the threaded bush (3) onto the threaded pin and tighten the threaded bush until it is tight and a groove is under the projection of the securing piece.

If the threaded bush is not tight enough, you need to turn the bush on slightly using a hammer, until the securing piece (4) can be installed.

. Install the securing piece (4) with the screws (5) and nuts (6).

Fig. 20: Securing the bit holder 1

5, 6

4 3

4 securing piece 5 hex. head screw M 16x45-8.8 6 hex. nut V M 16-8

. Lubricate the slide surfaces and adjustment grooves of the guide piece (Fig. 21, Item 2) and the slide surfaces of the bit turret guide (Fig. 21, Item a) well.

. Insert the bit turret together with the guide piece in the bit turret guide on the main body (Fig. 21, Item b), until they lie on the protruding part of the adjusting plate.

. Turn the bit turret's adjusting mechanism with a hexagon, WAF 36 (Fig. 17, item d) until the bit turret has reached the desired height.

. Mount the hex. head screws (Fig. 21, Item d) together with the washer disks (Fig. 21, Item c) and the nuts (Fig. 21, Item e).

Notice!

The washer disks serve as an extension stop, without which the bit turret could be moved outside the adjustment range.

This could result in the loss or destruction of the bit turret.

Make sure that the screws of the washer disks are inserted tightly.

. Replace the lifting eye (Fig. 21, Item 8) with the screw pin (Fig. 21, Item 7).

4.14

Gleithobel plow® GH 1600-3

Bucyrus Europe GmbH, Lünen 2010

1 bit holder 2 guide piece 3 threaded bush

E

2

How to install the Gleithobel plow Fig. 21: Installing the bit turret on the plow 7, 8

e c 2

a

b d

Bucyrus Europe GmbH, Lünen 2010

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1 bit holder 2 guide piece 7 screw pin M 24x30-12.9 8 lifting eye (load capacity = 3000 kg)

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a bit turret guide b main body c retaining washer d hex. head screw 20x65-10.9 e hex. nut V M 20-8

4.15

How to install the Gleithobel plow Gleithobel plow upper parts For installation, please proceed as follows:

. Place the Gleithobel plow upper part with the slot on the pegs (b) arranged on the Gleithobel plow body (a).

Fig. 22: Installing the Gleithobel plow upper part b

5

a

1

E

a plow body b peg

. Lift the Gleithobel plow upper part up in such a way so that the bottom section of the upper part grips the plow body.

. Insert the half-moon-shaped spacer pin (3) in the slot above the pivot pin (b). The upper part is fastened in its position this way.

. Insert the hex head screws (10) in the upper part. . Insert the securing device (4) and fasten it with the nuts (11). . Lubricate the pivot pin and the upper part using the lubricating nipple (Page 4.8, Fig. 12, Item e) below the retaining flap (a).

Fig. 23: Installing the Gleithobel plow upper part a

11 10

4 10

3 3 spacer pin 4 securing device for Gleithobel plow upper part 10 hex. head screw M 16x65-8.8

4.16

11 hex. nut M 16-8 a retaining flap

Gleithobel plow® GH 1600-3

Bucyrus Europe GmbH, Lünen 2010

1 Gleithobel plow upper part 5 lifting eye (load capacity = 3000 kg)

How to install the Gleithobel plow Bit holders Bit holders are located in the right hand and left hand main body.

The bit holders cut the preceding part of the Gleithobel plow free towards the roof.

The bit holders are swivel-mounted on hinges with hinged bolts.

Fig. 24: Bit holder on the main body 2 1 2

3

4 2

Bucyrus Europe GmbH, Lünen 2010

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1 upper part of the Gleithobel plow 2 bit holder

3 chain link 4 hinge pin

The bit holders are pushed into their recesses along with their hinge pins and then swiveled into their working position.

The chain links 30 x 162 (3) that are then to be fitted limit the swiveling area and secure the flaps against unintentionally swinging out. The chain link is secured by a bolted connection (5, 6) to prevent it from slipping off.

Fig. 25: Installing the bit holder 1

5, 6 3

2 4

1 upper part of the Gleithobel plow 2 bit holder 3 chain link

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4 hinge pin 5 hex. head screw M 20x75-8.8 6 hex. nut V M 20-8

4.17

How to install the Gleithobel plow Pulling sledge The plow chain pulling forces are directed into the Gleithobel plow via the pulling sledge. The connection to the plow body is established so that it positively engages via a groove-spring system.

The lifting eye (b) is used for temporarily fastening during installation, or is used for lifting and transporting the plow body with the pulling sledge on the plow body.

Fig. 26: Pulling sledge 1

b a

a

10, 15, 20

1 pulling sledge 2 switching solenoid 10 hex. head screw M 16x35-8.8

20 washer a groove (connection to plow body) b lifting eye

15 hex. nut M 16-8

c clearing wedge

Installing the pulling sledge lifting the plow

To install the pulling sledge, the plow body needs to be lifted. Insert two lifting eyes in place of the screw pins in the Gleithobel plow body.

Caution!

Only use lifting eyes with a minimum load capacity of 8000 kg to lift the plow body.

The pulling sledge must be inserted in the plow body from below. In doing so, the grooves (a) of the pulling sledge are pulled over the bars (b) on the plow body. Place the plow body on the guide. Lift the plow body at one end and insert the bar in the groove. Lower the plow body at the side again.

Caution!

The pulling sledge is not fastened to the plow body and will fall down when the plow/plow body is lifted. That could injure you.

Secure the pulling sledge using suitable means of attachment via the lifting eye on the plow body. Keep a safe distance from the plow and pulling sledge when lifting.

4.18

Gleithobel plow® GH 1600-3

E

2

Bucyrus Europe GmbH, Lünen 2010

c

How to install the Gleithobel plow Fig. 27: Installing the pulling sledge e

b

d

c

a a groove b bar c pulling sledge

d Gleithobel plow body e thrust rod

Chain attachments and connections Bucyrus Europe GmbH, Lünen 2010

E

The chain slings are permanently attached to the pulling sledge.

In order to prevent fine coal from briquetting in the plow guide, clearing wedges are mounted directly in front of the articulated skids on the chain slings.

Chain slings and eyes are designed in nominal size 48 and the plow chain in size 42x137.

The connection is established using block connectors, size: 48x144.

Fig. 28: Pulling sledge with chain slings 2

3

1 1 pulling sledge 2 switching solenoid 3 block connector 48x144

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3

4

a

4 size 48 eye for size 42 chain a plow chain 42x137

4.19

How to install the Gleithobel plow Fitting the plow on the conveyor The Gleithobel plow GH 1600-3 cannot be placed on the conveyor in completely assembled condition. The three main components, plow body, right main body and left main body, are placed on the conveyor one after the other and connected there.

Caution!

During installation only use the lifting eyes provided for that purpose.

After installation, the lifting eyes must be replaced with screw pins.

Warning!

When lifting the plow components, the articulated skids may slide off the guide pins.

Falling components can cause serious injury and death. Before lifting the plow body/main body, secure the articulated skids by pushing an approximately 150 mm long pin (Ø10 mm) into the hole on the articulated skid and the guide pin.

Requirements for plow installation: J The plow chain must be pulled into the conveyor.

J The articulated skids must be secured (see chapter 3,

page 3.7).

J The pulling sledge is installed and secured on the Gleithobel

plow body.

. Remove the Gleithobel plow upper guides and the guide beams from three rerouter pans (see separate operating manual for the conveyor).

. Hang the plow body with pulling sledge in suitable chain hoists and place it on the open guides.

. Connect the plow chain and pulling sledge and gently tension the chain.

. Use the chain tensioner to carefully move the plow body in the direction of the drive.

. Place the face side main body next to the plow body on to the guide.

. Connect the plow body and the main body with the dogbone connection (see page 4.10).

. Carefully move the plow body together with the first installed main body using the chain tensioner past the installation point in the direction of the center of the face to the closed guide.

Notice!

Make sure that the articulated skids, clearing wedges and the guide pieces slide onto the adjacent guides without tilting.

4.20

Gleithobel plow® GH 1600-3

Bucyrus Europe GmbH, Lünen 2010

You can find more detailed information on the individual steps in the sections on the individual components in this chapter.

E

Installation sequence

Bit arrangement . Fit the second main body and connect it to the plow body with the dogbone connection.

. Move the complete plow with the aid of the chain tensioner out of the installation area.

Notice!

Make sure that the articulated skids, clearing wedges and the guide pieces slide onto the adjacent guides without tilting.

. Reinstall the Gleithobel plow upper guides and the guide beam. . Remove all transport safety devices from the pulling sledge and the articulated skids.

Notice!

Functional impairments and damage to the plow can occur if the securing devices are not removed after installing the plow.

The securing devices are only required to install the plow. Before starting up the plow, they must be removed again.

. Tension the plow chain.

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. Check the correct installation of the plow on the conveyor and the installation the components of the plow.

Caution!

Any incorrect installation of the plow could result in severe damage to the plow and the conveyor. You and others could also be injured.

Only release the plow for operation when you are convinced that the installation was correct and the plow chain was pretensioned according to the specifications.

Refer to the operating manual for the chain tensioner used.

Bit arrangement Selecting plow bits Which bits are best used for which operation basically depends on the face structure and must be determined by testing.

Important!

GH 1600-3 type plows may only be equipped with plow bits of the DBT 2003 bit system.

Please consult our technical after-sales service regarding the choice of plow bits. defined advance

When operating the plow using “defined advance” the cut depth setting must not exceed the maximum permissible plow cut depth.

The cut depth is limited by the width of the bottom bits of the plow.

worn and blunt bits

Worn and blunt bits increase the cutting resistance and thus have a negative effect on the plow drive's efficiency. In addition, they increase wear to the articulated skids and the wear parts.

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Bit arrangement Fig. 29: Arrangement options for bits with slot fitting Example 1

Example 2

short

long Mountain emplacement

Relief cut

Caution!

Only plug-in bits with slot fitting of the same length may be used on one level (cut line).

Bits of different length on different levels lead to increased wear. In addition the bit pockets can be damaged.

Example for bit arrangement, DBT 2003 bit system Fig. 30: Bit arrangement - Example 003 - Roof bit

03-F - Ridge bit, right

003 001

001 001 - Slot-fitting bit, short 002 - Slot-fitting bit, long

003 001 002

012VS - Bottom bit, right 003 002 001

003 012VS *),(013VS) **) or 010VS ***),(011VS) ****)

*) **) ***) ****)

4.22

012VS = maximum cut depth 90 mm.

013VS = symmetrical to 012VS, LH design 010VS = design identical to 012VS but with a smaller maximum cut depth (70 mm).

011VS = symmetrical to 010VS, LH design

Gleithobel plow® GH 1600-3

Bucyrus Europe GmbH, Lünen 2010

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03-F

Bit arrangement The DBT 2003 bit system The DBT 2003 bit system includes all types of bits required to equip a GH 1600-3 Gleithobel plow. The bit pockets are identical for all types of bits. The fastening system enables bits to be changed within a very short time.

Fig. 31: DBT2003 bit system

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1

4

2

3

1 bit pocket 2 bit

3 retaining wedge 4 clamping piece

Installing a plug-in bit Bits from the DBT2003 bit system are pushed into bit pockets and are secured by a clamping piece and a retaining wedge. clamping piece

Before inserting the bit into the bit pocket the clamping piece must be fitted as shown in the following drawing.

Fig. 32: Installing a clamping piece

1 2

1 bit 2 clamping piece

Caution!

A used clamping piece must never be used again. After removing a bit with clamping piece, it cannot be used for securing any more due to deformations. The bit may be released and cause machine damage to the plow and conveyor.

Always install a new clamping piece if you use a used bit. retaining wedge

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The bit is then inserted into the bit pocket and secured by driving in the retaining wedge.

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4.23

Bit arrangement installation position

The retaining wedges must be fitted in such a way that the wear groove machined into the head of the retaining wedge is at right angles to the bit's shaft (see Fig. 34).

Fig. 33: Installing a retaining wedge

3 3 retaining wedge

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Fig. 34: Retaining wedge - installation position

3

5

3 retaining wedge

5 wear groove

Removing the plug-in bit In order to be able to remove the bit the retaining wedge must first be pulled out of the bit pocket.

The retaining wedge is removed using a multi-purpose tool.

Fig. 35: Multi-purpose tool W1 DBT2003

4.24

Gleithobel plow® GH 1600-3

Bit arrangement . Push the claw-shaped end of the multi-purpose tool behind the head of the retaining wedge.

. Then extract the retaining wedge from the bit pocket by pushing down the multi-purpose tool.

Fig. 36: Removing a retaining wedge

3

6

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3 retaining wedge 6 multi-purpose tool

Warning!

A “wear groove” has been machined onto the head of the retaining wedge (see Fig. 37). The retaining wedge can be removed safely using a multi-purpose tool as long as the groove is still visible.

If the retaining wedge is worn to the point where the groove is no longer visible the head may break off when you try to remove the retaining wedge.

Always use a new retaining wedge when securing a bit.

Fig. 37: Retaining wedge - wear groove

5

3

3 retaining wedge 5 wear groove

DBT 2003 ridge bit The topmost bit turret pockets are equipped with ridge bits.

Fig. 38: Ridge bit

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4.25

Bit arrangement DBT 2003 roof bit In the topmost bit pockets roof bits are used to cut the roof free.

Fig. 39: Roof bit

DBT 2003 slot-fitting bits The slot-fitting bits can be used either on the left or right. Long or short bits can optionally be installed so that the best cutting profile for the seam structure is established.

Fig. 40: Slot-fitting bit

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Slot-fitting bit, short

Slot-fitting bit, long

DBT 2003 bottom bit The cutting horizon and the cut depth are determined by the bottom bits. The bottom bits are designed in such a way that mirror-inverted installation is not possible.

Fig. 41: Bottom bit

Bottom bit, right

Bottom bit, left

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5

Operation

Steering the Gleithobel plow

Operation Steering the Gleithobel plow In normal plow operation a specific cutting horizon is to be maintained or reached. This is usually achieved by steering the plow using the outrigger steering system. The plow's top and bottom cut, i.e. the dimension by which the lower edge of the bottom bit is under or above the face side supporting edge of the plow guide, have a significant effect on the steerability of the plow.

If the bottom bit has been set correctly and if there are consistent geological conditions the plow ought to automatically maintain the cutting horizon. Correcting the steering direction using the outrigger steering system is usually only needed when the seam does not run in a straight line.

Operating the outrigger steering system requires a great deal of experience and must be carried out with utmost care.

If the geological conditions in the face change considerably it may be necessary to also correct the settings of the bottom bits.

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Caution!

Avoid oversteering the equipment. Under some circumstances, the support used may not be suitable for following the extreme changes in direction of the plow. It is essential that your take the support's capabilities into account before initiating extreme climbing or digging operations.

Setting the bottom bits The position of the bottom bits relative to the face side supporting edge of the plow guide determines the plow's top and bottom cut.

Depending on the setting the plow will tend to climb or dig to a greater extent. The setting's effect depends mainly on the geological conditions in the face.

The bottom bit settings influence the steerability of the plow significantly. They are defined according to the geological conditions in the face and experience and must therefore be carried out with great care.

As a rule, it is not advised to make extreme alterations. Changes should rather be made step by step. The success of an adjustment will not be evident after the first cut but only after several cuts.

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5.3

Steering the Gleithobel plow Changing the bottom bit settings 1

2 1 retaining flap 2 control shaft

After lifting the retaining flap (see chapter 4, page 4.6) four different bottom bit settings can be established by turning the control shaft (WAF = 36) each by 90.

The actual position set can be read off using the arrow on the control shaft and the markings on the retaining flap. A single dot indicates the highest setting and four dots indicate the lowest bottom bit setting.

J Setting D

: Climbing

J Setting DD

: Maintaining level

J Setting DDD

: Digging

J Setting DDDD

: Digging

You should only use bit setting DDDD for extreme control corrections.

Caution!

In order to clamp the control shaft after carrying out settings, the retaining flap must be repositioned over the square-end of the shaft.

The cut depths specified in Fig. 42 are theoretical (calculated) values.

Depending on the width of the conveyor and the plow equipment used, different cut depths are achieved even when the control shaft has been set in the same position.

Contact Bucyrus directly if you require further information about cut depths.

5.4

Gleithobel plow® GH 1600-3

Bucyrus Europe GmbH, Lünen 2010

approx. -35 setting DDDD Digging

approx. -21 setting DDD Digging

approx. -10 setting DD: Level

approx. +12 setting D: Climbing

Material on floor

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Fig. 42: Bottom bit settings

Steering the Gleithobel plow Setting the bit turret With the adjusting mechanism, you can adapt the cutting height to the thickness of the seam. The maximum adjusting range is 300 mm. At 10 revolutions of the hexagon, WAF 36 (b), the bit turret moves 25 mm.

Undo the screws (30) on the anti-rotation lock (8) and remove the anti-rotation lock to fit the hexagon.

The adjusting mechanism must be lubricated via the lubricating nipple (c) every week.

Notice!

After adjusting the bit turret, the anti-rotation lock must be reinstalled.

Notice!

The washer disks (13) serve as an extension stop, without which the bit turret could be moved outside the adjustment range. This can result in the loss or destruction of the bit turret and its support. Make sure that the screws of the washer disks are inserted tightly.

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Fig. 43: Setting the bit turret Bucyrus Europe GmbH, Lünen 2010

a 8, 29, 30

13, 25, 26

c 1

1 main body 8 anti-rotation lock 13 washer disk 25 hex. head screw M 20x65-10.9 26 hex. nut V M 20-8

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b

29 spring washer 30 hex. head screw M 24x45-8.8 a bit turret b hexagon, WAF 36 c lubricating nipple

5.5

Steering the Gleithobel plow Cut depth of the plow The maximum cut depth of the plow depends on the cutting width of the bottom bit. The cut depth corresponds to the amount by which the bottom bit projects over the front edge of the plow guide.

The plow can be equipped with bottom bits of differing widths according to the geological conditions. The maximum cut depth is 254 mm with the 80/70 bottom bits and 274 mm with the 80/90 bottom bits. For more information, please contact Bucyrus.

Fig. 44: Cut depth, schematic diagram

Caution!

When operating the plow using “defined advance”, the cut depth setting must not exceed the plow cut depth.

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max. cut depth

When faults occur When faults occur Identifying the cause of faults Tab. 5: Fault table Fault

Cause

Measures

Steering the plow is difficult due to the bottom bits

Blunt bottom bits

Replace bottom bits

Hard coal on the floor

Correct steering

The guide elements on the plow body are worn

Check for wear, place components as required.

Worn bits

Replace bits

Worn plow guides

Replace plow guides

Increased pan angle deviation due to broken dogbones

Replace broken dogbones

Excessive deflectiontowards the face

Correct conveyor position or correct misalignment by countersteering in time

Increased drive input

Conveyor position incorrectdue to oversteering

Excessive deflectiontowards the gob Excessive syncline E

Excessive saddle Bucyrus Europe GmbH, Lünen 2010

Spark formation

Inclusions

Reducing the cut depth Reduce the cutting speed Changing the plow lacing

Geological faults Faults in the seam such as pyrite inclusions and strata with high proportions of quartz can increase spark formation.

Warning!

Sparks can ignite explosive atmospheres. When working through faults be aware of increased spark formation. When there is increased spark formation reduce the cut depth and the speed of the plow. The type of plow bit may also need to be changed.

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When faults occur Excessive inclination of the plow guide Caution!

Exceeding the permissible inclination at the element transitions of the plow guide can lead to increased wear, particularly in the plow's guide elements and on the plow guides. In extreme cases this can lead to the plow jamming. It is therefore essential that you do not exceed the permissible values for the plow guide inclination.

Excessive deviations on the plow guide connection elements can be caused by damaged or destroyed conveyor or plow connecting elements, thus increasing friction between the plow guide and plow as well as between the plow guide and the plow chain. This increases the tensile load on the chains, causing increased wear accordingly. In extreme cases it can lead to the plow becoming jammed.

The maximum permissible plow pan inclination is illustrated in the following drawing, Fig. 45. See also chapter 6, section entitled “Gleithobel plow GH 1600-3”.

6º 1

2

1.5º

1 Gleithobel plow pan 2 dogbone connection

Warning!

Angular deviations which are too high will result in increased temperatures on the guides and the plow chain.

Hot surfaces can ignite explosive atmospheres and dust.

5.8

Gleithobel plow® GH 1600-3

Bucyrus Europe GmbH, Lünen 2010

Fig. 45: Maximum permissible angle deviations for Gleithobel plow pans

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The horizontal and vertical inclination of the Gleithobel plow pans are limited by face side and gob side dogbone connections.

How to maintain the Gleithobel plow How to maintain the Gleithobel plow Maintenance work may only be carried out by trained personnel.

Perform maintenance work regularly and carefully.

On the next few pages (from page 5.10 ff) there is an assembly drawing (maintenance assembly drawing) and related table (maintenance checklist). Here you will find information about maintenance tasks required and their prescribed intervals. In the following section “Maintenance - checklist details" you are given detailed information on the individual maintenance operations.

The maintenance intervals listed in this section depend on the conditions at the face, among other things. The intervals must be adjusted to requirements e.g. when there are faults in the seam.

Why perform wear inspections?

Performing regular wear inspections of the plow is essential for the operational safety of the equipment. Failing to perform these inspections at regular intervals will have noticeable consequences.

For example: J Excessive wear on the plow guides and on the conveyor plow Bucyrus Europe GmbH, Lünen 2010

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guides makes precise steering impossible.

J Worn Gleithobel plow guide elements can cause the plow to tilt

on its guide. This increases the plow motor's current consumption which can lead to more frequent interruptions.

J Excessive wear on the pulling sledge can cause the chain sling

to break.

The plow must be moved to the Gleithobel plow pans in the end area of the conveyor in order to perform a wear inspection.

In order to carry out a wear inspection, you must push the Gleithobel plow body using the face support shifting ram against a straight section of the face. At the same time the plow must contact the upper and lower pan guide beams on both sides.

Fig. 46: Contact surfaces (schematic)

1

2

1 upper guide beam

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2 lower guide beam

5.9

How to maintain the Gleithobel plow Maintenance assembly drawing Fig. 47: Assembly drawing - Maintenance

17 5 11

2

12

1

12

22

20

10

4

23

9

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6

13 14 18

13 8 9

15

7

3

25 16

27

26

24

19

= per shift = daily

5.10

= weekly = monthly

= duration (in min) = as required

Gleithobel plow® GH 1600-3

How to maintain the Gleithobel plow Maintenance checklist Tab. 6: Maintenance checklist Item

Maintenance points

Maintenance intervals

Per shift

1

Daily

Weekly

Monthly

Duration (in min)

As required

Plow bits

Wear inspection of the plow bits Replace plow bits 2

Inspection of bit holders

Inspection of the chain link securing devices Inspection of the screw tightening torques 3

Function test of the bit holders

Inspection for freedom of movement 4

Check whether the upper part of the Gleithobel plow can be moved freely during plow operation

E Bucyrus Europe GmbH, Lünen 2010

Function test on the upper part of the Gleithobel plow

5

Inspection of the upper part of the Gleithobel plow

Inspection of the securing devices Inspection of the screw tightening torques 6

Inspection of the stop plate on the upper part of the Gleithobel plow/control shaft

Inspection of the stop plate for damage Inspection of the screw tightening torques 7

Inspection of the retaining flap on the control shaft

Inspection of the retaining flaps Screw tightening torque check (the retaining flap must be moveable) 8

Function test of control shafts

Turn the control shafts by 360° 9

Lubrication of control shafts / GH top parts

Lubrication of control shafts, gob and face side and the GH upper parts 10

Inspection of the control shafts

Inspection of the screw tightening torques 11

Inspection of the fastening elements on the upper parts of the Gleithobel plow

Check the half-moon spacer pins for tight fit 12

Inspection of the plow body/main body dogbone connection

Inspection of the dogbone/dogbone retainer/dogbone pockets Inspection of the screw tightening torques 13

Inspection of the adjusting mechanism

Inspection of screw tightening torques (only when it is lowered)

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How to maintain the Gleithobel plow Item

Maintenance points

Maintenance intervals

Per shift

14

Daily

Weekly

Monthly

Duration (in min)

As required

Function test of adjusting mechanism

Operation of the adjustment mechanism 15

Lubricating the adjustment mechanism

Lubrication of the adjustment mechanism 16

Cleaning the adjustment mechanism

Backflushing the adjusting mechanism (followed by lubrication) 17

Inspection of the bit holder

Inspection of the securing piece Inspection of the screw tightening torques 18

Inspection of the bit pockets

Inspection of the bit pockets Inspection of the chain channel

Inspection of the covers Backflushing the chain channel (if the plow should be jammed) 20

Replacing the pulling sledge

1st change after 20000 minutes to determine the replacement intervals - otherwise as required 21

20000

Plow chain connector

Inspection of the plow chain connectors on the chain sprocket Replace after 10000 minutes 22

10000

Plow chain

Inspection of the plow chain Replacement of the plow chain 23

Articulated skids, plow body/main body

Inspection for wear Replacement of the articulated skids 24

Guide pieces (upper area), plow body/main body

Inspection of the wear marks Replacement of the guide pieces 25

Inspection of the switching solenoid

Inspection of the switching solenoid Inspection of the screw tightening torques 26

Inspection of the plow body

Inspecting the plow body for damage 27

Inspection of the main body Inspection of the main body for damage

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How to maintain the Gleithobel plow Maintenance checklist details 1 Plow bits Inspect the plow bits for wear at least once a shift. Pay special attention to the bottom bits as they have the largest proportion of the plow's total cutting force. In addition, the steerability of the plow primarily depends on the functionality of the bottom bits. replacement

Replace the bits immediately when J the carbide metal bits show signs of flaking, J the carbide metal bits are worn, J the bit body is worn, J the bit is not sitting firmly in the bit pocket.

Immediately replace worn and missing bits with new ones. How to replace plow bits is explained in chapter 4, from page 4.23.

Notice!

Always use new fastening elements when installing plow bits.

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2 Inspection of the bit holders chain link securing devices

Inspect the chain link securing devices (chain link securing device and bolted connections) on the bit holders for damage and wear.

Immediately replace damaged or worn chain link securing devices.

Check the tightening torque of the mounting bolts. If necessary you must retighten the bolts (see also chapter 4, page 4.17).

3 Function test of the bit holders

inspection for movement

Check the movement of the bit holders by swiveling them. Bit holders that won't move must be unjammed.

Notice!

When bit holders stick, wear on the bits and the bit holders is disproportionately higher. The current consumption of the plow drive also increases accordingly.

4 Function test on the upper parts of the Gleithobel plow

inspection for movement

Check if the upper parts of the Gleithobel plow move freely during operation. If the upper parts of the Gleithobel plow should not swivel you must check the free movement of the thrust rod. Additionally inspect the fastening elements of the upper parts of the Gleithobel plow.

Notice!

Upper parts of the Gleithobel plow that stick cause a higher amount of wear on the bits and the bit holders. The bottom bit cannot be swiveled into the required position. The plow can therefore no longer be steered. The current consumption of the plow drive also increases accordingly.

5 Inspection of the upper part of the Gleithobel plow

checking securing elements

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Inspect the securing elements on the pivot pins on the upper parts of the Gleithobel plow. Immediately replace damaged and missing parts with new ones.

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How to maintain the Gleithobel plow Check the tightening torque of the mounting bolts. If necessary you must retighten the bolts (see also chapter 4, page 4.16).

6 Inspection of the stop plate on the upper parts of the Gleithobel plow/control shaft Inspect the stop plates and the screw fastenings. Immediately replace damaged and missing parts with new ones.

Check the tightening torque of the mounting bolts. If necessary you must retighten the bolts.

7 Inspection of the retaining flap on the control shaft Check the retaining flaps. Immediately replace damaged and missing parts with new ones.

Check that the mounting bolts are fitted correctly and if necessary correct their position.

The screws that act as hinged bolts should only be tightened enough so that retaining flap can still be moved.

8 Function test of control shafts

Notice!

It is essential to keep the plow control shafts in a moveable condition. If not the control shafts will jam and the bottom bit can no longer be repositioned.

9 Lubricating the control shafts / GH upper parts Lubricate the control shafts via the lubrication nipple on the underside (face side) and via the lubrication nipple beneath the retaining flaps (gob side).

The GH upper parts are also lubricated via the lubricating nipple below the retaining flaps.

10 Inspecting the control shafts Check the tightening torque of the mounting bolts. If necessary you must retighten the bolts.

11 Inspection of the fastening elements on the upper part of the Gleithobel plow section Check that the fastening elements on the upper part of the Gleithobel plow are fitted correctly and that they are not worn or damaged.

Immediately replace worn, damaged and missing parts with new ones (see also chapter 4, page 4.16).

12 Inspection of the plow body/main body dogbone connection Check the dogbone, the dogbone retainer and the dogbone pockets for correct seating, wear and damage. Immediately replace worn, damaged and missing parts with new ones.

Check the tightening torque of the mounting bolts. If necessary you must retighten the bolts (see also chapter 4, page 4.10).

13 Inspection of the adjusting mechanism Check the tightening torque of the mounting bolts (only when the plow is at its lowest installation height. If necessary you must retighten the bolts (see also chapter 4, page 4.12).

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Turn the control shafts once by 360 degrees to prevent the shafts from jamming.

Bucyrus Europe GmbH, Lünen 2010

turning the control shafts

How to maintain the Gleithobel plow 14 Function test of adjusting mechanism turning the hexagon

Turn the hexagon (page 5.5, 6kt, WAF 36) of the adjustment shaft about 5 times. You thus prevent the adjustment mechanism from jamming.

Notice!

It is essential to keep the adjusting mechanism in a moveable condition. If not the height of the bit turret can no longer be adjusted.

After carrying out a function test it is important that you reset the required plow height.

15 Lubricating the adjustment mechanism Lubricate the adjustment shaft via the lubrication nipple (see page 5.5).

16 Cleaning the adjustment mechanism

rinsing the adjusting plate and guide

If the worm gear on the adjusting mechanism is difficult to turn, you must rinse the adjusting plate and bit turret guide with water.

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To do this, remove the plugs underneath the adjusting mechanism and then connect a water hose to the port DN 10.

After rinsing, reseal the opening using the plug (see also chapter 4, page 4.7) and then lubricate the adjusting mechanism.

17 Inspection of the bit holder Check the movement of the bit holders by swiveling them. Bit holders that won't move must be unjammed.

Check that the securing piece is fitted correctly and that it is not worn or damaged. Immediately replace worn, damaged and missing parts with new ones.

Check the tightening torque of the mounting bolts. If necessary you must retighten the bolts (see also chapter 4, page 4.14).

18 Inspection of the bit pockets Check the bit pockets for wear and damage. Immediately replace worn and damaged parts with new ones. replacing bit holders

A bit pocket is worn out if a new bit, which is not yet fastened with a retaining wedge, can be moved with a lot of play. There is a danger of losing plow bits.

Replace the affected bit holder (bit turret, bit holders and upper parts of the Gleithobel plow) with a new holder as quickly as possible.

19 Inspection of the chain channel Check if all of the chain channel's rinsing connections are fitted with protective caps.

ackflushing the chain channel

If the plow should be jammed backflush the chain channel via the rinsing connections (see also chapter 4, page 4.7).

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How to maintain the Gleithobel plow 20 Replacing the pulling sledge 1st replacement determining the replacement interval

Completely replace the pulling sledge for the first time after a duration of 20000 minutes (see also chapter 4, page 27).

Then determine the degree of wear on the removed pulling sledge.

This makes it possible to determine which replacement interval is best suited to the operating conditions.

min. 40

min. 42

Fig. 48: Wear limits - Pulling sledge and chain sling -

Tab. 7: Wear limits - Pulling sledge and chain sling Pulling sledge

Chain sling

Dimension right

right

left

59 mm

48 mm

40 mm

42 mm

Limit dimension 2nd 3rd 4th ... replacement

E

Actual dimension

Example of the calculation of subsequent maintenance intervals: 1st replacement after 20000 min, actual size a = 50 mm, actual size b = 44 mm 20000 min ≙ 9 mm wear

20000 min ≙ 4 mm wear

? min ≙ 19 mm max. wear

? min ≙ 6 mm max. wear

20000 min x 19 mm

20000 min x 6 mm

= 42222 min

9 mm

= 30000 min

4 mm

Even though the pulling sledge in the example would have only been worn out after approx. 42000 min., the complete sledge would have to have been replaced already after 30000 min as the chain sling would have already reached the maximum permissible limit value of 42 mm after this time.

Always replace the pulling sledge within the shortest replacement interval determined.

21 Plow chain connector Check the plow chain connectors on the chain sprocket for wear and damage. Immediately replace worn and damaged chain connectors with new ones. replacing chain connectors

Replace the plow chain connectors after 10000 minutes of operation.

22 Plow chain Check the plow chain for wear and damage. Immediately replace worn and damaged chains with new ones.

23 Articulated skids Check the articulated skids on the plow body and on the main bodies for wear and damage.

5.16

Gleithobel plow® GH 1600-3

Bucyrus Europe GmbH, Lünen 2010

Nominal dimension

left

How to maintain the Gleithobel plow Important!

The following wear dimensions have to be determined three times (plow body, right hand main body, left hand main body). determining wear

To determine the degree of wear, use the dimensions listed in Fig. 49.

Measure the gap dimension z of the lower Gleithobel plow guide area directly in front of or behind the plow body.

To determine the dimension e, the control shaft must be set to position DD (see page 5.4) and the Gleithobel plow upper part must be engaged.

Fig. 49: Wear limits of articulated skids

c

b

Bucyrus Europe GmbH, Lünen 2010

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z

d b guide play c dimension of guide piece (upper area) - upper guide beam

e d guide play e distance between lower area and bottom bit z gap dimension of lower area

Tab. 8: Gap dimension of lower area Actual dimension Nominal dimension Difference Δz

70 mm

Tab. 9: Wear limits - Articulated skid Dimension Nominal dimension Actual dimension + difference Δz Total S (actual dimension, difference Δz) Difference between total S and nominal dimension Limit dimension

b

c

d

e

right left 13 mm

right left 18 mm

right left 15 mm

right left 25 mm

± 3 mm

± 7 mm

± 5 mm 1)

± 15 mm

If one of the values determined in Tab. 9 exceeds the limit value, then you need to replace the articulated skids with new ones without delay (see separate operating manual for the conveyor).

1) Limit value applies only to new guide piece

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5.17

How to maintain the Gleithobel plow 24 Guide pieces(upper area) Check the guide pieces on the upper area for wear and damage.

If the permissible wear limit a of 18 mm has been reached, the guide pieces can be changed once from one side of the plow to the other. Immediately replace the guide pieces with new ones as soon as the permissible wear limit is reached (see also page 5.19).

Important!

The following wear dimensions have to be determined six times (plow body, right hand main body, left hand main body).

Fig. 50: Wear limit of guide piece

1 4 2

1 plow body 2 wear marks

3 guide beam 4 guide piece

Tab. 10: Wear limits - Guide piece Guide piece Dimension right Nominal dimension

left 30 mm

Actual dimension Limit dimension

18 mm

25 Inspection of the switching solenoid Check that the switching solenoid is fitted correctly and that it is not worn or damaged. Immediately replace a worn and damaged switching solenoid with a new one.

Check the tightening torque of the mounting bolts. If necessary you must retighten the bolts.

26 Inspection of the plow body Check the plow body parts for wear and damage. Immediately replace worn and damaged parts with new ones.

27 Inspection of the main body Check the main body parts for wear and damage. Immediately replace worn and damaged parts with new ones.

5.18

Gleithobel plow® GH 1600-3

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3

Replacing wear elements Replacing wear elements How to replace guide pieces in the upper area Lift the plow slightly with the appropriate lifting eyes. After undoing the two hex. head screws (5), you can pull the wear part (1) downwards out of the Gleithobel plow body and then sideways from the main body.

Fig. 51: Replacing wear parts a

Bucyrus Europe GmbH, Lünen 2010

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b

5 1 1 wear part 5 hex. head screw M 20x60-10.9

a Gleithobel plow body b main body

Replacing the pulling sledge and articulated skids To replace the pulling sledge and the articulated skids, the plow must be lifted. If necessary, the dogbone connection (see chapter 4, page 4.10) must be released to separate the plow body from the main body.

The procedure depends on the corresponding conveyor. Observe the separate conveyor operating manual.

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Replacing wear elements

5.20

Gleithobel plow® GH 1600-3

6

Technical data

Gleithobel plow® GH 1600-3

Technical data This chapter contains the main technical data for the Gleithobel plow. Information on the dimensions and weights of individual subassemblies and components of the plow are available in the corresponding spare parts catalog.

At the end of this chapter, you will also find information on the tightening torques for the bolted connections, on greases and lubricating pastes and on the identification of the plow.

Gleithobel plow® GH 1600-3 Main dimensions, weights and bit system

Bucyrus Europe GmbH, Lünen 2010

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Total weight Complete: . . . . . . . . .

Total length Without pulling sledge and chain slings: . . . . . . . .

Total height Min.: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Max.: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11264 kg 5796 mm 1145 mm 1445 mm

Height adjustment of the bit turret Infinitely variable, max.: . . . . . . . . . . . . . . . . . . . . . . 300 mm

Depth of cut 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . up to approx.

250 mm Top / bottom cut of the bottom bits 2) Position z: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . + 14 mm above guide level Position zz: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . - 11 mm below guide level Position zzz: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . - 23 mm below guide level Position zzzz: . . . . . . . . . . . . . . . . . . . . . . . . . . . . - 39 mm below guide level Bit system . .

DBT 2003 Operating conditions Plow guide, type: . . . . . . . . . . . . . . . . . . . . . . . . . . . GH 1600 Max. permissible plow guide inclination 3) Horizontal: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 degrees Vertical: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.0 degrees

1) depends on the bottom bit lacing 2) when the conveyor is at a neutral position 3) for GH-AFC PF 4/1132

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Technical description Technical description The Gleithobel plow was designed for the efficient mining of hard coal. It can be used in seams with a thickness of 1.2 to 1.5 m.

The height of the Gleithobel plow can therefore be adapted to the prevailing operating conditions. This is done via various assembly options and the infinitely variable bit turret height adjustment.

The following information on the Gleithobel plow refers to the Gleithobel plow section shown in Fig. 52.

The Gleithobel plow (1) is guided lengthways on the Gleithobel plow guide (2) located on the face side of the plow conveyor (4).

It is pulled by the plow chain (3) located in the bottom race of the plow guide. The plow is supported on the loading ramp of the plow guide by the two articulated skids located on the plow body. At the same time the articulated skids guide the plow in the lower area by engaging below the plow guide. In the upper area, the plow is guided by two guide pieces that engage above the upper guide.

The Gleithobel plow guide also functions as a loading ramp and holds the circulating plow chain. The plow chain is guided securely in two chain channels located on opposite sides.

1 Gleithobel plow 2 Gleithobel plow guide 3 plow chain

4 plow conveyor 5 relay bar assembly 6 outrigger steering system

The reset forces that develop when using the plow are absorbed by the relay bar assembly (5) of the support in combination with the outrigger steering system (6).

Conveyor steering devices can be used as required to hold the conveyor in the lengthwise position.

The relatively heavy weight of the plow causes it to run smoothly and be steered accurately. The articulated skids in the lower area and the coordinated upper guides allow the plow to move well around bends.

The plow can be steered using the outrigger steering system.

Depending on the selected setting, the plow will have a higher or lower tendency to dig or climb.

6.4

Gleithobel plow® GH 1600-3

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Fig. 52: Gleithobel plow, schematic diagram

Technical description The main features of the Gleithobel plow are: J bottom or top cut adjustable in 4 steps, J infinitely variable height adjustment of bit turret, J symmetrical structure of the plow body and extensions, J easily accessible and replaceable wear parts, J DBT 2003 bit system, J reduced bit wear. The trailing bit rows are swiveled out of the

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cut.

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Tightening torques Tightening torques Screws/bolts with ISO metric thread Tab. 11: Tightening torques at μtot. = 0.14 Tightening torque 4)

Pitch P (mm)

d

Coarse thread

M8

MA (Nm) 8.8

10.9

12.9

A 2-70

A 4-80

1.25

23

32.5

39

17

23

M 10

1.5

46

65

78

34

45

M 12

1.75

80

113

135

59

78

(M 14)

2

127

178

215

94

125

M 16

2

195

275

330

146

195

(M 18)

2.5

270

380

455

202

270

M 20

2.5

380

535

640

285

380

(M 22)

2.5

510

720

865

384

512

M 24

3

655

920

1100

490

654

-

1100

-

M 24

Fine thread

2

DM 24 2)

3

535

-

-

(M 27)

3

965

1360

1630

-

1600

-

(M 27)

2

(DM 27 2))

3

580

-

-

M 30

3.5

1310

1845

2215

-

1450

-

M 30 3)

2

(M 33)

3.5

1780

2500

3000

M 36

4

2290

3220

3860

(M 39)

4

2970

4170

5000

M 42

4.5

3670

5160

6190

(M 45)

4.5

4590

6450

7740

M 48

5

5540

7790

9350

Important!

The tightening torques specified in the spare parts lists must also be observed during installation and maintenance work.

1) 2) 3) 4)

6.6

The dimensions listed in brackets are applied in exceptional cases only.

According to works standard (EWN 6110, February 1985 edition).

Only for expansion bolts with a reduced shaft cross-section of 24.2 mm.

The tightening torques comply with the works standard (EWN 6003).

Gleithobel plow® GH 1600-3

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(mm)

Bucyrus Europe GmbH, Lünen 2010

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Permissible media Permissible media Lubricating greases and pastes Important!

The lubricants to be used are specified in the respective chapters, e.g. Installation, Maintenance.

Lubricating greases properties

A1 grease

Lithium soap

NLGI class:

2

Worked penetration:

265 to 295 (0.1 mm)

Reaction in the presence of water:

practically insoluble in water

Service temperature range:

-20 to +120 °C

Flashpoint:

≧ 200 °C

Lubricating greases for general applications, e.g. for roller bearings subject to normal load, for labyrinths and for installation (according to EWN *) 7068).

Tab. 12: Lubricating greases for general applications

E Bucyrus Europe GmbH, Lünen 2010

Base:

A2 lubricating grease

Flashpoint °C

Supplier

Type

ARAL

Aralub HL 2

300

ESSO

BEACON 2

200

Lubricating greases containing additives for high pressure applications, e.g. for roller bearings and bearing points subject to extreme load.

Tab. 13: Lubricating greases with additives Flashpoint in °C

Supplier

Type

ARAL

Aralub HLP 2

300

ESSO

BEACON EP 2

200

Important!

The lubricating listed in the same table can be mixed with one another. Other products may only be used if the supplier can guarantee that they are equivalent. Differently composed lubricating greases must not be mixed as this may change the consistency, i.e. the mixture can become thinner so that the lubrication effect is not sufficient.

It is also not advisable to use lubricating greases that have the same saponification base but are from different sources. If in doubt, the manufacturer of the lubricating grease to be used should be contacted to confirm the compatibility of the grease in question.

*)

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Permissible media Lubricating pastes B3 lubricating paste

Lubricating pastes free from molybdenum disulfide, containing solid lubricants for lubricating centering bores and connections of splined shafts of sprocket drums and chain sprockets during installation.

Tab. 14: Lubricating pastes free from molybdenum disulfide Supplier

Type

Base

gleitmolybdän

gleitmo 805 *)

Li

NLGI class

Flashpoint in °C

2

220

When the equipment is lubricated at our factory for the first time, the lubricant type used as B 3 lubricating paste in accordance with the Bucyrus works standard EWN 7068 is: gleitmolybdän “gleitmo 805” B6 lubricating paste

Parting agents and lubricants with organic lubricating media on a synthetic base material for greasing threaded areas and fitting points on props and hydraulic props, of pin connections and similar connecting elements at the support.

-34 to +120 °C

When the equipment is treated at our factory for the first time, the lubricant type used as B 6 lubricating paste in accordance with the Bucyrus works standard EWN 7068 is: Chesterton parting and lubricating agent 785 (flashpoint 132 °C) Important!

The instructions for mixing greases apply likewise to the lubricating pastes.

*)

6.8

The greases listed in table 12 are suitable for filling adjacent cavities.

Gleithobel plow® GH 1600-3

Bucyrus Europe GmbH, Lünen 2010

Service temperature range:

E

Reaction in the presence of water: resistant

Gleithobel plow identification Gleithobel plow identification The following information is provided on the plow.

Manufacturer: . . . . . . . . . . . . Bucyrus Europe GmbH Type: . . . . . . . . . . . . . . . . . . . Gleithobel plow GH 1600-3 Year of manufacturing: . . . . . MM/YY (e.g.: 06/10 ≙ June 2010) ID No.: . . . . . . . . . . . . . . . . . . 6050 015 000 00 XX *) Weight: . . . . . . . . . . . . . . . . . . max. 11264 kg The following markings are on the plow's Gleithobel body.

Fig. 53: Type plate and CE-marking, example Type plate

1 2

Bucyrus Europe GmbH 3

12345 10/09

678

4

Bucyrus Europe GmbH, Lünen 2010

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6050 015 000 00 01 5 6GH 1600-3

7

11264 kg

CE-marking

1 manufacturer 2 order no.

3 date of manufacture 4 serial component no.

5 device number 6 type 7 weight

The plow complies with European Directive 94/9/EC and DIN EN 1710 in its design and is for use in explosive atmospheres.

*) X = placeholder for variant ID number

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6.9

6.10

Gleithobel plow® GH 1600-3 Bucyrus Europe GmbH, Lünen 2010

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For your information

Standards and directives

For your information If you should require spare parts or if technical problems occur, please contact our after-sales service personnel or contact us directly (homepage: www.bucyrus.com).

Standards and directives Referenced standards and directives Tab. 15: Standards and directives, extract

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Designation

Date of issue

Title

Directive of the European Parliament and the Council on Directive 2006/42/EC the approximation of the laws of the member states relating to machinery EC Directive on the approximation of the laws of the memDirective 94/9/EC ber states concerning equipment and protective systems intended for use in potentially explosive atmospheres DIN EN ISO 12100-1 Safety of machinery DIN EN ISO 12100-2 Safety of machinery Petroleum products and bituminous materials DIN ISO 3733 - Determination of water - Distillation method Non-electrical devices for use in potentially explosive atDIN EN 13463-1 mospheres - Part 1: Basic method and requirements Electrical apparatus for explosive gas atmospheres DIN EN 60079 - Part 0: General requirements DIN EN 60445 Basic and safety principles for man-machine interfaces Underground mining machinery - Specification DIN EN 12321 for the safety requirements for armored face conveyors Equipment and components intended for use in potentially DIN EN 1710 explosive atmospheres in underground mines Mobile extracting machines at the face - Safety requireDIN EN 1552 ments for shearer loaders and plow systems Preparation of instructions DIN EN 62079 - Structuring, content and presentation DIN 2000 Quality of drinking water DIN 6789 Documentation system DIN 20043 Plug connectors for hydraulics DIN 24320 Fire-resistant hydraulic fluids DIN 24343 Maintenance and inspection list for hydraulic systems DIN 24346 Hydraulic systems - Design principles DIN 51558-1 Determination of the neutralization number DIN 51575 Determination of sulfate ash

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2006-06-09

1994-03-23 2004-04 2004-04 2003-02 2007-05 2004-12 2000-08 2003-08 2008-08 2003-09 2001-11 2000-10 1990-09 2003-09 2006-12 1982-02 1984-12 1979-07 1984-11

7.3

Standards and directives Date of issue

Designation

Title

EWN 6003 1)

Tensioning forces, tightening torques and surface pressure for steel bolts Hammer head bolts Greases & solid lubricants Non-metallic surface protection Approval procedure for fire-resistant HFA fluids in mining

1985-02 1992-06 1985-02 2008-01

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EWN 6110 1) EWN 7068 1) EWN 7069 1) EWN 8350-1 1)

1985-02

1) EWN = works standard

7.4

Gleithobel plow® GH 1600-3