DOWNLOAD PDF : CAT Continuous Miner 35M3L Electrical Operation & Maintenance Manual

BI000983

CONTINUOUS MINER

INTRODUCTION Maintenance A6474X363

BI000983

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This manual is intended to provide GENERAL product information. The illustrations, descriptions and procedures contained in this publication apply only to THIS machine. Bucyrus reserves the right to revise models and designs without prior notice.

This machine was manufactured under the guidelines, procedures and requirements of the appropriate government regulatory agencies.

At the completion of the manufacturing process, this unit was issued the appropriate approval numbers and nameplates indicating it met the technical requirements of these regulatory agencies. Any change to the design or structure of this unit, without the consent of Bucyrus and these regulatory agencies, or any repair or replacement of parts contrary to Bucyrus’ instructions, may invalidate these approvals and render this unit unsafe to operate.

Strict compliance with all laws, regulations and practices regarding the safe operation and maintenance of underground mining equipment and strict adherence to the instructions in this manual is necessary for the personal safety of those working on or around this unit.

While this manual attempts to anticipate the most important operations and maintenance needs for this unit, unforeseen circumstances may arise that have not been addressed in this manual. If any concerns or questions arise, please contact your Bucyrus Service Representative immediately.

This work contains information protected under trade secret and other intellectual property laws, and is protected under the U. S. Copyright Act of 1976, as amended. This work is provided under license and the license is non-transferable. Distribution and access is limited only to authorized personnel. Disclosure, reproduction, distribution or unauthorized use may be a violation of federal and state laws and may subject the unauthorized user to criminal liability.

© BUCYRUS 2011.

ALL RIGHTS RESERVED

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Table of contents Safety Precautions ............................................................................ 4 General Maintenance Instructions .................................................... 6 Lock Wiring Fasteners....................................................................... 8 Self-locking Screws ........................................................................... 8 Locknuts ............................................................................................ 8 Torque Values ................................................................................... 9 Lubrication and Maintenance Schedule ............................................ 11 Specific Lubrication and Maintenance Procedures ........................... 17 Every Shift ................................................................................. 17 Daily .......................................................................................... 20 Weekly....................................................................................... 28 Crawler Chain Adjustment Procedure.................................. 30 Conveyor Chain Tension Adjustment Procedure................. 34 Monthly...................................................................................... 36 Every Three Months.................................................................. 42 Every Six Months ...................................................................... 47 Tail Shim Adjustment Procedure....................................................... 49 Lubricant Specifications ................................................................... 52

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Safety Instructions _______________________________________________ Safety Precautions

The following safety precautions should be observed whenever operating or performing any maintenance, repair, or adjustment procedure on this machine.

Additional precautions may appear in each section of this book. All precautions listed applicable to this machine, as well as all applicable regulatory agency rules and regulations must be followed at all times.

!

DANGER

Do not make any type of temporary repairs to the trailing cable or trailing cable connections except as allowed by applicable regulatory agencies. Contact with high voltage power supply will result in severe injury or death from electrocution.

!

DANGER

Only qualified personnel are permitted to make repairs to permissible equipment. The permissibility of any permissible component must be verified after any maintenance or repair work and at regular intervals. Failure to maintain permissible components to OEM standard may result in a fire or explosion. Serious injury or death could occur.

!

WARNING Do not attempt to operate this continuous miner until you have been sufficiently trained on this machine and have read and understood this manual and are familiar with all controls and indicators. Operating this machine without the proper training and knowledge may result in serious injury or death to the operator or other personnel.

!

WARNING Federal law requires that temporary roof supports be in place before approaching the machine to reset a circuit breaker. Under no circumstances should personnel be under unsupported roof. Failure to follow these regulations may result in serious injury or death.

!

WARNING Only use the Emergency Stop Override to tram the miner away from the rib, releasing the accidentally pushed Machine Stop button. Never use the Emergency Stop Override when a Machine Stop switch has been activated by personnel. Failure to comply with this warning may lead to severe injury or death of personnel.

!

WARNING The Continuous Miner is radio remote controlled during production operations. Manual operation via machine mounted controls is not permitted for production operations.

Manual operation is for troubleshooting and maintenance under supported roof only.

Operating the Continuous Miner with manual or pendant controls under unsupported roof may result in sever injury or death.

!

WARNING Before performing maintenance or repair work on this machine, the circuit breaker must be in the “OFF” position and the trailing cable disconnected. Follow all applicable rules and regulations regarding the lockout/tagout procedures. Accidental machine movement or electrical shock may result in serious injury or death to the operator or other personnel.

!

WARNING Some procedures or test may require the cover of the electrical controller to be removed and some may require the controller to be energized during the procedure. Tall all necessary precautions to prevent electrical shock while working within the controller. An MSHA certified electrician must supervise and inspect all work.

!

WARNING Do not alter, bypass, or remove and emergency or machine stop device. Failure to heed this warning may result in serious injury or death.

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_______________________________________________ Safety Instructions

!

WARNING Do not use an emergency or stop device as a means of disconnecting power to the miner. Whenever instructed to disconnect power, it is always meant to turn the main circuit breaker to the “OFF” position and to physically remove the trailing cable and lockout/tagout the machine. Failure to do so may result in serious injury or death.

!

WARNING Never disconnect a hydraulic hose if the circuit is pressurized or there is a load on the circuit. Pressurized hydraulic fluid or falling loads may result in serious injury or death.

!

WARNING Do not rely on load holding valves when working under the cutter head or the conveyor.

Always block the cutter head and conveyor in the elevated position. Serious injury or death may occur if the cutter head or conveyor are not mechanically blocked.

!

WARNING Never work under any assembly or component of this machine that is elevated. Always install enough blocking to support the machine or component or lower the component to ground level.

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General Maintenance Instructions___________________________________ Introduction

Maintenance at regular intervals increases the operational safety and prolongs the service life of the machine. This manual contains recommendations on machine and component inspections, machine lubrication, lubricant (oil) change procedures, filter maintenance, and adjustment procedures to properly maintain the machine.

Tools

General tools are required for maintenance. If a procedure requires a specialty tool or material, it will be identified in the procedure.

Illustrations and Procedures The maintenance intervals and procedures given in this manual are based on typical machines and typical mine conditions. Mine conditions and machine configuration may require the recommended intervals or maintenance procedure be modified from those given.

The illustrations used in this manual are for a typical machine and may vary from your machine. If repair work is required, always refer to the specific drawing in the Bucyrus Parts Book supplied with your machine.

Maintenance Notes Before performing maintenance on this machine, observe the following: 1. In order to avoid individual components not being serviced or being inadequately serviced, Bucyrus recommends that a general maintenance plan be developed.

2. Use only suitable and approved tools for maintenance work.

3. Use only original Bucyrus spare parts when replacing components.

4. All electrical work must be supervised and inspected by a certified electrician.

5. Anyone performing maintenance on this equipment must be trained on machine operation.

6. Shutdown the machine on level ground.

7. Turn circuit breaker to the "OFF" position and disconnect the trailing cable.

Follow all Mine, State, and Federal lockout/tagout procedures.

8. Only work on the miner in an area where the roof is properly supported.

9. Block any and all elevated assemblies before working under them. Make sure that the blocking can support the weight of the assembly without slipping or failing.

10. Relieve all hydraulic pressures and position the levers and controls, if applicable, in Neutral or Off. 11. After ensuring that all personnel are clear of the machine, test all controls to ensure that the unit will not move.

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__________________________________ General Maintenance Instructions 12. Test the air for methane (if applicable) before and during any maintenance or repair work.

13. Do not perform maintenance on a circuit while there is a load resting on the hydraulic cylinder. Booms must be securely blocked with the boom in the raised position if maintenance is to be performed.

14. Do not perform maintenance in a congested area. This could endanger the maintenance person or others in the vicinity.

15. Whenever a potential problem is uncovered during a periodic maintenance check, it is imperative that it be corrected immediately by a qualified maintenance technician.

16. Cleanliness cannot be overemphasized as the essential ingredient of a good maintenance program. Machines should be kept as free as possible of dirt and debris which could impede performance or infiltrate systems and cause premature wear or failure.

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Special Fasteners ________________________________________________ Introduction

Various types of specialty fasteners, self-locking bolts and nuts, lock wiring, Super Bolts, etc., may be in use on the machine. It is important that these fasteners be used in the correct manner to provide the locking qualities required.

Locking Wire Fasteners

When using a single locking wire, insert the wire through the fastener from the inside to the outside of the bolt circle, advancing in a clockwise direction (Fig. 1).

When using wired pairs, insert the wire in the left hand fastener (as viewed from the center of the bolt circle) from the inside to the outside of the bolt circle. Insert the right end of the wire through the right hand fastener (Fig. 1).

Fig. 1: Lock wire fasteners

Self-Locking Screws

1. Self-locking screws are generally used where measured torque is required.

2. Use a hand wrench, not a power wrench, to tighten to get an accurate reading.

3. Performance is reduced with each use. Limit reuse to twice.

4. If assembly requires shimming, establish the shimming requirements using standard fasteners. After shimming requirements are established, replace standard fastener with self-locking and torque as required.

Lock Nuts

1. Lock nuts with nylon or fiber inserts should not be reused.

2. Lock nuts with a spring steel lock ring in the head can be reused.

3. Hand thread the nut to engage the threads before using a power wrench.

4. Bolt or stud threads should extend beyond the nut.

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___________________________________________________ Torque Values Introduction

The following charts list the recommended torque values for common fasteners used on the Continuous Miner. Use these torque values unless the Bucyrus drawing or instructional material states otherwise.

Do not use these tables for any bolt grades except those specifically listed.

Use a calibrated torque wrench for accuracy.

Imperial Bolts

Grade 8 Imperial Bolts Torque Recommendations (calculated at 75% proof load) Bolt size Dry Lubricated (inches) ft-lbs ft-lbs 12 6 1/4 25 12 5/16 44 22 3/8 70 35 7/16 107 53 1/2 154 77 9/16 212 106 5/8 376 188 3/4 606 303 7/8 909 454 1 1287 644 1-1/8 1875 938 1-1/4 2382 1191 1-3/8 3161 1581 1-1/2 4988 2494 1-3/4 7500 3750 2 10969 5484 2-1/4 15000 7500 2-1/2 17794 8897 2-3/4 23507 11753 3 30286 15143 3-1/4 38266 19133 3-1/2 47545 23773 3-3/4 58100 29085 4

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Torque Values ___________________________________________________ Metric Bolts

Metric Bolts Torque Recommendations (calculated at 75% proof load) Property Class

8.8

10.9

12.9

M6 - M16: 800 M20 - M30: 830

1040

1220

Minimum Tensile Strength (MPa) Nominal Size and Thread Pitch

Dry ft-lbs (in-lbs)

Lubricated ft-lbs (in-lbs)

Dry ft-lbs (in-lbs)

Lubricated ft-lbs (in-lbs)

Dry ft-lbs (in-lbs)

Lubricated ft-lbs (in-lbs)

M5 X 0.80 M6 X 1.00 M7 X 1.00 M8 X 1.25 M10 X 1.50 M12 X 1.75 M14 X 2.00 M16 X 2.00 M18 X 2.50 M20 X 2.50 M22 X 2.50 M24 X 3.00 M27 X 3.00 M30 X 3.50 M33 X 3.50 M36 X 4.00

(54) (92) (156) (2250 37 65 104 161 222 314 428 543 796 1079 1468 1886

(41) (69) (116) (169) 28 49 78 121 167 235 321 407 597 809 1101 1415

(78) (133) (222) (333) 53 93 148 230 318 449 613 776 1139 1543 2101 2699

(59) (99) (167) (242) 40 69 111 172 238 337 460 582 854 1158 1576 2024

(91) (156) (260) (377) 62 108 173 269 372 525 716 908 1331 1804 2455 3154

(68) (116) (195) (284) 47 81 130 202 279 394 537 681 998 1353 1842 2366

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____________________________________________Maintenance Schedule Introduction

This section outlines the frequency at which maintenance tasks should be carried out. Depending on operating conditions, more frequent intervals may be required.

Lubricant and Fluid Capacities

The following lubricant specifications and fluid capacities should be observed when adding or changing a lubricant or greasing a component.

Location

Specification

Approximate capacity

Hydraulic oil tank GH Assembly CLA Primary GH Assembly CLA POT Tram Drive Assembly Drum Drive Assembly, high speed (back) Drum Drive Assembly, low speed (front) Motor Lube Hoses

Spec. 100-1 Spec. 100-15 Spec. 100-15 Spec. 100-15 Spec. 100-15

156 gals. (592 L) 1 gal (3.79 L) 2.5 gal (9.46 L) 3 gal (11.36 L) 0.5 gallon (1.89 L)

Spec. 100-15

5 gal (18.93 L)

Spec. 100-14

Variable

Notes

1

Spec, sheets, listing both the physical characteristics and vendors and lubricants that are known to meet each specification, are given at the end of this section.

Notes: 1. All motor lube hoses are to be filled with high temperature electric motor grease (Spec. 100-14) before assembling them to the electric motor to ensure that there are no air gaps between the grease nipple and the point where the grease enters the motor.

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Maintenance Schedule ____________________________________________ Item

Description

Places

Lubricant

Specification

Every Shift 1

Cutter head lift cylinder pin, upper

2

Lithium based grease

Spec. 100-3

2

Cutter head lift cylinder pin, lower

2

Lithium based grease

Spec. 100-3

3

Conveyor swing cylinder pin, front

1

Lithium based grease

Spec. 100-3

4

Conveyor swing cylinder pin, rear

1

Lithium based grease

Spec. 100-3

5

Cutter head pivot pin

2

Lithium based grease

Spec. 100-3

6

Cutter head bits

Inspect

Daily 7

Tail roller

2

Lithium based grease

Spec. 100-3

8

Gathering head pivot pin

2

Lithium based grease

Spec. 100-3

9

Crawler idler roller

2

Lithium based grease

Spec. 100-3

10

Conveyor raise pivot pin

2

Lithium based grease

Spec. 100-3

11

Stabilizer shoe cylinder pin, upper

2

Lithium based grease

Spec. 100-3

12

Stabilizer shoe cylinder pin, lower

2

Lithium based grease

Spec. 100-3

13

Conveyor raise cylinder pin, upper

2

Lithium based grease

Spec. 100-3

14

Conveyor raise cylinder pin, lower

2

Lithium based grease

Spec. 100-3

15

Conveyor swing pivot pins

8

Lithium based grease

Spec. 100-3

16

Gathering head cylinder pin, upper

2

Lithium based grease

Spec. 100-3

17

Gathering head cylinder pin, lower

2

Lithium based grease

Spec. 100-3

18

CLA head pot assembly (Check)

2

High demulsibility EP gear oil

Spec. 100-15

19

CLA head transfer case (Check)

2

High demulsibility EP gear oil

Spec. 100-15

20

Tram gear case (Check)

2

High demulsibility EP gear oil

Spec. 100-15

21

Input cutter head gear case (Check)

2

High demulsibility EP gear oil

Spec. 100-15

22

Main cutter head gear case (Check)

2

High demulsibility EP gear oil

Spec. 100-15

23

Hydraulic oil level (Check)

1

AW hydraulic oil

Spec. 100-1

24

Stab shoe pivot, frame

2

Lithium based grease

Spec. 100-3

25

Weekly Pressure filter

1

See Parts Book

26 27

Pilot pressure filter, non-bypassing Pilot pressure filter, bypassing

1 1

See Parts Book See Parts Book

28

Power fill filter

1

See Parts Book

29

Water filter

1

See Parts Book

30

Crawler chain

Inspect

31

Conveyor chain

Inspect

32

Fasteners (nuts, bolts, screws)

Inspect

33

Electrical cables, conduits, and glands

Inspect

34

Hydraulic/water hoses and connections

Inspect

35

Lighting

Inspect

36

Reflectors and warning tags

Inspect

37

Machine stop switch (Inspect)

2

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____________________________________________Maintenance Schedule Item

Description

Places

Lubricant

Specification

2 2 2 2 Inspect 2 2 2 2 2 1

High demulsibility EP gear oil High demulsibility EP gear oil High demulsibility EP gear oil High demulsibility EP gear oil

Spec. 100-15 Spec. 100-15 Spec. 100-15 Spec. 100-15

Sample Sample Sample Sample Sample Sample

See Note 1 See Note 1 See Note 1 See Note 1 See Note 1 See Note 1

High temperature lithium complex grease High temperature lithium complex grease High temperature lithium complex grease

Spec. 100-14

Monthly 38 39 40 41 42 43 44 45 46 47 48

CLA head pot assembly (Change) CLA head transfer case (Change) Input cutter head gear case (Change) Main cutter head gear case (Change) CLAs Input cutter head gear case Main cutter head gear case CLA head pot assembly CLA head transfer case Tram gear case Main hydraulic tank

49

Every three months Cutter motor

4

50

Gathering head motor

4

51

Pump motor

2

52

Every six months Tram gear case (Change)

2

High demulsibility EP gear oil

Spec. 100-15

53 54 55

Hydraulic oil (Change) Suction strainer, hydraulic oil tank (Change) Breathers

1 2 All

AW hydraulic oil

Spec. 100-1 See Parts Book See Parts Book

Spec. 100-14 Spec. 100-14

Note 1: When the oil sample and oil change interval are identical, a sample of the old oil is to be taken and sent for analysis prior to changing the oil (see the Oil sampling procedure in this chapter). Always inspect breathers when taking hydraulic oil samples.

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Maintenance Schedule ____________________________________________ Fig. 2: Lubrication and maintenance chart

22, 41, 44

3 - Conveyor swing cylinder front pin 4 - Conveyor swing cylinder rear pin 22, 41, 44 - Main cutter head gear case 23, 48, 53, 54, 55 - Hydraulic oil tank 37 - Machine stop switch 47, 52 - Tram gear case

23, 48, 53, 54, 55

47, 52

47, 52

37

4

3

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____________________________________________Maintenance Schedule Fig. 2: Lubrication and maintenance chart, continued 9 - Crawler idler roller 12 - Stabilizer shoe cylinder lower pin 13 - Conveyor raise cylinder upper pin 15 - Conveyor swing pivots 16 - Gathering head cylinder upper pin 18, 38, 45 - CLA head pot assembly 19, 39, 46 - CLA head transfer case 20 - Tram gear case 21, 40, 43 - Input cutter head gear case 25, 26, 27 - Hydraulic filters 30 - Crawler chain 37 - Machine stop switch 49 - Cutter motor 50 - Gathering head motor

21, 40, 43 49 50 18, 38, 45 19, 39, 46

9

16

30 25, 26, 27 51

20

12 37 13 15

15

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Maintenance Schedule ____________________________________________ Fig. 2: Lubrication and maintenance chart, continued 9 - Crawler idler roller 12 - Stabilizer shoe cylinder lower pin 15 - Conveyor swing pivots 16 - Gathering head cylinder upper pin 18, 38, 45 - CLA head pot assembly 19, 39, 46 - CLA head transfer case 20 - Tram gear case 21, 40, 43 - Input cutter head gear case 49 - Cutter motor 50 - Gathering head motor 15

15

12 20

16

18, 38, 45

9

19, 39, 46 50

49

21, 40, 43

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__________________________________________Maintenance Instructions Specific lubrication and maintenance procedures Every shift The purpose of this section is to describe the following maintenance procedures, to be performed every shift: 1. Cutter head lift cylinder pins (upper and lower, left and right) lubrication 2. Conveyor swing cylinder pins (front and rear) lubrication 3. Cutter head pivot pin lubrication 4. Cutter head bit inspection Cutter Head Cylinder Pins (upper and lower)

Lubricate the upper and lower cutter head cylinder pins (right and left). The upper pins are lubricated through the grease fittings located on each pin (Fig. 3). The lower cylinder pins are lubricated through a lubrication block mounted on each side of the machine (Fig. 3). Pump approximately 50 cubic cm (3 cubic inches) into each fitting.

Fig. 3: Cutter head cylinder pins (typical both sides)

Upper cutter head cylinder pin

Lower cutter head cylinder pin grease fitting

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Maintenance Instructions __________________________________________ Conveyor Swing Cylinder Pin (front and rear)

Lubricate the front and rear conveyor swing cylinder pins through the grease fittings located on each end of the cylinder (Fig. 4). Pump approximately 50 cubic cm (3 cubic inches) into each fitting.

Fig. 4: Conveyor swing cylinder pin lubrication Conveyor swing cylinder pin, rear

Cutter Head Pivot Pin (left and right)

Conveyor swing cylinder pin, front

Lubricate left and right cutter head pivot pins through the grease fittings located on the left and right front lubrication blocks (Fig. 5). Pump approximately 3 cu. in. (50 cu. cm) of grease into each fitting.

Fig. 5: Cutter head pivot pins (typical both sides) Cutter head pivot pin lubrication

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__________________________________________Maintenance Instructions Cutter Head Bits

Inspect the cutter head bits to ensure that they will rotate in their holders and for damaged or missing bits (Fig. 6). Replace bits immediately if any are missing or damaged.

Fig. 6: Cutter head bits Bit holder

Bit

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Maintenance Instructions __________________________________________ Daily The purpose of this section is to describe the following maintenance procedures, to be performed daily: 1. Tail roller lubrication 2. Gathering head pivot pin lubrication 3. Crawler idler roller lubrication 4. Conveyor raise pivot pin lubrication 5. Stabilizer shoe cylinder pin (upper and lower, left and right) lubrication 6. Conveyor raise cylinder in (upper and lower, left and right) lubrication 7. Conveyor swing pivot pin lubrication 8. Gathering head cylinder pin (upper and lower, left and right) lubrication 9. CLA head pot and transfer gear cases, oil level check 10. Tram gear cases, oil level check 11. Main and input cutter head gear cases, oil level check 12. Hydraulic oil level check 13. Stab shoe pivot lubrication Tail Roller Lubrication

Lubricate the tail roller through the two (2) grease fittings located on the shaft (Fig. 7). Pump approximately 3 cu. in. (50 cu. cm.) of grease into each fitting.

Fig. 7: Tail roller lubrication

Grease fittings (2)

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__________________________________________Maintenance Instructions Gathering Head Pivot Pin (right and left)

Lubricate the left and right gathering head pivot pins through the grease fittings located on the left and right front lubrication blocks (Fig. 8). Pump approximately 3 cu. in. (50 cu. cm.) of grease into each fitting.

Crawler Idler Roller (right and left)

Lubricate the left and right crawler idler rollers (Fig. 8) through the grease fittings located on the outside face of the crawler idler roller.

Conveyor Raise Pivot (right and left)

Lubricate the conveyor raise pivot through the grease fitting located on the right and left front lubrications blocks (Fig. 8). Pump approximately 3 cu. in (50 cu. cm) of grease into each fitting.

Fig. 8: Gathering head pivot pin, conveyor raise pivot, and crawler idler roller (typical both sides) Conveyor pivot pin lubrication

Gathering head pivot pin lubrication

Crawler idler roller

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Maintenance Instructions __________________________________________ Upper Stabilizer Shoe Cylinder Pin (right and left)

Lubricate the upper stabilizer shoe cylinder pins (right and left) through the two grease fittings located on the lubrication block on the left side of the machine (Fig. 9). Pump approximately 3 cu. in (50 cu. cm) of grease into each fitting.

Lower Conveyor Raise Cylinder Pin (right and left)

Lubricate the lower conveyor raise cylinder pins (right and left) through the two grease fittings located on the lubrication block on the left side of the machine (Fig. 9). Pump approximately 3 cu. in (50 cu. cm) of grease into each fitting.

Stabilizer Shoe Pivot Pin (right and left)

Lubricate the stabilizer shoe pivot pins (right and left) through the two grease fittings located on the lubrication block on the left side of the machine (Fig. 9).

Pump approximately 3 cu. In (50 cu. Cm) of grease into each fitting.

Fig. 9: Lubrication block - stabilizer shoe and conveyor lift pin lubrication manifold

Lower Stabilizer Shoe Cylinder Pin (right and left)

Lubricate the lower stabilizer shoe cylinder pins (right and left) through the grease fittings located on the rod end of each cylinder (Fig. 10). Pump approximately 3 cu. in (50 cu. cm) of grease into each fitting.

Fig. 10: Lower stabilizer shoe cylinder pin (typical both sides)

Lower stabilizer shoe cylinder pin

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__________________________________________Maintenance Instructions Upper Conveyor Raise Cylinder Pin (left and right)

Lubricate the upper conveyor raise cylinder pins through the grease fittings located on the right side of the conveyor (Fig. 11). Pump approximately 3 cu. in (50 cu. cm) of grease into each fitting.

Fig. 11: Upper conveyor raise cylinder pin lubrication

Upper conveyor raise cylinder pin grease fittings (2)

Conveyor Swing Pivot Pins

Lubricate the conveyor swing pivot pins through the four (4) grease fittings located each side of the conveyor (Fig. 12). Pump approximately 3 cu. in (50 cu. cm) of grease into each fitting.

Fig. 12: Conveyor swing pivot pin Conveyor swing pivot pin lubrication fittings (2) (typical both sides)

Conveyor swing pivot pin lubrication fittings (2) (typical both sides)

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Maintenance Instructions __________________________________________ Gathering Head Raise Cylinder Pins

Lubricate the upper gathering head raise cylinder pins (Fig. 13) through the grease fittings located on each end of the cylinder. Pump approximately 3 cu. in (50 cu. cm) of grease into each fitting.

Fig. 13: Gathering head raise cylinder pins (typical both sides)

Gathering head raise cylinder pin (upper)

Gathering head raise cylinder pin (lower)

CLA Head Pot Assembly (right and left)

Level the miner and place the gathering head on grade before checking or adding lubricant. Check the oil level in the pot assembly (Fig. 14). If oil is needed, add oil through the fill hole until oil comes out the breather.

CLA Head Transfer Case (right and left)

Level the miner and place the gathering head on grade before checking or adding lubricant. Check the oil level in the hydraulic transfer case (Fig. 14). If oil is needed, add oil through the fill hole until oil comes out the breather.

Fig. 14: CLA head pot assembly and transfer case lubrication Oil fill, pot assembly

Oil check, transfer case

Oil check, pot assembly

Oil fill, transfer case

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__________________________________________Maintenance Instructions Tram Gear Case (right and left)

With the miner in a level position, check the oil level in both tram gear cases by looking at the sight glass located on the side of each gear case (Fig. 15). Oil should be visible in each sight glass. If oil level is low, add oil through either the fill pipe (accessed from the top of the machine) or the fill plug hole (accessed from the side of the machine).

Check that the breather is clean and free of debris.

Fig. 15: Tram gear case oil level (typical both sides) Oil fill plug

Breather (behind cover)

Oil check

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Maintenance Instructions __________________________________________ Input Cutter Gear Case

Ensure fill areas are clean and free of debris. With the gathering head lowered to ground level and the cutter head boom level with ground, check the oil level in both of the input cutter gear cases by removing the check plug located on each side of the cutter head assembly (Fig. 16). Oil should flow from check plug hole when plug (s) is removed. If oil level is low, add oil through the fill plugs located on each side of the gathering head.

Fig. 16: Input cutter gear case oil level (typical) Oil fill plug (one per side)

Oil check plug (one per side)

Main Cutter Gear Case

Ensure fill areas are clean and free of debris. With the cutter head boom level with ground, check the oil level in both of the main cutter head gear cases by removing the check plug located on the front of each gear case (Fig. 17). Oil should flow from check plug hole when plug (s) is removed. If oil level is low, add oil through the fill plug hole located on top of each gear case.

Fig. 17: Main cutter head gear case oil level (typical) Oil fill plug (one per side)

Oil check plug

(one per side) ________________________________________________________________ 26 Bucyrus – 35M3 Maintenance

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__________________________________________Maintenance Instructions Hydraulic Oil Level

With all of the machine cylinders in the fully collapsed position, check the hydraulic oil level (Fig. 18). Remove dipstick from tank and wipe clean. Insert dipstick back into tank and remove. The oil should be level with the full line indicated on dipstick. If oil level is low, add oil until full level is met.

Fig. 18: Hydraulic oil tanks Hydraulic oil tank

Hydraulic oil tank

Dip stick location

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Maintenance Instructions __________________________________________ Weekly The purpose of this section is to describe the following maintenance procedures, to be performed weekly: 1. Pressure filters (bypassing and non-bypassing), check and change as required 2. Return filter, check and change as required 3. Power fill filter, check and change as required 4. Water filter, check and change as required 5. Crawler chain, inspect 6. Conveyor chain, inspect 7. Inspect/check tightness/condition of all fasteners (nuts, bolts, screws, etc.)

8. Inspect electrical cables, conduits, and glands 9. Inspect hydraulic and water hoses and connections 10. Inspect lighting 11. Inspect reflectors and warning tags 12. Inspect/check the function of each machine stop switch Pressure Filter

Pilot Pressure Filters

Power Fill Filter

Change the pressure filter elements (Fig. 19). If the element is extremely dirty, a more frequent change interval may be required.

Change the pilot pressure filter elements (bypassing and non-bypassing) (Fig. 19). If the elements are extremely dirty, a more frequent change interval may be required.

Change the power fill filter element (Fig. 19). If the element is extremely dirty, a more frequent change interval may be required.

Fig. 19: Hydraulic filter location Pilot pressure filter (non-bypassing)

Pressure filter

Pilot pressure filter (bypassing)

Power fill filter

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__________________________________________Maintenance Instructions Water Filter

Change the water filter element (Fig. 20). If the element is extremely dirty, a more frequent change interval may be required.

Fig. 20: Water filter location

Water filter

Crawler Chain Tension

Check the crawler chains for proper tension.

To check for proper tension: 1. Raise the complete crawler assembly off of the ground and securely block under the machine. The machine must be securely supported off the ground.

2. Chain sag should be 2-1/2 inches (64 mm) to 3-1/2 inches (89 mm) at the center of the crawler (Fig. 21).

Fig. 21: Crawler track tension measurement

Bottom of tractor wear shoe

2 1/2” - 3 1/2” gap (64 - 89 mm)

Top of tram track

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Maintenance Instructions __________________________________________ Crawler Chain Adjustment Introduction

It is critical to maintain proper crawler chain tension. Loose chains can damage the sprocket and tight chains can cause excessive wear on the tram track assembly, including motors and drives. Both conditions reduce crawler chain life.

The crawler chain tension is adjusted using the front idler take-up jacks.

Grease is added to tighten or bled off to loosen the track .

Tool List

Standard tool set Grease gun

Procedure

To adjust the crawler chain tension: 1. Lower the conveyor tail section until it is level with the floor.

2. Raise the gathering head and cutter head and block both assemblies following standard blocking procedures.

3. Lower the gathering head and cutter head onto the blocking so that the front end of the miner lifts off the floor.

4. Extend the stabilizer completely so that the rear end of the miner lifts off the floor.

5. Securely block under the machine. The machine must be securely supported off the ground with the tram track free to turn.

6. Raise the stabilizer, gathering head, and cutter head assemblies so that the weight of the miner rests on the blocking.

7. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine lockout/tagout regulations.

8. Double check the tractor frame support blocking now that the weight of the tractor frame is completely upon it.

9. Evaluate the tram track for proper tension (Fig. 21). The tram track is at the proper tension when it hangs approximately 64 to 89 mm (2-1/2 to 3-1/2 inches) from the bottom wear shoes when the tractor frame is blocked off the floor. Using this evaluation, determine whether step 11, 12, or 13 provides the appropriate sub-procedure to correct improper track tension.

10. Locate the front idler take-up jack grease fitting and attach the grease gun to the fitting.

11. If the tram track tension is too tight, readjust the idler position using the following steps: a. Pump grease into the take-up jack to extend the cylinder and remove pusher plate pressure on the idler shims. b. Remove one or more idler adjustment shims from the idler slide channel.

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__________________________________________Maintenance Instructions c.

Open the pressure release valve for the front idler take-up jack and allow the jack to contract. The pusher plate will slide backwards until it is stopped by the remaining idler shims.

d. Pump grease into the idler take-up jack to extend the cylinder, move the idler assembly forward and tighten the tram track until it is at the correct tension. The tram track is at the proper tension when it hangs 64 to 89 mm (2-1/2 to 3-1/2 inches) from the bottom wear shoes when the tractor frame is blocked off the floor.

12. If the tram track is too loose, readjust the idler position using the following steps: a. Pump grease into the idler take-up jack to extend the cylinder, move the idler assembly forward and tighten the tram track until it is at the correct location. The tram track is at the proper tension when it hangs 64 to 89 mm (2-1/2 to 3-1/2 inches) from the bottom wear shoes when the tractor frame is blocked off the floor. b. Insert shims (Fig. 22) into the idler slide channel until the space between the tractor frame and the pusher plate is filled. c.

Open the pressure release valve (Fig. 22) for the front idler take-up jack and allow the cylinder to contract. The idler adjustment shims will keep the idler stationary and the track tensioned.

d. Evaluate the resulting track tension and repeat these steps until the track reaches proper tension.

CAUTION

Shims must be inserted completely into the idler slide channel. A shim that is not correctly seated on the idler slide channel’s inside surface provides uneven support that can cause idler slant. A slanted idler can cause uneven wear and stress on the tram track and can cause improper operation of or damage to the tram system.

IMPORTANT

Check that the shims are correctly seated on the idler slide channel’s inside surface by looking at the channel’s inside surface from the opposite side of the miner through the space between the gathering head and the idler assembly.

!

13. If the tram track tension is still too loose when the entire 5” shim set is inserted into the idler slide channel, re-adjust the idler position after removing a tram track link using the following steps: a. Pump grease into the take-up jack to extend the cylinder and remove the pusher plate pressure on the idler shims. b. Remove all of the idler adjustment shims from the idler slide channel. c.

Open the pressure release valve for the front idler take-up jack and allow the cylinder to contract.

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Maintenance Instructions __________________________________________ d. The tram track tension should now be reduced and separation of the tram track will be easier. e. Locate a tram track link near the tram idler. f.

Remove the four Conelok nuts and flat head screws that secure the crawler pins (Fig. 22).

g. Using the hammer and punch, remove the crawler pins to disconnect the link from the track. Remove the disconnected link. h.

Connect the two ends of the tram track and secure the two end links together with the crawler track pin.

i.

Secure the crawler track pin between the two links with the 3/8-16X11/4 flat head socket head screws and 3/8-16 Conelok nuts.

j.

Pump grease into the idler take-up jack to extend the cylinder, move the idler assembly forward and tighten the tram track until it is at the correct tension. The tram track is at the proper tension when it hangs approximately 64 to 89 mm (2-1/2 to 3-1/2 inches) from the bottom wear shoes when the tractor frame is blocked off the floor.

k.

Insert shims into the idler slide channel until the space between the tractor frame and the pusher plate is filled.

l.

Open the pressure release valve for the front idler take-up jack and allow the cylinder to contract. The idler adjustment shims will keep the idler stationary and the track tensioned.

m. The idler adjustment shims will keep the idler stationary and the track tensioned. n. Evaluate the resulting track tension and repeat until the track reaches proper tension.

14. When the tram track has been adjusted to the proper tension, remove the grease gun from the idler take-up jack grease fitting.

15. Open pressure release to take pressure off of take-up cylinder.

16. Close the front rub rail cover and secure the front rub rail to the tractor frame with hex head capscrews and lock washers.

17. Connect the trailing cable to energize the miner.

18. Raise the tractor frame off the blocking by lowering the stabilizer and gathering head and cutter head assemblies.

19. Carefully remove the support blocking from under the tractor frame.

20. Lower the tractor frame onto the floor by raising the stabilizer and gathering head and cutter head assemblies.

21. Carefully remove the blocking from underneath the raised stabilizer, gathering head, and cutter head assemblies.

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__________________________________________Maintenance Instructions Fig. 22: Tram track adjustment Crawler chain take-up lubrication

Take-up cylinder

Shims

Pressure relief valve

Idler assembly

Pad

Cleat

Lock bolt Conelok nut

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Maintenance Instructions __________________________________________ Conveyor Chain Tension

There are two different types of chain commonly used on the machine: Cincinnati chain (standard) or Joy chain (optional). To check the chain tension: Cincinnati chain: 1. Make sure the conveyor chain area is clean and free of any loose material.

2. Position the rear conveyor section in a straight line with the cutting head to maximum possible height.

3. Position yourself to the side of the gathering pan, under protected roof, and start the conveyor. a. There should be a smooth transition or flow of the chain as it comes through and over the foot shaft sprocket. If the arch of the chain is trailing above the sprocket, the chain needs to be tensioned. b. If, when the conveyor is rapidly started and stopped, the chain tends to fold back on itself, the chain needs tensioned. c.

If, when the conveyor is swung to the extreme left to right, there is too much excess chain, the chain may need to be adjusted in that position.

If adjusted in this position, swing the conveyor back straight and recheck adjustment to verify that the chain has not been over-tensioned.

5. With correct tension, there should be no deflection of the flight tips near the tail roller.

Joy chain: 1. With the machine locked and tagged out, place a hand on each end of a chain flight near the end of the conveyor. the ends should be not more than 50 mm (2 inches) from center or 100 mm (4 inches) top to bottom. If the deflection is more than 100 mm (4 inches), the chain is too loose and needs tensioned. If the deflection is less than 50 mm (2 inches), the chain is too tight and needs loosened.

Conveyor chain tension adjustment The conveyor chain is tensioned with a hydraulic take-up cylinder. If the chain tension is not being maintained, then: 1. The conveyor chain take-up valve may need to be adjusted. See the Conveyor chain take-up valve adjustment procedure (Pilot/auxiliary pump circuit relief valve adjustments) in this section. If the valve adjustment is correct, then 2. The cylinder may be fully extended and, therefore, unable to take up any more chain slack. Remove a link from the chain or replace chain as necessary.

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__________________________________________Maintenance Instructions The miner is subjected to continual shock loading and vibration and close attention to all mounting bolts and screws is required. Loose fasteners will cause premature wear and failure of bearings, couplings, etc. Inspect the following fasteners and tighten as required:

Fasteners

1. Cutter head gear case bolts 2. Cutter head motors bolts 3. Center drums bolts 4. End drums bolts 5. Tram cases bolts 6. Tram motors bolts 7. Gathering head CLAs bolts 8. Gathering head pots bolts 9. Gathering head motors bolts Electrical Cables, Conduits, and Glands

Visually inspect all electrical cables and glands for signs of wear or damage.

Hoses and Fittings

Visually inspect hydraulic and water hoses and fittings for signs of wear, damage, or leakage. This inspection should be performed with the machine running. Observe the following precautions/procedures while checking for leaks or making repairs: 1. Relieve pressure before disconnecting hoses.

2. Check for leaks with a piece of cardboard. Do not use hands.

3. Do not exceed the working pressure of hydraulic hoses.

! WARNING

Use extreme caution when inspecting for leaks with the machine running. Unexpected machine movement, or contact with moving parts, could result in injury.

Escaping fluids under pressure can penetrate skin and cause serious injury. Do not attempt to locate hydraulic leaks by feeling hoses and fittings with bare hands. Pin hole leaks can penetrate the skin.

Lighting

Turn on the lights and visually inspect for bulbs that need to be replaced.

Reflectors and Warning Tags

Visually inspect the condition and readability of all warning tags, labels, and reflectors for signs of wear or damage. Replace any reflector or tag that is missing or damaged.

Machine Stop Switches

Check the machine stop switches located on each side of the machine for proper operation. Start the machine and strike the switch; the machine pump motor will shutdown, in turn shutting down all other motors. Repeat for the other switch.

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Maintenance Instructions __________________________________________ Monthly The purpose of this section is to describe the following maintenance procedures, to be performed monthly: 1. CLA head pot and transfer gear cases, change the oil 2. Input and main cutter head gear cases, change the oil 3. Inspect the CLAs 4. Sample the oil in the input and main cutter head gear cases, the CLA head pot and transfer gear cases, the tram gear cases, and the main hydraulic oil tank CLA Head Pot Assembly

Change the oil in both CLA head pot assemblies (Fig. 23).

1. Level the miner, raise the gathering head pan, and secure in place.

2. Clean dirt and debris from around the drain plug located under the gear case.

3. Remove the drain plug and allow oil to completely drain from the gear case.

4. Clean and reinstall drain plug.

5. Clean dirt and debris from around the check plug and remove the plug.

6. Clean dirt and debris from around the fill plug and remove the plug.

7. Slowly add oil through the fill plug until oil begins to flow from the check plug hole. Allow sufficient time for the oil to ravel through the gear case when filling.

8. Clean and reinstall the check and fill plugs.

CLA Head Transfer Case

Change the oil in both CLA head transfer cases (Fig. 23).

1. Level the miner, raise the gathering head pan, and secure in place.

2. Clean dirt and debris from around the drain plug located under the gear case.

3. Remove the drain plug and allow oil to completely drain from the gear case.

4. Clean and reinstall drain plug.

5. Clean dirt and debris from around the check plug and remove the plug.

6. Clean dirt and debris from around the fill plug and remove the plug.

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__________________________________________Maintenance Instructions 7. Slowly add oil through the fill plug until oil begins to flow from the check plug hole. Allow sufficient time for the oil to ravel through the gear case when filling.

8. Clean and reinstall the check and fill plugs. ! NOTICE

If the gear case is scheduled for oil drain and refill, obtain the oil sample prior to the oil change.

IMPORTANT

Always collect oil samples using a siphon pump. Do not remove the drain plug and collect oil by allowing it to run out into the bottle.

If the gear case is scheduled for oil drain and refill, obtain the oil sample prior to the oil change.

Fig. 23: CLA pot assembly and input transfer case Oil fill, pot assembly

Oil check, transfer case

Oil check, pot assembly

Oil fill, transfer case

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Maintenance Instructions __________________________________________ Input Cutter Head Gear Case Change the oil in both input cutter head gear cases (Fig. 24).

1.

Position the cutter head horizontally (flat back in a vertical position). Clean dirt and debris from around the drain plug located under the gear case.

2.

Remove the drain plug and allow oil to completely drain from the gear case.

3.

Clean and reinstall the drain plug.

4.

Clean dirt and debris from around the check plug and remove the plug.

5.

Clean dirt and debris from around the fill plug and remove the plug.

6. Slowly add oil through the fill plug until oil begins to flow from the check plug hole. Allow sufficient time for the oil to travel throughout the gear case when filling.

7. Clean and reinstall the check and fill plugs.

Fig. 24: Input cutter head gear case (typical) Oil fill plug (one per side)

Oil check plug (one per side)

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__________________________________________Maintenance Instructions Main Cutter Head Gear Case Change the oil in both main cutter head gear cases (Fig. 25).

1. Lower the cutter head completely to the ground. Clean dirt and debris from around the drain plug, located under the gear case.

2. Remove the drain plug and allow oil to completely drain from the gear case.

3. Clean and reinstall the drain plug.

4. Clean dirt and debris from around the check plug and remove the plug.

5. Clean dirt and debris from around the fill plug and remove the plug.

6. Slowly add oil through the fill plug until oil begins to flow from the check plug hole. Allow sufficient time fro the oil to travel throughout the gear case when filling.

7. Clean and reinstall the check and fill plugs.

Fig. 25: Main cutter head gear case Oil fill plug (one per side)

Oil check plug (one per side)

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Maintenance Instructions __________________________________________ CLAs

Inspect the CLAs (Fig. 26) for damage. If a CLA needs replaced, see CLA removal and installation procedure in the Mechanical section of this manual.

Fig. 26: CLAs CLA

Oil sampling plan This plan contains specific instructions to be followed in order to correctly collect gear case lubricant samples, and preparation of the samples for laboratory analysis. Adherence to these instructions will insure that all oil sample analysis reports give an accurate picture of the oils condition as well as wear trends of gears, bearings, etc. Accurate reporting and analysis of oil samples will prove extremely beneficial providing a tool to allow planning of scheduled down-time and prevention of costly equipment breakdown.

Preparation prior to sample collection For each machine to be sampled, you will need a supply of sample collection bottles and identification labels (Fig.29) sufficient to sample each identified gear case (every sixty shifts).

One sample bottle and collection hose is required for each gear case to be sampled. Label each container with the identifying name of the gear case (crawler gear case, left or cutter head gear case, right front, etc.).

Collection of oil samples If the gear case is scheduled for oil drain and refill, obtain the oil sample prior to the oil change.

Each oil sample should be taken while the oil is at normal operating temperature. If the machine has not been operating just prior to sampling, run the machine until oil temperature reaches approximate normal operating temperature.

Shutdown the machine and allow 2 - 3 minutes for the oil to drain back and stabilize it’s level.

IMPORTANT

Always collect oil samples using a siphon pump. Do not remove the drain plug and collect oil by allowing it to drain into the bottle.

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__________________________________________Maintenance Instructions Always use the collection hose provided with each bottle. Always discard hose immediately following collection of the oil and do not use it for the next sample.

To do so will contaminate the next sample with oil from the previous sample.

After taking sample, check and refill gear case back to proper fill level.

Following collection of all oil samples, record the specific brand and product name of the lubricant that has been installed in each gear case.

Recommended gear cases to be sampled: 1. Input cutter head gear case (left and right) 2. Main cutter head gear case (left and right) 3. Input gathering head gear case (left and right) 4. Main gathering head gear case (left and right) 5. Main hydraulic oil tank

Fig. 27: Oil sampling procedure Oil fill plug

Typical siphon pump and bottle

Oil level

Place end of siphon tube approximately half way into sump

Note: Hold sample pump and bottle below oil level

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Maintenance Instructions __________________________________________ Every three months The purpose of this section is to describe the following maintenance procedures, to be performed every three months: 1. Lubricate the cutter motors 2. Lubricate the gathering head motors 3. Lubricate the pump motor IMPORTANT

For motor bearings that require high temperature lithium complex grease (Spec. 10015), Bucyrus provides a special “button” style lubrication fitting to prevent the accidental use of multi-purpose lithium complex grease at these locations.

Cutter Motor Bearings

Lubricate the left and right cutter head motor bearings with high temperature lithium complex grease through the two grease fittings located on each side of the cutter head (Fig. 28) using the following procedure: 1. Open the cover (Fig. 28) to access the motor.

2. Inspect the grease fittings on the exit side of the front and rear motor bearing.

If the exit side motor bearing ports are equipped with spring loaded relief fittings, then a. Lubricate both motor bearings until new grease appears out of the relief ports on the exit side of the bearing. b. Operate the motor for five (5) minutes and then inspect for grease leaks in the bearing area.

If the exit side motor bearing ports are equipped with plugs, then: a. Remove the plug and lubricate both motor bearings until new grease appears out of the relief ports on the exit side of the bearing. b. Operate the motor for five (5) minutes and then inspect for grease leaks in the bearing area.

3. Replace the plugs in the ports.

! NOTICE

Incorrect grease or over greasing of the electric motor may cause serious damage to the motor. Follow the greasing procedure outlined above.

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__________________________________________Maintenance Instructions Fig. 28: Cutter motor bearing lubrication (typical each side)

Motor located behind cover

Button type grease fitting

Cutter motor lubrication (2)

Spring loaded grease relief fitting

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Maintenance Instructions __________________________________________ Gathering Head Motor Bearings

Lubricate the left and right gathering head motor bearings with high temperature lithium complex grease through the two grease fittings located on each motor (Fig. 29).

To lubricate the motors: 1. Open the cover (Fig. 29) to access the motor.

2. Inspect the grease fittings on the exit side of the front and rear motor bearing.

If the exit side motor bearing ports are equipped with spring loaded relief fittings, then a. Lubricate both motor bearings until new grease appears out of the relief ports on the exit side of the bearing. b. Operate the motor for five (5) minutes and then inspect for grease leaks in the bearing area.

If the exit side motor bearing ports are equipped with plugs, then: a. Remove the plug and lubricate both motor bearings until new grease appears out of the relief ports on the exit side of the bearing. b. Operate the motor for five (5) minutes and then inspect for grease leaks in the bearing area.

3. Replace the plugs in the ports.

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__________________________________________Maintenance Instructions Fig. 29: Gathering head motor bearing lubrication (typical each side)

Gathering head motor lubrication

Motor located behind cover

Button type grease fitting

Spring loaded grease relief fitting

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Maintenance Instructions __________________________________________ Pump Motor Bearings

Lubricate the pump motor (Fig. 30) with high temperature lithium complex grease (Spec. 100-14) through the two (2) grease fittings located the right side of the machine using the following procedure: 1. Open the cover (Fig. 30) to access the motor.

2. Inspect the grease fittings on the exit side of the front and rear motor bearing.

If the exit side motor bearing ports are equipped with spring loaded relief fittings, then a. Lubricate both motor bearings until new grease appears out of the relief ports on the exit side of the bearing. b. Operate the motor for five (5) minutes and then inspect for grease leaks in the bearing area.

If the exit side motor bearing ports are equipped with plugs, then: a. Remove the plug and lubricate both motor bearings until new grease appears out of the relief ports on the exit side of the bearing. b. Operate the motor for five (5) minutes and then inspect for grease leaks in the bearing area.

3. Replace the plugs in the ports.

Fig. 30: Pump motor bearings

Pump motor lubrication fitting (2)

Motor located behind cover

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__________________________________________Maintenance Instructions Every six months The purpose of this section is to describe the following maintenance procedures, to be performed every six months: 1. Change the oil in the tram gear cases 2. Change the hydraulic oil 3. Change the hydraulic oil tank suction strainer 4. Inspect and clean/change all breathers Tram Gear Case

Change the oil in both tram gear cases (Fig. 31).

1. Remove the drain plug and allow oil to completely drain from the gear case.

2. Clean and reinstall the drain plug.

3. Replace the breather, located in the fill tube.

4. Remove the fill plug located on top of the gear case or on the fill tube.

5. Add oil through the fill plug hole until oil is visible in the sight glass. When filling, allow sufficient time for the oil to travel throughout the gear case.

6. Clean and reinstall the fill plug.

Fig. 31: Tram gear case Oil fill plug

Oil check

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Maintenance Instructions __________________________________________ Hydraulic Oil, Suction Strainer, and Breather

Change the oil in the hydraulic oil tank (Fig. 32).

1. Clean all dirt and debris from around the fill cap and the drain plug.

2. Remove the drain plug and allow the oil tank to completely drain.

3. Remove and replace the suction strainer.

4. Clean and reinstall the drain plug.

5. Replace both breathers.

6. Add oil to the tank until the oil level is correct on the dipstick.

7. After filling, start the machine and engage all hydraulic cylinders for their full length of travel (full extend and retract) in order to purge the hydraulic system of air.

8. Recheck the oil level on the dipstick. Add more oil as needed.

Fig. 32: Hydraulic oil tank Hydraulic oil tank

Hydraulic oil tank

gear case breathers

Dip stick location

Change the breathers on the main and input cutter gear cases, the CLA head pot and transfer gear cases, and the tram gear cases. Reference drawings in the Bucyrus parts book for your machine for breather locations.

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__________________________________________Maintenance Instructions Tail shim adjustment As the conveyor wears the tail section may sag relative to the conveyor front section. The conveyor has been designed to allow correction of the sag by adding shims.

1. Lower the cutter head and gathering head assemblies until they touch the floor.

2. Position the conveyor tail section directly behind the miner and raise it to its highest position.

3. Insert blocking under the tail section and lower the tail onto the blocking.

The conveyor should be at an angle with the rear end of the tail section slightly higher than the front.

4. Insert blocking between the top of the tractor frame and the bottom of the conveyor, leaving about 51 mm (2 inches) of space between the blocking and the conveyor bottom.

5. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine lockout/tagout regulations.

6. Loosen the socket head capscrews that secure the shims between the shim retainer and the conveyor lower pivot plate (Fig. 33).

Fig. 33: Shim removal Socket head capscrews

Shim retainer

Lower pivot plate

Shims

7. Connect the trailing cable to energize the miner.

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Maintenance Instructions __________________________________________ !

WARNING The following steps releases the shims, which will fall free. Watch out for falling shims when loosening the capscrews.

8. Slowly lower the conveyor slightly so that the front section rests on the frame support blocking. The slotted shims will now fall free.

9. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine lockout/tagout regulations.

10. Replace the removed shims (Fig. 33) and add the number of shims required to level the conveyor front and tail sections.

11. Tighten the socket head capscrews.

12. Connect the trailing cable to energize the miner.

13. Raise the conveyor tail from the blocking.

14. Remove both sets of blocking and lower the conveyor tail until it is level with the floor.

15. Check the gap and alignment at the juncture of the conveyor front and tail sections for alignment (Fig. 34). If the sections are not horizontally aligned, then add or subtract shims as required.

16. Re-insert the blocking between the top of the tractor frame and the bottom of the conveyor following mine standard blocking procedures.

17. Securely retighten the socket head capscrews.

Fig. 33: Tail shim adjustment Correct gap and alignment Conveyor tail section

Conveyor front section

Add shims Conveyor tail section

Conveyor front section

Remove shims Conveyor tail section

Conveyor front section

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___________________________________________Lubricant Specifications Introduction

The following lubricants specifications are referenced throughout this manual.

Any lubricant used must meet these standards listed. For your convenience, a list of manufacturers and lubricants that have been identified as meeting these standards is given for each specification.

Failure to use lubricants that meet the standard listed may reduce component life and may void any associated warranty.

Spec. 100-1: Anti-wear hydraulic oil specification Limit

Type

ISO VG

61/75

68

ASTM Grade

380/345

315

Pour Point (ASTM D-97)

Max. 20° F (-29° C)

-20° F

Flash Point (ASTM D-92)

Min. 415° F (212° C)

400° F

Viscosity SUS @ 100° F 283-347

352

SUS @ 210° F 50-58

56

CST @ 40° C

61.2 - 74.8

CST @ 100° C

8.5 Typ.

Viscosity Index (ASTM D-2270)

Min. 90

96

Oxidation Test (ASTM D-943)

2.0 mg KOH max after 1000 hrs

Rust Prevention Test (ASTM D-665, A & B

Pass

Pass

Foam Test (ASTM D-892-46T)

Pass

Pass

Four Ball Wear Test (ASTM D-2266) (40 KG, 1800 RPM, 130° F, one hour)

Not more than 0.50 mm scar diameter

0.50 mm

400 mg max

294 mg

Copper

200 mg max

131 mg

Iron

100 mg max

3 mg

50 mg max

25 mg

Sludge & Metal Corrosion (ASTM D-943) (conducted at conclusion of 1000 hour oxidation test) Insoluble sludge in oil and water layers plut that adhering to the catalyst coils or the test tub.

Metals in combined oil, water, and sludge (ASTM D-810-59)

Pump Wear Test (ASTM D-2882) (Total Ring and Vane Weight Loss) Hydrolytic Stability Test (ASTM D-2619)

0.1

Copper Specimen Weight Loss

0.05 mg/CM2 max

Acidity of Water Layer

6.0 mg KOH max

0.5

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Lubricant Specifications___________________________________________ Spec. 100-1: Anti-wear hydraulic oil approved suppliers 1 2 3 4

Supplier Amoco Oil Company Gulf Oil Mobil Oil Corporation Chevron U.S.A.

5 6 7 8 9 10 11 12

Sun Oil Company Unocal 76 Shell Oil Company Century Lubricating Oils, Inc. Atlantic Richfield Company Texaco Lubricants Company Exxon Pennzoil

13

Standard Oil Company Standard Oil Co. of Ohio Boron Oil Company BP Oil Inc. Lubricating Engineers Conoco Inc. Hydrotex Phillips Miners Oil

14 15 16 17 18

Brand name Amoco AW Oil No. 68 Harmony 68 AW Mobil DTE-16 Chevron hydraulic Oil Aw ISO 68 Sunvis 868 Unax AW 68 Shell Hydraulic Oil #33 Hydraulic AW 68 Duro AW S-315 Oil Texaco Rando Oil HD 68 Nuto 68 Pennzbell AW 68 Hydraulic Oil Industron 54 Industron 53 Energol HLP-C68 6120 Monolec Hydraulic Oil Super Hydraulic oil 68 Systems 5K 68 Maginus A Oils 81350 Hydraulic Oil 68AW

________________________________________________________________ 52 Bucyrus – 35M3 Maintenance

BI000983

___________________________________________Lubricant Specifications Spec. 100-3: Extreme pressure motor bearing grease and hand grease specification Limit NLG1 Grade Number 2

Type 2

Worker Penetration (ASTM D-217)

265-295

280

Dropping Point (ASTM D-566) Bomb Oxidation (ASTM D-942)

Min. 350° F (177° C) Not more than 10 PSI DROP

373° F 2.5

Rust Inhibitors

Required

Yes

Wheel Bearing Test (ASTM D-1263) (6 Hours @ 235° F )

Not more than 5% loss

Water Washout (ASTM D-1264)

Loss not more than 5% @ 100° F Loss not more than 15% @ 175° F

Grease Mobility

Not less than 0.1 gram flow per Second @ 0° F

Timken OK Load (ASTM D-2509)

Not less than 50 lbs.

(50 lbs.)

Four Ball EP Test (ASTM D-2569)

Load wear index not less than 30.0 Weld point not less than 200 kg. Min.

31 200

4.25 4.00

Four Ball Wear Test (ASTM D-2266) Not more than 0.60 mm. SCAR diameter 0.44 (20KG., 1800 RPM, 130° F, One Hour) Spec. 100-3: Extreme pressure motor bearing and hand grease approved suppliers 1

Supplier Amoco Oil Company

2 3 4 5 6 7 8

Gulf Oil Mobil Oil Corporation Chevron U.S.A. Sun Oil Company Unocal 76 Shell Oil Company Century - Fuchs

9 10 11 12 13

Texaco Lubricants Company Exxon Pennzoil Lubricating Engineers Conoco Inc.

14

Hydrotex

15 16

Phillips Atlantic Richfield Company

Brand name Amolith Grease 2 EP Rykon Premium Grease 2 EP Gulfcrown Grease EP#2 Mobilux EP-2 Chevron Dura-Lith Grease EP-2 NLGI 2 Sun Prestige 742EP Multiplex EP2 Alvania EP-2 Hullith EP2 Multipurpose Grease, or Replex 2, or Uniwrl 2, or Uniwrl EMB, or Hullith GP 2, or Hullith EP 2 Texaco Multifak EP 2 Lidok EP 2 Pennlith EP 712 Grease 3752 Almagard Vari-Purpose Lubricant EP Conolith Grease No. 2, or Super Sta Grease No. 2 LC-65 Hyplex Philube EP Grease Litholine H EP-2 Grease

______________________________________________________________ A6474X363 REV 0 53

BI000983

Lubricant Specifications___________________________________________ Spec. 100-14: Synthetic lithium complex grease for electric motor bearings Limit

Type

NLG1 Grade

2

Thickener

Lithium soap complex

Base Oil Type

Synthetic polyalphaolefin base oils (POA)

Worked Penetration (60 strokes) (ASTM D-217)

265 - 295

280

Dropping Point (ASTM D-2265)

470° F (243° C) min

509° F (260° C)

Water Washout Resistance Weight 10% or less Loss @ 175° F (79° C) (ASTM D-1264)

6%

Grease Mobility (US Steel Test LT-37)

18 grams/min @ 0° F (-18° C) min

20 grams/min

Four Ball Wear (ASTM D-2266)

0.70 mm Max scar diameter

0.50 mm

Four Ball EP Weld Load (ASTM D2596)

530 lb (240 kg) min

550 lb (250 kg)

Timken OK Load (ASTM D-2509)

55 lb (25 kg) min

65 lb (30 kg)

Rust Corrosion Protection (ASTM D1743)

Pass

Pass

Base Oil Viscosity @ 104° F (40° C)

95 - 120

100

Spec. 100-14: Synthetic lithium complex grease for electric motor bearings approved suppliers

1

Supplier Mobil Oil Corp.

Brand name Mobility SHC 100

2 3

Conoco-Phillips Shell

Triton 100 Albida EMS 2

________________________________________________________________ 54 Bucyrus – 35M3 Maintenance

BI000983

___________________________________________Lubricant Specifications Spec. 100-15: High demulsibility extreme pressure gear oils specification Limit

Type

ISO VG

220

220

A.G.M.A. Grade

5EP

5EP

Viscosity Index (ASTM D-2270)

Min. 95

98

Flash Point (ASTM D-92)

Min. 450° F (232° C)

480° F (250° C)

Pour Point (ASTM D-97)

Max. 15° F (-9° C)

-27° F (-17° C)

Timken Test (ASTM D-2782)

Min. 65 lbs.

70 lbs.

FKOUR Ball EP Test (ASTM D-2783)

Weld load kg. Min. 260 load wear index not less than 51.0

270 57

Oxidation Stability (ASTM D-2893) Viscosity Increase @ 100° C

Not more than 6%

4.6%

FZG Scuffing Test (ASTM D-5182) Failure Load Stage

Not less than 12th stage.

>12

SUS @ 100° F

950-1200

1119

SUS @ 210° F

85-110

95.5

CST @ 40° C

198-242

212

CST @ 100° C

15.24

18.7

DEMULSIBILITY (ASTM D-1401) Min. 30 @ 180° F ml Oil, Water, Emulsion

0 ml. Emulsion Max.

42 ml. Oil 38 ml. Water 0 ml. Emulsion

Copper Corrosion (ASTM D-130)

1 or 1b

1b

Foam Test (ASTM D-892)

Pass

Pass

Rust Test (ASTM D-665)

Pass

Pass

Viscosity (ASTM D-445)

Spec. 100-15: High demulsibility extreme pressure gear oils approved suppliers

1

Supplier Conoco Inc.

Brand name GLW Gear Oil 220

______________________________________________________________ A6474X363 REV 0 55

BI000983

_______________________________________________________________

________________________________________________________________ 56 Bucyrus – 35M3 Maintenance