Storage and transport
This chapter contains important information on the correct storage and transport of the Miner. Observance of the instructions and tips will increase the service life and availability of the Miner. You will also be able to carry out the transport work quicker and more safely. Paying careful attention to the points in this chapter will help you to simplify your day-to-day work.
Components coated with temporary corrosion inhibitor are protected for around six months. Protect the equipment against direct exposure to sunlight. Store the electrical equipment, electronic components, spare parts of rubber or plastic - such as seals and hoses - and hydraulic fluids only in closed rooms at temperatures of 15° C to 25° C.
Protect all parts of the equipment stored outdoors against moisture and dirt, e.g. using tarpaulins.
The mounting surfaces of hydraulic components must be protected against corrosion and sealed with blind plates. Protect the hydraulic plug connectors and the connectors of the electrical cables with the caps and plugs supplied.
During short-term storage (approx. 4 weeks) of equipment out-doors, but at temperatures above freezing, electrical components must not be removed. Such components must be particularly protected against excessive temperatures, dirt and moisture.
During long-term storage (more than 4 weeks), the equipment must not be stored outdoors. It must be stored in a dry, well ventilated room.
After a storage period of approx. two years, a random sample inspection must be performed to determine whether the measures taken and the method of storage has prevented damage. On request, the inspection can be carried out by DBT.
Even with proper storage, seals and hoses are subject to natural ageing. A storage period of approx. two years is therefore quoted as an indicative value for these parts.
Ensure when storing that any new supplies are stored separately from existing stocks in such a way that on removal, old stocks are taken first.
Before transporting or storing gearboxes with oil cooler at ambient if the temperatures is below freezing, the oil cooler must be flushed with antifreeze.
WARNING
temperatures below freezing
Transport
Load Units; Dimensions and Weights
Observe the transport sheets for the various transport units. They contain information on:
Ø Dimensions
Ø Weight
Ø Lifting points
Ø Center of gravity, etc.
Where technically possible, the load units have suitable lifting points for transport and erection.
Use only load handling devices complying with the technical and legal regulations for transporting loads. You could be seriously injured or even killed by falling loads. Use only suitable load handling devices.
Before Transport
Transport of equipment at temperatures between –21° C and -40°C is only permissible when certain measures were taken, to meet these conditions, at the design and manufacturing stages. Nevertheless, the individual parts and devices of this equipment must not be subjected to sudden impact loads at low temperatures.
During transport of this equipment, measures must be taken to ensure that the parts and devices are not subjected to sudden impact loads. At very low temperatures and on poor roads, the transport vehicle speed must therefore be limited to maximum of 25 kph for truck transport.
antifreeze measures for oil cooler
electrical and electronic components
Before transporting, the oil cooler must be flushed with anti-freeze.
Electrical and electronic components must be removed for over seas transport or prolonged storage outdoors unless these components or the complete equipment is protected against harmful environmental influences by a suitable packaging.
If the electrical cables remain in the equipment, they must be carefully protected against transport damage and soiling of the connections.
Start-Up
miner operator’s qualifications
pre-shift inspection
The miner operator must be completely familiar with all features and controls of this machine in order to operate it safely and productively This requires OEM training as available, a thorough study of this manual, and a visual inspection of the actual machine.
The following sections of this manual outline essential procedures and cautions for starting the miner prior to mining operations.
All pre-shift inspections and maintenance work must be preformed under properly supported roof in accordance with Federal, State and local safety regulations dictated by the mining company.
Check the operational report from the prior shift to note any problems or discrepancies with the miner. If such problems still exist, notify the shift or maintenance foreman and determine a plan of action for correcting the problems. In any case, do not start up the machine if problems exist which may cause safety hazards or danger.
Use the wash-down hose to clean off the machine as much as practical.
Conduct a visual walk-around inspection of the miner to look for signs of leaks in hydraulic cylinders and hoses, water hoses and gear boxes, frayed electrical cables, damaged or plugged water sprays, or other visible problems.
Check the dust collector filter screen and clean it with the wash-down hose as necessary.
Ensure that all machine covers are in place and properly secured.
Ensure that maintenance personnel have checked all lubrication points on the miner for proper oil levels in gear boxes and adequate greasing at grease fittings in accordance with OEM recommended practice.
Check the full length of the trailing cable for damage. Ensure that the trailing cable is properly suspended across intersections, and that the trailing cable clamp at the miner is secure.
CAUTION
Do not start-up and operate the miner unless all daily checks and schedules maintenance have been completed. Do not start-up the miner until any noted operational faults have been corrected.
Only trained and authorized personnel, or trainees under a supervising instructor, should operate this miner.
CAUTION WARNING
Make certain, by a visual check and shouted warning, that all personnel are completely clear of the miner prior to start-up. Verify that any loose material, tools, oil cans or other objects are cleared from the area before start the machine.
C Energize the main circuit breaker at the power center to enable power up to the miner.
C Turn the following manual circuit breaker handles, located on the control case and illustrated in Figure 2-1.2, to the ON position:
C MAIN CIRCUIT BREAKER (1000-VAC power to the miner)
C CONTROL CIRCUIT BREAKER (120-VAC power to machine controls)
C TRACTION MOTOR BREAKER (1000-VAC power to the tram transformer and the dust collector fan motor)
For the following activities, the operator can refer to the radio transmitter control and operation.
C Turn on the radio transmitter by pressing the green TX PWR ON pushbutton.
C Turn on the pump motor by first pressing the green ENABLE pushbutton, then moving the PUMP toggle switch to the START position. Listen for any abnormal sounds from the pump, which could indicate oil starvation of the pump.
WARNING
If any other machine function is operating at the same time as this miner, push the machine stop button to de-energize the miner immediately. A fault is present in the system and must be corrected.
Before further operations, the operator must do another visual walk around inspection to check for hydraulic leaks and proper machine lighting.
C Turn on the machine lights by pressing the green LIGHTS push-button.
WARNING NOTICE
Stand well clear of the miner during operation and movement of the various machine components and ensure that other personnel are also clear of the miner.
C Using the CUTTER HEAD RAISE/LOWER toggle switch, raise and lower the cutting head and check for proper operation.
C Using the GATHERING HEAD RAISE/FLOAT toggle switch, raise and lower the gathering head and check for proper operation.
C Using the CONVEYOR RAISE/LOWER toggle switch, raise and lower the conveyor and check for proper operation.
C Using the CONV SWING LEFT/RIGHT toggle switch, swing the discharge conveyor right and left to full travel and check for smooth operation.
C Start the conveyor and CLAs by pressing the green ENABLE pushbutton, then moving the CONVEYOR START toggle switch to the START position. Check the conveyor chain and CLAs for proper operation.
C Check the conveyor chain for proper tension by swinging the discharge conveyor right or left to its full 45o position and observing the chain behavior at the gathering head footshaft. A loose chain will tend to rise up off the deck immediately after disengaging from the footshaft sprocket.
Before tramming the miner, observe these cautions:
C Ensure that all machine lights are on.
C Check both the trailing cable and water hose for sufficient slack and freedom.
C Lower the cutting head halfway and raise the gathering head off the mine bottom.
Prior to tramming the machine, make certain by a visual check and a shouted warning, that all personnel are clear of the miner and that they are aware that it will be tramming.
Remember that the TRAM ENABLE signal is only valid for 2seconds. If the operator delays in tramming the miner for more than 2-seconds, the TRAM ENABLE switch must again be used The TRAM ENABLE switch takes the place of the traditional “DEAD MAN” foot pedal on miners equipped with an operator’s kitchen (pit).
C Select a tram speed by pressing the green TRAM HIGH or the red TRAM LOW pushbutton.
C The miner is trammed by moving the TRAM ENABLE toggle switch either forward or backward, then using the TRAM joystick controls to move the miner.
After turning off power to the miner, never walk away and leave the transmitter turned on. Failure to turn the transmitter off could result in an accident causing serious injury or loss of life.
The continuous miner is inherently subjected to a severe working environment. Keeping the miner productive in these conditions requires an ongoing dedicated preventive maintenance program. Such a maintenance program includes:
F Thorough inspections
F Periodic adjustments
F Proper scheduled lubrication
F Accurate maintenance and repair records which are available on the working section.
F Routine servicing of the various systems on the machine, i.e., hydraulic, electrical, mechanical systems.
While most mines have underground maintenance personnel trained to care for the equipment, the continuous miner operator is in the best position to monitor the machine’s performance and its condition on a regular basis. He must be properly trained to monitor constantly specific areas of the machine for developing trouble For example:
These should be inspected after every major cut. The cutting head takes major punishment during mining, and the cutting bits and their holders are at the front of this action. Worn cutting bits will impact cutting productivity, while missing bits or bit holders will induce vibration to the cutting head and the miner which can damage the pivot, hydraulic cylinders and even electrical components mounted on the miner chassis.
All gear boxes on 30M miners have either oil level sight gages or oil level check plugs which facilitate checking oil levels. These essential checks should be made daily whether by trained maintenance personnel or the operator himself Where visible, the external areas of gear boxes should be inspected for signs of leaks.
While the 30M miners have their hydraulic suction pipe located optimally at the bottom center of the hydraulic oil reservoir, a major hydraulic oil leak could soon result in pump cavitations and damage. The oil level in the main tank should be checked daily and topped off as necessary. The operator is in the best position to detect significant hydraulic leaks.
30M miners all use greased-adjusted shim-lock or constant pressure tensioning devices to maintain proper tension on both the crawler and conveyor chains. However, if the chain is allowed to wear excessively, the tensioning device will reach its limit of travel and will no longer be able to maintain proper chain tension. In this case, the chain must either be shortened or replaced.
unusual noises
dirt and debris accumulation torques
The operator must be aware of unusual noises from gear boxes or electric motors which could be a sign of impending failure.
The operator should keep his miner as clean of dirt and debris as is practical Heavy rock slabs sloughing off the roof should be cleared with a pry bar to prevent them from slipping off the miner and causing serious injury to nearby personnel, or falling into the conveyor and causing a jam. Wash down hoses are available on each side of the rear of most miners for use in washing off lesser debris and dust. Keeping dirt and debris from accumulating is the best way to be able to spot leaks or other signs of trouble.
GENERAL MECHANICAL MAINTENANCE
It is important that all cap screws be tightened as specified in the maintenance procedures, diagrams, or the torque chart in Figure 2-1 1 in this manual, and in assembly drawings shown in the Parts Book Special tightening torques as noted in the text or shown in the illustrations should be maintained. Any specific torque information given in these sections regarding the maintenance of a component manufactured by a company other than DBT and installed on this machine shall prevail for that particular component. If a specific torque is not found, consult with your local DBT representative.
Figure 2-1.1 Recommended Torque Values for Fasteners Commonly Found on DBT 30M Miners
mating pairs
housing preparation
Duo-Cone seals consist of a pair of matched sets. Each set is made up of a metal seal ring and a rubber toric (see Figure 2-1 2).
The special seal rings are precision lapped to ensure positive sealing at the mating surfaces. The torics position the seal rings and furnish the floating action that allows for shaft deflection and end play They also provide a constant sealing face pressure, seal the back sides of the sealing rings to adjacent parts, and transmit the force needed to turn one metal ring, while holding the other stationary.
The faces of the mated sealing rings form a sealing band 0 8 mm (1/32”) wide that retains the oil lubricant and keeps out dirt As wear occurs, the contact band broadens, moving slowly inward until the inside diameter is reached Thus, a simple visual check will show the amount of remaining life.
Duo-Cone seals must always be installed in mated pairs, two new seals together or two seals that have previously run together. Never assemble one new seal and one used seal together, or two used seals that have not previously run together.
Proper handling and installation of these seals is vital to get maximum life and positive sealing protection given by these precision units. Special attention was given during shipping to ensure absolute cleanliness. For maximum service, keep seals clean during installation and when filling with oil.
The housing components that contact the rubber toric rings (3 and 4) must be free from foreign material (oil, grease, dirt, metal chips, dust or lint particles, etc.) before installing the seal. This should be done with a lint-free wipe and a non-petroleum based solvent. Dry with a clean wipe.
2-1.3 Preparation
Figure 2-1.2 Duo-Cone Seal Components
Figure
approved assembly lubricants
Place the rubber torics on the metal seal ring at the bottom of the seal ring ramp and against the retaining ring (see Figure 2-1.3). Make sure the rubber toric is straight on the seal ring and not twisted. Be careful not to nick or cut the torics during this assembly, as this can cause leaks.
Put the installation tool onto the metal seal ring and rubber toric (see Figure 2-1.4). Lightly dampen the lower half of the rubber toric with the appropriate assembly lubricant.
Techniques to dampen the toric include wiping with a lint-free towel, lubricating using a clean foam brush, or dipping in a container lined with towels saturated in the assembly lubricant (see also Figure 2-1.4).
Isopropyl Alcohol**
Houghton-Grind 60 CT Quaker® Solvo Clean 68-0
(*) do not use Stanosol or any other liquid that leaves an oil film or does not evaporate quickly.
(**) all applicable safety and disposal guidelines for flammable liquids must be followed.
installation process
With the lower half of the rubber toric seal still wet, use the installation tool to position the seal ring and the rubber toric squarely against the housing (see Figurer 2-1-5). For smaller diameter seals, use sudden and even pressure to push the rubber toric under the retaining lip of the housing.
For larger diameter seals which will not press in with sudden and even pressure, it is acceptable to work the toric past the retaining lip by starting on one side and tapping the opposite side of the installation tool with a rubber mallet until it is engaged past the retaining lip of the housing.
Figure 2-1 4 Lubricating the Toric Ring
Figure 2-1.5 Seal Installation
Check the assembled height (A) (see Figure 2-1 6) in at least four places, 90o apart, using a caliper, tool makers’ rule or any other calibrated measuring device. The difference in height around the ring must not be more than 0.040 inches. If small adjustments are necessary, do not push or pull directly on the seal ring. Use the installation tool to push down and your fingers to pull up uniformly on the rubber toric and seal ring.
The rubber toric can twist if it is not wet all around during installation or if there are burrs or fins on the retaining lip of the housing. Twists, misalignment, and bulges of the toric will result in seal failure. If correct installation is not obvious, remove the seal from the housing and repeat the process.
The rubber torics must never slip on the ramps of either the seal ring or the housing. To prevent slippage, allow adequate evaporation time for the lubricant before proceeding with further assembly Once correctly in place, the rubber toric must roll on the ramp only.
Wipe the face of each seal ring using a lint-free wipe. No particles of any kind are permissible on the sealing surfaces. (Even a hair can hold the seal surfaces apart and cause a leak.) Apply a thin film of oil on the entire seal face of one or both seals using a clean finger or a lint-free applicator. Oil must not contact surfaces other than the sealing faces.
While completing the assembly of the unit, make sure that both housings are in correct alignment and are concentric. Slowly bring the two housings together. High impact can scratch or break the seal components.
If the rubber toric slips at any location, it will twist, causing the seal rings to cock. Cocked seals create uneven pressure on the seal faces, resulting in galling, scoring and leakage. Any wobbling action can cause dirt to enter by pumping mud past the torics.
Figure 2-1.7 gives approximate weights for various components of a 30M miner. These weights may vary for different miner configurations and should be used only as a general guide in maintenance work.
Figure 2-1.6 Checking the Installation final
Figure 2-1 7 Approximate 30M Miner Component Weights
Proper service and repair is important to the safe, reliable and productive operation of the 30M continuous miner. The maintenance procedures recommended by DBT and described in this manual are effective methods of performing maintenance operations.
It is important to note that many statements against using some maintenance procedures that can damage the machine, render it unsafe for operation, or cause physical danger to working personnel, are stated in this manual. These statements are neither exhaustive nor complete, and it would be impractical for DBT to attempt to produce such a complete document of warnings and cautions. Anyone who uses a maintenance procedure or tool which is not recommended by DBT must first satisfy himself that neither his safety nor machine safety will be jeopardized by the maintenance methods he selects.
Certain dangers common to performing maintenance on continuous miners are emphasized in this manual. Typically, they involve working under major components which include:
F the cutting head
F the gathering head
F the conveyor
F the stabilizer shoe
and which are supported and activated by hydraulic cylinders. A worker should never rely on the locked-in hydraulic pressure of a cylinder to maintain its position, and his own safety, because unexpected leaks or other maintenance work could cause this pressure to be lost unexpectedly and result in serious injury or loss of life. The cutting head, gathering head and conveyor should each be blocked securely in their raised position if work is to be performed under them Likewise, when the stabilizer shoe is used to raise the rear of the miner for maintenance, the miner chassis should be blocked securely in its raised position before working around it.
Two other examples related to hydraulic pressure are the constantpressure take-up cylinders maintaining tension in the conveyor chain (and the crawler chains if so equipped) When the miner is shut down, circuit pressure remains locked in these cylinders. If a worker should attempt to undo a fitting in one of these hydraulic circuits, the sudden release of this pressure could cause injury Each of these circuits has either a needle valve or a vent which can be used to release pressurized oil before performing maintenance.
Specific warning plates are attached to 30M miners to alert personnel to these dangers.
For further information about maintenance, see PREVENTIVE MAINTENANCE in this manual.
cutting head assembly
GENERAL DESCRIPTION
The cutting head assembly of the 30M2, shown in Figure 2-2.1, is powered by two 280 hp (186 Kw) AC electric motors mounted one on each side of the cutting head support frame.
LH Input Gear Case
AC Drive Motor
Cutting Head Support Frame
AC Drive Motor
Cutting Head Pivot Eye
RH Input Gear Case
LH Cutting Drum
Final Drive Gear Case
Center Cutting Drum
RH Cutting Drum
The drive arrangement for the cutting head is shown in Figure 2-2.2
Each motor drives through a torque-limiting clutch to an input gear case, which in turn drives a main gear case in the drum The two main gear cases drive a common shaft, allowing the two drive motors to share the cutting load. Each input gear case is removable as a separate unit from the main cutting head gear case
The cutting final drive is shown in Figure 2-2.3.
Figure 2-2.1 Cutting Head Assembly
Raise Cylinder Clevis
The cutting head is attached to the main frame at a heavy-duty pivot (see later Figures 2-2.11 and 2-2.12). Two double-acting hydraulic cylinders raise and lower the cutting head.
End Drum Removal
1. Place the miner so the front can easily be reached and there is side clearance to pull the end drums off both ends of the cutting head. 2. Lower the cutting head to a comfortable work height, and block it so the drums can be removed without affecting the supports.
Inadequate or improper support while this work is performed can cause serious injury or death.
Switch all machine circuit breakers to “OFF”. Verify power is disconnected and locked-out to the miner. Failure to comply could result in serious injury or death.
3. Remove the four 7/8” cap screws from the four puller holes in the end cap (they protect the puller hole threads).
4. Remove the eight 7/8” socket head cap screws securing the end cap (see Figure 2-2.4).
Figure 2-2 2 Cutting Head Drive
Shaft
Limiting Clutch
Figure 2-2.3 Cutting Head Final
Wedge
The cap screws may be stuck with loctite. The use of heat and a hammer may be required to loosen the cap screws.
5. Using the four puller holes in the end cap and four of the eight 7/8” socket head screws just removed, remove the end cap. If the assembly is seized, you may have to pry on the edges, but take care not to damage the O-ring or its seal land.
6. Attach a lifting device to the end drum being removed and apply lifting tension.
7. Loosen the eighteen 1” socket head cap screws that secure the wedge block assembly and the drum to the cutting head hub. Remove the cap screws and wedge.
Match-mark both the end drum and the cutting head hub so that the cutting bit arrangement is not disturbed upon re-assembly.
8. Slowly pull the end drum off the main assembly, and maneuver it away from the miner.
9. Repeat above Steps 4 through 9 to remove the end drum from the opposite side.
1. With a lifting device attached to each half of the center drum, remove the four 1” cap screws, nuts and washers from the RH and LH end flanges of the center drum (see Figure 2-2.5).
Ensure that the lifting devices have adequate tension on both halves of the center drum; otherwise they could fall off the cutting head and cause serious injury or even death.
2. Remove the sixteen 1” cap screws holding the center flanges of the center section together.
Figure 2-2.5 Center Cutting Drum
Flange
removal of a cutting head motor
removal of the cutting motor clutch clover and motor input shaft
removal of the motor
1. Place the miner in a location where the front and both sides of the cutting head can easily be reached.
2. Lower the gathering head until the dozer blade rests on the mine floor.
3. Lower the cutting head to a comfortable working height and block it in this position under the support frame, leaving the cutting head gear case free for removal.
Inadequate or improper blockage of the cutting head support frame can result in serious injury or death.
Switch all machine circuit breakers to “OFF”. Verify all power is visually disconnected and lock-out to the miner. Failure to comply could result in serious injury or death.
4. Disconnect both electrical cables and cooling water hoses from the motor.
5. Remove the cutting motor clutch cover on the RH side of the machine by removing 16 5/8” special hex head cap screws (see Figure 2-2.6).
6. Remove the seal cap and internal retaining ring which restrains the motor input shaft.
7. Remove the motor (input) shaft from the inside of the motor going into the input gear case.
Removal of the Motor
8. Attach a lifting device securely to the motor and apply lifting tension.
9. Loosen, but do not remove, the four 1-1/4” X 4” hex head cap screws at the base of the motor support bracket.
10. Loosen, but do not remove, the four 1-1/4” X 11” hex head motor attach cap screws and their 1-1/4” heavy hex elastic stop nuts (see Figure 2-2.6).
In addition to the four cap screws at the base of the support bracket and the four cap screws at the front, the motor is also supported by the motor pilot into the bore in the cutting head support frame.
11. Adjust tension on the lifting device to neutralize the weight of the motor.
12. Remove the four cap screws at the base of the motor support bracket.
13. Ease the motor rearward until its pilot disengages from the bore in the cutting head support frame.
removal of the cutting head gear case
Cutting
1-1/4” Hex Head Screws (4 per
Motor Support
1-1/4” Hex Head Screws w/ Heavy
Cutting Head
Motor
Motor
Input Case
Retainin g Rings
Seal Clutc
5/8” Hex Head Clutch Cover
1-1/4” Hex Head Motor Attach
14. Complete the removal of the four cap screws in the front motor flange and move the motor away from the cutting head support frame.
The cutting head gear case must sometimes be removed from the miner by itself for replacement of internal components such as the input gear cases. The cutting head gear case may be removed with the cutting drums installed, but this task is easier with the drums removed. Figures 2-2.7, 2-2.8 and 2-2.9 show details of the cutting head attachment to its support frame.
1. Place the miner in a location where the front and both sides of the cutting head can easily be reached.
2. Lower the gathering head until the dozer blade rests on the mine floor.
3. Lower the cutting head to a comfortable working height and block it in this position under the support frame, leaving the cutting head gear case free for removal.
Inadequate or improper blockage of the cutting head support frame can result in serious injury or death.
Switch all machine circuit breakers to “OFF”. Verify all power is visually disconnected and lock-out to the miner. Failure to comply could result in serious injury or death.
Figure 2-2.6 Cutting Head Motor
4. Block the cutting head gear case securely, and recheck secure blocking of the cutting head support frame.
WARNING
Inadequate or improper blockage of the cutting head support frame can result in serious injury or death.
Torque Limiting Support Frame
AC Drive Spacer (Some
Hex Head Gear Case Attach
Figure 2-2.7 Cutting Head Side View
During loosening and removal of the cap screws, it may be necessary to adjust the blockage of the cutting head gear case to ensure that it is properly aligned and slippage will not occur.
Figure 2-2.8 Cutting Head Attachment Details (Rear Support Torque Limiting 1-1/4” x 13” Hex Head Motor
NOTICE
CAUTION
1-1/4” x 13” Motor Attach
1-1/4” x 11”
1-1/4” x 8”
1-1/4” x 11”
1-1/4” x 11”
1-1/4” x 8”
1-1/4” x 11”
5. Carefully loosen and remove the forty (40) 1-1/4” cap screws holding the cutting head gear case to the cutting head support frame together. The 20 cap screws on each side are as follows (see Figures 2-2.8 and 2-2.9):
F Ten, 11” long, secured by heavy nuts.
F Six, 11” long, threaded into holes in the support frame.
F Four, 13” long, secured by heavy nuts and holding the front flange of each cutting motor.
6. Carefully separate the cutting head gear case from the support frame.
Some 30M models have a separate spacer between these two components. The presence of this spacer depends on the preselected cutting diameter of the cutting head.
There are 2” dowel pins, which are press-fitted into the support frame at the top of each cutting motor. Upon separation, they should remain in the support frame and case must be taken to prevent damage to these pins.
Figure 2-2.9 Cutting Head Attachment Details (Front View)
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7. Engage the cutting head lockout switch located on the display box. This will lock out power to the cutting head while power is applied to the miner for tramming.
8. Apply power to the miner.
Do not attempt to start the cutting head. Failure to comply could result in serious injury or death.
WARNING CAUTION
In this configuration, each cutting head motor is held in with a support bracket at the rear and the motor bore into a pilot hole in the support frame at the front. Excessive bumping might cause the motor to fall.
1. Remove the access plug at the rear of the input gear case (see Figure 2-2.10).
2. Remove the first of two retaining rings and a plug and its captive Oring.
3. Remove the second retaining ring and any shims installed behind the retaining ring. This will expose the drive shaft.
4. Using the threaded puller hole in the end of the drive shaft, extract the shaft completely.
5. Remove the eight (8) ¾” nylok socket head cap screws The case is also secured by a 1” dowel as shown in Figure 2-2.10. This may require the removal of a couple of the ½’ cap screws securing bearing retainers on either side of the case, and using a slap hammer with a ½” threaded end to ease the case away from the main gear case structure.
Figure 2-2.10 Cutting Head Input Gear Case Attachment Details
Access Plug for
¾” Nylok Socket
Main Gear
Input Gear
1” Dowel Pin
removal of the cutting head assembly from the main case
WARNING
1. Place the machine to a location where both sides are accessible in front of the crawlers and can be reached easily.
2. Lower the gathering head until the dozer blade rests on the mine floor.
3. Lower the cutting
1. Switch all machine circuit breakers to “OFF”. Verify that all power is disconnected and locked-out. Failure to comply could result in serious injury or death.
2.
4. Clean off an area of the machine where parts can be set. Place clean rags or cardboard on this area and keep dirt off the parts by keeping them covered until needed.
5. Remove any necessary access covers.
6. Disconnect electrical leads from the RH and LH cutting head drive motors. Tag these leads for identification in re-assembly. Pull them rearward off the support frame and lay them on the machine chassis.
7. Disconnect water lines going to the cutting head Tag them and lay them on the chassis.
8. Disconnect lubrication and hydraulic lines going to the cutting head, and all lubrication lines to the main pivot pins and hydraulic cylinder pins. Tag them and set on the machine chassis.
NOTICE
Cables, water and hydraulic lines to the gathering head do not need to be disconnected.
9. Provide support under the rear of the cutting head support frame.
10. Relieve pressure in each cutting head raise cylinder circuit.
11. Remove the two 3/4” flat head cap screws and keeper plates from the upper cylinder pins on each side (see Figures 2-2 11 and 22.12).
12. Remove the upper cutting head cylinder pin from both sides of the cutting head frame.
13. Lower each raise cylinder so that it rests on the gathering head frame.
14. Remove the two 5/8” nylok socket head cap screws from the retaining keys on the RH and LH main pivot pins (see Figures 2-2.9 and 2-2.10).
15. Remove the retainer keys.
Ensure that the cutting head support frame is well-blocked at both main pivot points. Failure to comply could result in serious injury or death.
16. On either side of the miner, force the main pivot pin inward from the outboard side, using the two tapped jack screw holes if necessary.
Should the pivot pin be difficult to remove, verify the support frame is properly blocked and weight is removed from the pivot area.
Pivot Retaining 5/8” Nylok
installation of cutting head assembly
1. For each side of the miner, inspect the bushings to the following:
F Main frame pivot (inner and outer)
F Cutting head pivot
F Raise cylinder lower rod end
F Raise cylinder lower clevis
2. Be sure that the bushings and eyes are free of dents, scratches, and peenings.
Figure 2-2-12 Cutting Head Pivot Pin Arrangement
Figure 2-2.12 Cutting Head Pivot Pin Arrangement
3. Be sure that the bushing ends are not mushroomed over. If necessary, replace the bushing.
4.
5. Before attempting to install any pin, make sure that it and its bushings are well-coated with grease to aid assembly.
All bushings are interference fit. If a new one is to be installed, it must be frozen and shrunk before installation.
5. Be sure that the pivot bushing is in place on each side of the support frame. Now position the support frame to align with the pivot points to the main frame.
6. On one side of the machine, with the grease connection at the top, install the cutting head pivot pin into the main frame and the cutting head frame pivot bushings from the inboard side out.
7. Repeat Step 3 to the other side of the miner.
8. Secure each pivot by installing the pivot pin retainer with two 5/8” cap screws with LOCTITE No. 242 on the threads. Tighten them to proper torque.
9. Secure each keeper plate/bracket with four 3/4” cap screws with Loctite No 242 on the threads, tightened to proper torque.
10. Align the cutting head frame to insert each cylinder pin through the frame clevis and the end of the cylinder.
11. Install each pin keeper plate using the two cap screws with lock washers, tightened to proper torque.
12. Connect water lines and motor leads to the head. Also connect all lubrication and hydraulic lines to the cutting head and any to the pivot pins.
13. Grease the support frame pivots and the cylinder pins before operating.
Failure to grease pivot points and cylinder pins can cause damage to these parts during subsequent operation.
14. Remove all blocking, and clean all rags, cardboard, extra parts, and tools from the machine area.
15. Check the oil level in both the RH and LH cutting head final drive gear cases.
16. Check the oil level in both cutting head input gear cases.
Be sure all personnel are clear of the miner prior to conducting the following checks.
17. Restore power to miner. Check the hydraulic raise and lower functions for smooth operation and check electric motor phasing.
GENERAL DESCRIPTION
The gathering head assembly is shown in Figure 2-3.1 The two drive motors are shown; each is connected to an input gear case through a torque shaft.
Figure 2-3.1 Gathering Head Assembly
This torque shaft is easily replaced and provides protection to the drive train from severe shock loadings which might occur during loading and conveying
Each input gear case drives a gathering head gear case, or “pot”, which turns a 3-blade centrifugal loading arm (CLA). The RH and LH pots are connected to a common foot shaft with a sprocket which drives the conveyor chain.
The gathering head is raised or lowered by two hydraulic raise cylinders
When performing maintenance on the gathering head, especially when removing the gathering head, lowering the gathering head to the mine bottom will not relieve pressure in the raise / float circuit. This must be accomplished by opening the manuals bleed valve located on the right hand side of the miner.
The foot shaft will differ slightly with machine model depending on what conveyor chain is specified All foot shafts have the same basic components and can be removed and replaced according to the following procedure.
Switch all machine circuits to “OFF”. Verify that all power is disconnect and locket-out. Failure to comply could result in serious injury or death.
1. Refer to Figures 2-3 2 and 2-3.3.
2. Disconnect the conveyor chain (see Conveyor section).
3. Disassemble the foot shaft by removing the four (4) ½” socket head cap screws on each clamp ring, and removing the clamp rings. Slide both adapter shafts toward the machine center against the sprocket shaft. This will free the sprocket shaft and adapter shafts from the protruding shafts of the pot pinion gears, and the sprocket shaft can be removed.
Figure 2-3.2 Foot Shaft Assembly
Lube Fitting
Sprocket Shaft ½” Socket Head Screw (4 per side) Clamp Ring
Seal Carrier
Adapter Shaft Pot Output Pinion
5. Remove the eight (8) 1” socket head cap screws from the CLA retainer plate, and remove the retainer plate Two 1” diameter puller holes, protected by cup-point set screws, are provided in the retainer plate to assist with its removal.
6. From the center of each CLA, remove the three (3) ¾” socket head cap screws, the retainer plate and the adapter ring. The CLA is now free to come off Three ¾” puller holes, protected by cup-point set screws, are provided to aid removal.
removal of the input gear case, pot and motor (right hand or left hand) NOTICE
On the CLA assembly, there are three (3) 2” dowel pins, which secure and position the CLA to the pot disc (see figure 2-3-3)
1. Remove the 5/8” hex head cap screws (a total of eleven per side) securing the 3 pot covers on the corner of the pot (see Figure 23.1).
There are two different lengths of these screws, 2-1/4” (quantity-6) and 4” (quantity-5). They should be tagged for replacement in their correct location during assembly. Refer to the spare parts book for further details.
Figure 2-3.3 Gathering Head CLA Assembly
2” Dowel RH Pot
Pot
¾” Socket Head Cap
Puller Holes
Socket Head Cap Retainer Plate
Input Gear Case
x 2-1/2”
Head Cap
(9 per
x 20” Motor
x 20” Motor
2. Remove the top cover over the input gear case. First, remove the two 5/8” hex head cap screws which secure the top cover to its input gear case. Then remove a total of sixteen (16) 5/8” socket head cap screws from the edge of the top cover.
There are different lengths of these screws, some with washers and some without. They should be tagged, as removed, for replacement in their correct locations during re-assembly.
Figure 2-3.4 Motor, Input Case & Pot Installation
Foot Shaft Cover Pot Gear Wedge
7/8”
Hex
Screw
3. Remove the foot shaft cover by removing the two ¾” socket head cap screws securing the cover (see Figure 2-3 4).
4. Remove the motor access cover on the side of the gathering head frame (see Figure 2-3.1).
5. Disconnect the electrical power cable and water lines from the motor.
6. Remove the bearing cap cover from the exposed end of the motor (See Figure 2-3 5).
7. Remove the snap ring and plug from the end of the motor, exposing the torque shaft.
8. Remove the torque shaft.
Securely block the motor in position before removing the motor attachment bolts. Failure to comply could result in serious injury or death.
9. Remove the eight (8) motor bolts on the motor (see Figure 2-3 4). Carefully back the motor out of its pilot hole engagement and move away from the gathering head.
Drive
Figure 2-3.5 Motor/Gear Case Attachment
Plug Snap
Bearing Cap
Torq
Input Gear
RH Pot Case 1” x 2-1/2” Socket
Dowel 1” x 2-1/2” Hex
VIEW A-A
IMPORTANT NOTICE
Securely block the input gear case in position prior to removing the connecting screws to the pot. Failure to securely block the input gear case could result in the gear case falling when the bolts are removed.
The input gear case and the pot case should be removed as a unit. At this stage, only the pot case is attached to the gathering head frame.
10. Disconnect any oil fill lines or pipes connected to the pot.
11. Fit a lifting device securely to the top surface of the pot and input gear case.
12. Loosen the pot case attachment to the frame by removing the nine (9) 7/8” hex head cap screws from the four corners of the pot (see Figure 2-3.4). Removing these screws will also remove the four wedge blocks which secure the pot in position.
13. Lift the pot and input case unit from the gathering head frame.
14. The input gear case may now be separated from the pot case by removing the eight (8) 1” socket head cap screws and two (2) 1” hex head cap screws holding the input gear case to the pot case (see Figure 2-3 5).
15. Back the input gear case away from the pilot bore in the pot case and move it away from the gathering head.
re-assembly of gathering components
removal of the gathering head components
IMPORTANT WARNING
All components should be reassembled into the gathering head frame in the reverse order of the above procedure.
1. Place the machine in a position where both sides in front of the crawlers are accessible.
2. Lower gathering head until the dozer blade rests on the mine floor.
3. Raise the cutting head frame and block it securely.
Lowering the gathering head to the mine bottom (float command) will not relieve pressure in the raise / float circuit. This must be accomplished by opening the manual bleed valve located on the right hand side of the miner.
Failure to properly block the cutting head in its raised position could result in serious injury or death. Verify that all power has been disconnected and locked-out. Failure to comply could result in serious injury or death.
4. Clean off an area of the miner where parts can be set. Place clean rags or cardboard on this area, and keep dirt off the parts. Cover them if necessary.
5. Disconnect the electrical leads from the gathering head/conveyor drive motor. Tag them for ease in re-assembly.
6. Disconnect all water and lubrication lines going to the gathering head conveyor drive motor and the gathering head gear cases.
The electrical wiring and water lines going to the cutting head do not have to be disconnected.
7. Disconnect the conveyor chain (See Section 2-4, CONVEYOR CHAIN REMOVAL). In this case, the chain need not be completely removed from the miner. After disconnecting the chain at the foot shaft, the top strand must be pulled back clear of the gathering head conveyor section The bottom of the chain can be left where it is.
8. Support the gathering head frame with separate blocking from that used for the cutting head frame.
The gathering head frame must be supported on the mine bottom, and at the rear of the frame as close to the pivot a possible to prevent falling when the pivot pins are removed.
9. Support the rod end of the gathering head raise cylinders.
The gathering head raise cylinders do not need removed from the frame. If they are to remain in place, rotate them away from the gathering head and securely wire or support them on the main frame.
10. Remove the spiral pins from the upper cylinder pins and remove the pins (See Figure 2-3 6).
Cylinder
Cylinder
Cylinder Pin Main frame
Spiral
Gathering Head Frame Bushing
Cylinder
Gathering Head Frame Bushing
Lube Lube Fitting Upper Cylinder
Cylinder Pin
Gathering Head
Cylinder
Lower Cylinder Pin Keeper
Figure 2-3.6 Gathering Head Installation Details
11. Remove the six 3/4” cap screws holding the pivot pin retainer (See Figure 2-3.7) and remove the retainer.
12. Force the gathering head hinge pin out from the outboard side going in. If the pin does not come out, check to see that there is adequate, but not forcing, support under the rear of the gathering head
Do not attempt to start the cutting head.
The miner can now be backed slowly and carefully away from the gathering head.
13. Engage the cutting head lockout switch located on the display box. This will lock out power to the cutting head while power is applied to the miner for tramming.
14. Apply power to the miner.
Prior to moving the miner, be certain the lower section of the conveyor chain is free of the foot shaft so that, when the miner is trammed backward, the chain will pull free of the return deck of the gathering head.
15. Raise the cutting head off its blocking so that it is free to move rearward.
The miner can now be backed slowly and carefully away from the gathering head.
16. Slowly tram the miner away from the gathering head until the gathering head is clear and the conveyor chain is free.
17. Lower the cutting head to the floor.
Figure 2-3.7 Gathering Head Pivot Details
Main Frame
Gathering Head
Pivot Pin
Main Frame
¾” x 2” Hex Head Cap
Gathering Head
Gathering Head
Main Frame
installation of the gathering head
1. Apply power to the miner and raise the cutting head so that it will be clear of the gathering head.
When the gathering head was removed, the lower length of the conveyor chain was pulled free of the gathering head. This end of the conveyor chain must be brought forward when the miner is trammed to the gathering head.
2. Tram the miner to the gathering head frame. Using a puller cable or wire, feed the lower end of the conveyor chain through the gathering head return deck and up to the foot shaft.
3. By tramming the miner, position it to align the pivots in the main frame with those of the gathering head.
Because the miner is tramming, the cutting head cannot be blocked up. Make certain that all personnel stay clear of the cutting head until the miner is in position to mate with the gathering head.
4. When the gathering head pivots are aligned, block the cutting head securely in its raised position.
Failure to securely block the cutting head could result in serious injury or loss of life.
Switch all machine circuit breakers to “off” and disconnect and lock out the machine trailing cable at the power center. Failure to comply with this warning could result in serious injury or death.
5. Before attempting to install the pivot pins, make sure that the pins and their bushings are well-coated with grease to aid assembly.
6. Install the RH and LH gathering head pivot pins. Be sure that the pivot bores in the gathering head frame and the main frame are aligned, and that you do not damage the end of the pivot bushing when starting the pin in.
7. Force each pivot pin in from the center, until they are flush with the main frame pivot bushing.
8. Insert the pivot pin retainer between the two pivot pins.
9. Install the six 3/4” cap screws to secure the retainer. Tighten the cap screws to the proper torque.
10. Align the gathering head frame clevises and both raise cylinders to accept the upper cylinder pins. Install the upper cylinder pins through the gathering head frame clevis and the eye of each cylinder.
11. Install spiral pins in the upper cylinder pins to secure them in place.
12. Lubricate the cylinder pins and pivot pins.
13. Reassemble the conveyor chain.
14. Connect the water lines and lubrication lines going to the gathering head motors.
15. Connect the electrical leads to the motors.
16. Remove all gathering head and cutting head blocking. 17. Clear all rags, cardboard, extra parts, and tools from the machine area.
18. Check oil levels in the gathering head pot cases and the gathering head input gear case.
Be sure all personnel are clear of the miner before conducting the following checks.
19. Apply power to the machine and check for smooth gathering head raise and lower operation and check for proper motor phasing.
The conveyor assembly is shown in Figure 2-4.1. The conveyor can be raised and lowered by hydraulic cylinders to facilitate loading The assembly is attached to the main frame at a pair of raise pivots, and can be elevated by two hydraulic raise cylinders. The discharge section of the conveyor has a double-clevis swing pivot and can be swung 45o left or right to aid in maneuvering around intersections or loading the haulage vehicle. Some 30M miners have twin hydraulic swing cylinders, while others have only one swing cylinder.
1. Place the miner in a place under supported roof and where the top of the conveyor and both ends of the machine can be reached. Allow sufficient room at the back of the miner to pull the chain off the conveyor.
2. Raise the cutting head, and block it securely.
Failure to securely block the cutting head could result in serious injury or loss of life.
3. Swing the discharge conveyor to align it straight with the intermediate conveyor, and lower the conveyor to its lowest position.
Switch all machine circuit breakers to “off” and disconnect and lock out the machine trailing cable at the power center. Failure to comply with this warning could result in serious injury or death.
4. Open the proper needle valve on the RH side of the machine which will release hydraulic oil volume from the constant tension take-up cylinders on the discharge conveyor. This will relax tension on the conveyor chain.
To avoid injury from flying chips of hardened steel, safety glasses (or a face shield) for eye protection and gloves should be used.
5. Use a pry bar to lift the chain off the conveyor deck several times to relieve tension in the chain.
6. Remove the two retaining pins from the closest connecting pin to the foot shaft, and remove the connecting pin (See Figure 2-4.2).
7. Pull the top half of the conveyor chain off the back of the machine.
To facilitate re-installation of the same chain or a new chain, attach a long puller cable to the forward end of the chain. When the conveyor chain is removed, this puller chain will travel with the forward end through the return deck to the back end of the conveyor, and will then be available to pull the new conveyor chain through the return deck and forward to the foot shaft. Leave this cable in place on the miner for use in installing the new chain.
8. Removing the gathering head foot shaft is not necessary, but be sure that the chain is disengaged from the foot shaft sprocket. Pull the other half of the conveyor chain rearward and out of the conveyor return deck.
Figure 2-4.2 Conveyor Chain Flight
conveyor chain installation
1. Ensure that the cutting head remains securely blocked.
Inadequate blocking of the cutting head can cause serious injury or loss of life.
2. Lay the new chain, uncoiled and upside down, behind the conveyor, with the nearest end near the tail roller.
The conveyor chain does not have a right or wrong running direction, only a correct up and down side. The flat side of the flight chains must run on the deck.
3. Connect the pulling cable (see previous section, Steps 8 and 9) to the nearest end of the conveyor chain.
4. Pull the conveyor chain under the tail roller and through the return deck, stopping when the chain reaches the foot shaft.
5. Pull the conveyor chain up over the foot shaft sprocket and lay it in gathering pan.
6. Disconnect the pulling cable from the front end of the chain and run it along the top conveyor deck to the back of the miner.
7. Connect the pulling cable to the other end of the conveyor chain on the mine floor. Pull it over tail roller, through the conveyor deck, and up to the other end of the chain on the gathering pan.
8. Connect the chain using a connecting pin and two retaining pins (one in each end of the connecting pin). Bend the retaining pins opposite the direction of conveyor chain travel.
9. Close the bleed valve in the conveyor chain take-up circuit so that the take-up circuit can be pressurized when power is re-applied.
10. Clear the area of all tools.
Be sure all personnel are clear of the miner before conducting the following checks. Do not stand behind the conveyor when the chain is running.
11. Apply power to the miner, raise the cutting head, and remove the blocking.
12. Swing the discharge conveyor full right and left to ensure that the chain is clear.
13. Turn on the CLA motors to run the conveyor chain. Elevate the conveyor full up and down, and swing the discharge conveyor full right and left and check that the chain is running smoothly
14. Observe the chain as it comes off the foot shaft and ensure that there is no excessive slack, as indicated in Figure 2-4 3 and that the chain does not contact the CLA arms.
15. If such excess is observed, adjust the chain tension by adjusting the setting of the pressure-reducing relief valve in the conveyor take-up circuit located on the RH side of the miner.
16. If the relief valve can no longer be adjusted, a chain link segment must be removed to shorten the chain.
1. Using miner hydraulic power, raise and block the conveyor in an elevated position so as to provide access to the upper conveyor raise cylinder pins.
Inadequate blocking and securing of the conveyor can result in serious injury or loss of life.
Switch all machine circuits to “OFF”. Verify that all power is disconnect and locket-out. Failure to comply could result in serious injury or death.
2. Maintaining the blocking at the rear of the conveyor, attach lifting devices to both the intermediate and discharge conveyor sections and tension them without raising the conveyor.
3. Relieve the pressure in the conveyor chain take-up circuit (see CONVEYOR CHAIN REMOVAL).
4. Use a pry bar to lift the chain off the conveyor deck several times to relieve tension in the chain.
5. Disconnect the conveyor chain and remove it from the machine.
6. Support the rod end of each conveyor raise cylinder. Remove the cotter pins from each upper cylinder pin and remove the cylinder pins (see Figure 2-4.4).
Figure 2-4.3 Illustration of Excessive Conveyor
Excessive
7. Appropriately block or secure the conveyor assembly laterally to prevent it from swinging when the hydraulic lines are removed from the swing cylinders. On many miners, this drift may not occur, depending on the side slope of the mine floor and the amount of wear at the pivot area. But the danger still exists. Obviously, the greater the slope of the mine floor, the higher the tendency of the conveyor to drift. One recommended method of blocking is to use crib blocks in the conveyor deck, or weld a bar across the pivot. In any case, ensure that it will not swing either way.
Inadequate blocking and securing of the discharge conveyor can result in serious injury or loss of life
10. Release any pressure that might exist between the lateral sway guides and the guide discs (Figure 2-4.4) by backing out the 1” square head set screw on each side. DANGER
8. Remove the hydraulic lines going to the swing cylinder. Cap off the hose ends and cylinder ports.
9. Disconnect lube lines going to the RH and LH pivot pins.
Figure 2-4.4 Conveyor Installation Details
Bushing Upper Cotter
Conveyor
1” Square
1” Hex Jam
¾” Hex Head Cap Guide Guide Main Frame
Lower Cylinder
1” Socket Head Cap Screw
Cylinder Pin
Lateral Sway
Lateral Sway Guide
Guide Plate
Conveyor Raise
Pin Cap
Pivot retainer
Conveyor
Lateral Sway Guide
Guide Plate
Cylinder Pin Cap
Pivot retainer
Conveyor
Conveyor Raise Cylinder
2-4.5 Conveyor Installation Details
11. Remove the six ¾” x 2” cap screws from the conveyor pivot pin retainer (see Figures 2-4.5 and 2-4.6) and remove the pivot pin retainer.
12. Push the conveyor pivot pins toward the center until they are free.
Figure 2-4.5 Conveyor Installation Details
Cylinder
¾” Socket Head Cap Screw
Cylinder
¾” x 2” Hex Head Cap Screws
Main Frame
Figure
¾” Socket Head Cap Screw
¾” x 2” Hex Head Cap Screws
Main Frame
If the pivot pin is tight, be sure the lifting device is not binding the pivot. If it is not, then use the 1” tapped puller hole to aid removal of each pin
13. With the lifting device, slowly maneuver the conveyor assembly away from the machine.
1. Attach a lifting device to the conveyor assembly and slowly maneuver onto the machine.
2. With the conveyor pivot in position, grease the conveyor pivot pins to facilitate their installation and drive them into the pivot bores.
3. Install the pivot pin retainer with six ¾” x 2” hex head cap screws. Uncap and reconnect the lube lines in each pivot pin.
4. Using the lifting device, pivot the conveyor into an elevated position and securely block the conveyor.
Inadequate blocking and securing the conveyor can result in serious injury or loss of life.
5. Uncap and reinstall the hydraulic lines going to the swing cylinders.
6. Attach the conveyor raise cylinders to the clevises on the underside of the conveyor by installing the upper conveyor raise cylinder pins.
7. Reconnect the conveyor chain (see CONVEYOR CHAIN INSTALLATION).
8. Reapply nominal pressure of the guide discs to the lateral sway guides.
9. Clear all tools, parts and debris from the area.
10. Remove the lifting device.
Be sure all conveyor components are installed correctly, and that the conveyor chain is properly engaged to the foot shaft sprocket, before starting the miner.
11. Apply power to the machine. Turn on the CLA motors to run the conveyor chain. Elevate the conveyor full up and down, and swing the discharge conveyor full right and left and check that the chain is running smoothly
1. Tram the machine to a place where the top and bottom of the conveyor can be reached, and there is enough room at the back for the removal of the conveyor chain and the discharge conveyor.
2. Raise the conveyor far enough to provide adequate work space under the swing pivot. Securely block the intermediate conveyor section so the swing pivot remains accessible.
You will be working beneath the conveyor! Inadequate blockage can result in serious injury or loss of life.
3. Align the discharge conveyor straight with the centerline of the intermediate conveyor.
Switch all machine circuit breakers to “off” and disconnect and lock out the machine trailing cable at the power center. Failure to comply with this warning could result in serious injury or death.
4. Relieve the pressure in the conveyor chain take-up circuit (see CONVEYOR CHAIN REMOVAL).
5. Attach a lifting device to the discharge conveyor and tension it to support the weight.
6. Use a pry bar to lift the chain off the conveyor deck several times to relieve tension in the chain.
7. Disconnect the conveyor chain at a connecting pin close to the end of the discharge conveyor.
8. Disconnect the hydraulic lines from the discharge conveyor swing cylinders. Cap the lines and cylinder ports.
9. Remove the forward swing cylinder pin at the intermediate conveyor section.
10. Remove the ½” x 1 ½” carriage bolts and ½” heavy hex elastic stop nuts that attach flexible sideboards to each side of the intermediate conveyor (see Figure 2-4.7).
11. Slide each sideboard from its sideboard guide on the discharge conveyor and remove it.
If the sideboards are not free to slide, remove the four ¾” hex head cap screws (one 1 ½” long, three 2” long) and their ¾” spring lock washers from each flexible sideboard guide assembly and remove them from the top of discharge conveyor on each side.
12. Remove the six ¾” x 2 ½” Nylok socket head cap screws from the top pivot pin (see Figure 2-4.7) and remove the top pivot pin. Two ¾” tapped puller holes, protected by set screws and located on top and bottom of each pivot pin, are provided to aid in removing the pivot pin. As seen in Figure 2-4.8, a pivot retainer will remain in the top pivot bore. If not already released, this retainer can be tapped loose and removed from the area between the top and bottom conveyor decks.
¾” x 2 ½” Nylok Socket Discharge ¾” Pivot
Bushing
Adjustment
1” x 4 ½” Socket Head Cap Screw and Washer
½” Anti-Rotation Dowel
Intermediate Pivot
2-
13. Repeat this procedure for the bottom pivot pin and pivot retainer If the bottom pin is not free to come off, check the tension on the lifting device to help free the pin. Remove the bottom pivot retainer. 14. Slowly and carefully maneuver the discharge conveyor away from the intermediate conveyor section.
1. With the intermediate conveyor securely blocked, attach a lifting device to the discharge conveyor and slowly lift and maneuver the conveyor into the intermediate conveyor section.
Switch all machine circuit breakers to “off” and disconnect and lock out the machine trailing cable at the power center. Failure to comply with this warning could result in serious injury or death.
Failure to securely block the intermediate conveyor or securely attach the lifting device to the discharge conveyor properly can result in serious injury of loss of life.
Figure
2. Check the top and bottom pivot pins and bushings for wear or damage, and replace them as necessary Lubricate all pins and bushings with grease prior to installation.
3. Install the top pivot pin and pivot retainer, using six ¾” x 2 ½” Nylok socket head cap screws (see Figure 2-4.8). Note that the pivot pin has an anti-rotation dowel which must be positioned in the slot in the top conveyor deck.
4. Similarly, install the bottom pivot pin and pivot retainer, using six ¾” x 2 ½” Nylok socket head cap screws. The bottom pivot pin also has an anti-rotation dowel which must be positioned in the slot in the top conveyor deck.
5. Adjustment shims are provided (see Figure 2-4 8) in the event that the decks of the intermediate and discharge conveyors are misaligned due to wear or damage to the discharge conveyor.
6. Using the lifting device, swing the discharge conveyor fully to the left and right to make sure that it does not bind.
7. Grease the four pivot surface lube points (two on each side) until grease is visible on the mating sections of the conveyor. This will lubricate the pivot pins and bushings as well as the large plates which slide on each other.
8. Using the lifting device, position the conveyor to align the swing cylinder clevises with both swing cylinder eyes. Lubricate the cylinder pins with grease and insert them, securing each with a new ¼” cotter pin.
9. Uncap and reconnect the hydraulic lines to the cylinders.
10. With the discharge conveyor straight, reconnect the conveyor chain (see CONVEYOR CHAIN INSTALLATION).
11. Install a flexible sideboard on each side of the conveyor, using three ½” x 1 ½” carriage bolts with heavy hex elastic stop nuts on each sideboard.
12. Install the two flexible sideboard guides on each side of the discharge conveyor using two ¾” x 1 ½” long hex head cap screws in the rear holes and six ¾” x 2” long hex head cap screws in the remaining holes.
13. Clear all tools, parts and debris from the area.
14. Apply power to the machine.
15. Raise the conveyor and remove the blocking.
16. Operate the conveyor raise, lower, swing right and swing left and check for smooth operation.
1. Place the machine to where the take-up roller can be comfortably reached and enough room is available for removal.
2. Align the discharge conveyor straight with the centerline of the intermediate conveyor.
3. Lower the conveyor to a comfortable work height, and support it securely.
Failure to securely block the conveyor can result in serious injury or loss of life.
WARNING
Switch all machine circuit breakers to “off” and disconnect and lock out the machine trailing cable at the power center. Failure to comply with this warning could result in serious injury or death.
4. Relieve the pressure in the conveyor chain take-up circuit as described in the CONVEYOR CHAIN REMOVAL section.
5. Use a pry bar to lift the chain off the conveyor deck several times to relieve tension in the chain.
6. Break the conveyor chain near the tail roller and clear the chain from the roller.
7. Remove the cover over each side of the tail roller by removing four 5/8” x 1-1/4” socket head cap screws from each cover (see Figure 2-4.9).
8. The tail roller may now be removed from the take-up slide.
If removal of a take-up cylinder is required, do steps 1 through 8 above and continue as follows:
1. Remove the cotter pin from the rod end of each take-up cylinder.
2. Remove the two ¾” x 4” socket head cap screws and the cylinder retainer cap from the forward end of each take-up cylinder.
3. Pull the cylinder forward until it clears the take-up shaft and spring
4. Additionally, the take-up shaft on each side can be removed by knocking out the 3/8” diameter roll pin which secures it to the takeup slide.
Tail
¾” x 4” Socket Head Cap Screw
Take-Up Spring & Cylinder Assembly (both
Surface Lube
Cylinder Retainer Bushing Lube
traction system
Cotter
5/8” x 1-1/4” Socket Head Cap Screw Tail Roller
½” x 1-1/2” Socket Head Cap Screw
Roll Pin
Take-Up
Ca Shaf
Swing Cylinder
Section A-
The RH and LH traction drive systems each consist of a D.C. tram drive motor, a tram drive gear case, a crawler chain, a chain takeup roller and a grease-adjusted shim-lock or a constant-tension hydraulic chain take-up device. These components are mounted in a crawler frame which is an integral part of the main frame weldment. See Figures 2-5.1 and 2-5.2.
Figure 2-4.9 Conveyor Tail Roller
2-5.2
Figure 2-5.1 shows the tram transformer box mounted in the RH crawler frame. This transformer steps down 995-VAC machine power to 380-VAC which goes to the traction control system. The LH crawler frame, shown in Figure 2-5 2, contains the pump drive assembly which provides hydraulic pressure for various machine functions.
Some 30M miners have the tram transformer and pump drive assembly in the LH and RH crawler frames, respectively
RH RH Tram
Main Crawler
Crawler
Constant Take-up
Tram Transformer
Figure 2-5.1 RH Traction System
Figure
LH Traction System
Pump Drive
Operating the tram control levers causes DC voltage to be supplied to the tram drive motors. The drive motor on each side of the miner powers an input planetary (see Figure 2-5.3) which is connected to a set of transfer gears on the inboard side of the motor. The transfer gears send power through the tram drive shaft into an output (crawler) planetary which drives the large 7T crawler chain drive sprocket and the crawler chain.
1. Place the miner to where the side of the machine being worked on has enough room available for removal of the crawler drive gear case and motor assembly.
The crawler drive gear case and motor can be removed as one unit.
2. Lower the conveyor to its down position, and lower the gathering head to the mine bottom.
3. Lower the stabilizer shoe to its full travel, raising the rear of the miner off the bottom.
Figure 2-5.3 Tram Gear Case
Tram Drive
Duo Cone
Duo Cone Gear
Tram Drive
removal of tram drive gear case
4. Securely block the rear of the miner.
5. Lower the cutting head all the way to raise the miner fully off the mine bottom. Be sure that the crawler frame is level by adjusting either the cutting head or stabilizer shoe.
If the crawler frame is not level, re-installation of the gear case assembly will be more difficult.
6. Securely block the miner using crib blocks under both crawler chains but avoiding the area near the tram gear case to be removed
Failure to properly block the miner can result in serious injury or loss of life.
Switch all machine circuit breakers “OFF”. Verify that all powers has been disconnected and locked out. Failure to comply could result in serious injury or death.
7. Remove or disconnect all assemblies mounted in the area of the tram gear case. This will include such items as center rub rails with the tram motor covers attached, the trailing cable connection box, lighting fixtures, water sprays and any other items which might get in the way of removal of the gear case assembly.
8. Remove the four 1” hex head cap screws from the top tram cover (see Figure 2-5 4). This cover will remain, but the screws must be removed to allow removal of the tram case.
9. Separate the crawler chain at a convenient point near the tram gear case (see CRAWLER CHAIN REMOVAL) and move the chain clear of the drive sprocket.
10. Disconnect all water and lubrication lines from the gear case. Tag them for later identification. The main gear case and final planetary gear case may be drained if desired, but it is not necessary.
11. Disconnect the electrical leads from the motor and tag them for later identification.
12. Remove the four 1” set screws inserted in the jacking holes on each side of the gear case (See Figure 2-5.5).
13. Remove the four ¾” x 4” socket head cap screws and wedge blocks.
14. Clean off the side of the gear case. Now remove the nine 1” cap screws out of the mounting plate (four on the rear/sprocket side, and five on the forward/motor side).
Figure 2-5.4 Tram Gear Case Covers Top Tram
Tram Motor Cover
Center Rub Rail
Tram Motor Cover
1” x 4-1/4” Hex
1” x 2” Hex
Note: RH side shown, LH
15. Insert a 1” x 6” cap screw into each of the four jacking holes just uncovered. Using these cap screws, slowly jack the main case loose from the frame.
16. Position a loading device, such as a scoop, to the bottom edge of the main case. Connect a couple of adequate chains between the scoop and the back of the mounting plate
17. Continue jacking the main case out of the crawler frame along its keyways onto the loading device. If necessary, use longer 1” cap screws.
Over-stressing the chains could cause failure resulting in serious injury.
18. Slowly maneuver the gear case and motor assembly clear of the machine and onto the loading device.
19. Thoroughly clean out the keyways so that they are ready for later re-installation. Cover the crawler compartment to keep out dirt and debris.
Figure 2-5 5
1” Threaded
¾” x 4” Socket Head
1” x 6” Socket Head Cap
Wedge
1” x 3” Socket Head Cap
1” x 4” Socket Head Cap
1” x 3 ½” Socket
installation of the tram drive gear case assembly
1. Ensure that the crawler frame mounting area is cleared of dirt and debris. Be especially sure that the keyways, and the bore in the inner face of the main frame, are clean Apply a light coating of MOLYKOTE G-N paste to aid re-installation.
2. Coat the mounting keys on the gear case with MOLYKOTE G-N paste. Also coat the bearing carrier on the inboard end of the main gear case (See Figure 2-5.6) with MOLYKOTE G-N paste. This bearing carrier serves as a plug to fit into the bore in the main frame.
NOTICE
CAUTION
The crawler drive gear case and electric motor can be installed as one unit.
Mounting Key
Mounting Key
Bearing Carrier (Plug)
Mounting Key
Mounting Key
3. Slowly maneuver the gear case and motor into position next to the machine aligning the keys on the gear case with the keyways/slots on the crawler frame.
If the machine and gear case assembly are not both level and aligned with each other, installing the assembly into the frame will be more difficult.
Figure 2-5.6 Mounting Keys
removal of a tram drive motor DANGER
4. With the runners aligned, slowly push assembly into the crawler frame, allowing the keys on the gear case to engage the keyways in the main frame. Be sure that the cap screw mounting holes line up. Also be sure that the mounting surfaces for the mounting plate are free of contaminants.
5. Install the eight 1” x 6” socket head cap screws and the single 1” x 3 ½” socket head cap screw, and washers, at the side of the assembly (see Figure 2-5.5), partially tightening each one in turn, and then repeating. If necessary, first use 1”-longer cap screws to start the assembly sliding into the frame before installing the regular 6” cap screws.
6. Pre-tighten each of the nine 1” cap screws to 200 ft-lb. Be absolutely sure that the mounting plate is in against the main frame all the way.
7. Torque each of the cap screws sequentially to 1,010 ft-lb.
8. Install the four wedge blocks with the four ¾” x 4” socket head cap screws and apply torque to 400 ft-lb.
9. Remove the scoop device and lifting tool from the area.
10. Install the four 1” set screws into the jacking holes on each side of the gear case, and tighten them to 1,010 ft-lb.
11. Reconnect all water and lubrication lines to the gear case. Make sure the fittings are tight.
12. Reconnect the electrical leads to the motor. Make sure the leads are connected correctly.
13. Refill or top off the oil in the gear case.
14. Reconnect the crawler chain (see CRAWLER CHAIN INSTALLATION).
15. Switch all circuit breakers to the ON position.
16. Apply power to the machine. Operate the tram lever on the side which was re-installed and check for smooth and proper operation.
17. Trip all circuit breakers to the OFF position.
18. Reconnect or re-install all assemblies mounted in the area of the tram gear case.
19. Clear the area of all tools, parts or other material.
20. Remove all blocks from the miner.
21. Switch all circuit breakers to the ON position.
22. Apply power to the miner and raise the stabilizer shoe and cutting head to lower the miner to the mine bottom.
1. Place the miner to where the side of the machine being worked on has enough room available for removal of the crawler drive motor.
2. Lower the conveyor to its down position, and lower the gathering head to the mine bottom.
3. Lower the stabilizer shoe to its full travel, raising the rear of the miner off the bottom.
4. Lower the cutting head all the way to raise the miner fully off the mine bottom. Be sure that the crawler frame is level by adjusting either the cutting head or stabilizer shoe.
5. Securely block the miner chassis.
Failure to properly block the miner chassis can result in serious injury or loss of life.
WARNING
NOTICE
Switch all machine circuit breakers to “off” and disconnect and lock out the machine trailing cable at the power center. Failure to comply with this warning could result in serious injury or death.
6. Remove or disconnect all assemblies in the area of the tram gear case and motor, including rub rails, electrical enclosures, lighting fixtures, water sprays, or any other auxiliary components that would impair removal of the motor.
7. Disconnect all wires and hoses going to the motor.
While it is not necessary to drain the final planetary gear case, most of its oil will drain since it shares common oil with the main gear case.
8. Remove the four M10 x 25 hex head cap screws which secure the end cap on the tram motor (see Figure 2-5.7).
9. Remove the snap ring inside the motor shaft and remove the plug, exposing the quill shaft.
10. Remove the quill shaft.
11. Remove the two 1” x 3” and two 1” x 4” socket head cap screws securing the motor to the gear case (see Figure 2-5.5).
12. Place slings around the front flange of the motor, being sure that they will be able to support the weight of the motor.
13. Using slate bars behind the ears/flanges of the motor, slowly separate it from the gear case and edge it out.
14. Pull the motor straight out and onto a loading device (e.g., scoop, shovel, forklift).
15. Discard the O-ring on the rim of the rear bell.
IMPORTANT
installation of a tram drive motor CAUTION NOTICE
Be careful not to damage any of the gland cover protrusions on the motor when removing it from the miner.
1. Clean the motor and the motor cavity thoroughly.
2. Install a new O-ring (lubricated) on the motor mounting flange (rear bell).
3. Put some oil around the bore of the input planetary (in the motor cavity), to help ease installation.
4. Maneuver the motor assembly slowly into the cavity and along its bottom. Go easy. Make sure not to damage any of the gland cover protrusions.
Be careful not to damage the o-ring around the rear bell, or any of the gland cover protrusions.
5. Position the motor further into the cavity, using slate bars to jockey it into the bore of the input planetary inside.
Once the motor pilot starts into the pilot bore, the motor should go in relatively easy.
6. Keep working the motor in until it seats and the flange ears are flush. If the ears are not flush (to within .020”), the motor is not seated properly.
7. Install the motor quill shaft and rotate it until splines of the inner end mesh with the internal splines of the pinion gear in the input planetary assembly (see Figure 2-5.3).
8. Install the plug and snap ring (Figure 2-5.7), and install the motor end cap with the four M10 x 25 hex head cap screws. Tighten to a torque of 50 ft. lb.
9. Install the 1” motor socket head cap screws and washers, and slowly tighten them to proper torque.
10. Refill the tram gear case with oil to the proper level Check the gear oil level using the sight gage on the outer face of the final planetary drive.
11. Reconnect all wires and hoses going to the motor.
12. Turn on power to the miner, and check the tram operation on that side to ensure proper and smooth operation of the tram system.
Switch all machine circuit breakers to “off” and disconnect and lock out the machine trailing cable at the power center. Failure to comply with this warning could result in serious injury or death.
13. Reconnect or re-install all assemblies in the area of the tram gear case that were removed.
14. Clear the area of all tools, parts or other material.
15. Restore power to the miner, and remove all blocking.
tram brake removal (if equipped)
Tram brakes are installed on some 30M miners depending on the particular mining application. The tram brake installation is shown in Figure 2-5.8 It is in the form of an add-on gear case to the top of the tram gear case with a multi-disc wet brake unit installed at the top of the gear train.
This brake unit is a spring-applied hydraulic-release type brake. This procedure will only cover removal of the brake unit itself. The procedure is as follows:
1. Remove all covers and components necessary to gain access to the rear top of the tram gear case as shown in Figure 2-5.8.
2. Disconnect three (3) oil lines attached to the brake unit.
3. Remove the four ½” x 6” hex head cap screws securing the brake unit to the tram brake gear case and remove the brake unit.
It can be seen from figure 2-5.8 that for machines equipped with tram brakes, to remove the tram gear case, it is necessary to remove the top tram cover (disconnecting all components mounted to this cover) to allow the tram gear case to clear the cover.
Tram Brake Gear
Top Tram
Tram Motor
Tram Brake
Tram Brake
½” x 6” Hex head
Section View of Brake Unit
Figure 2-5.8 Tram Brake Installation Details
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crawler chain removal grease take-up option
For 30M miners equipped with a grease-type shim-lock crawler chain take-up (see Figure 2-5 9 for details of this arrangement), the following procedure is for removing a crawler chain:
Grease Input Fitting
End
Mount
Crawler Frame
Take-up Cylinder Shims
2” for Max Cylinder Extension
Position of Shims Go Here
Detail of Grease Take-Up Cylinder
Take-up
x 5½” Hex Head
Section A-A
Position of
1. Place the machine in a position where there is sufficient side room to work and enough space available to pull the chain off.
2. Lower the stabilizer shoe and the cutting head to raise the entire machine so the crawler chain may be removed. Securely block the miner chassis. The machine blocking cannot be in the way of the crawler chain.
Improper blocking of the miner can cause serious injury or death..
3. Raise the gathering head to its maximum up position and securely block it.
4. Lower the cutting head to rest on the gathering head.
5. Lower the conveyor to its down position.
Switch all machine circuit breakers to “off” and disconnect and lock out the machine trailing cable at the power center. Failure to comply with this warning could result in serious injury or death.
Figure 2-5.9 Crawler Chain Grease Take-up Details
NOTICE IMPORTANT
6. Apply grease pressure to the take-up cylinder to free up the locking shims.
7. Remove the ¾” x 5½” hex head cap screw securing the shims to the take-up housing and remove all shims.
The total shim pack on each side includes seven ½” shims, one ¼” shim and two 10-gauge (0.1345”) shims.
8. Bleed off pressure in the grease take-up cylinder by opening the needle valve in the grease line Be sure that the cylinder collapses to relieve tension in the crawler chain.
9. Disconnect the crawler chain assembly at a convenient location near the tram drive gear case.
The end of the chain just forward of where it will be separated should be blocked to minimize its fall when it is disconnected –see figure 2-5.10.
Separation Point
Chain Blocking
Mine Bottom
Figure 2-5.10 Chain Blocking Prior to Separation
Ø Select the crawler link to be disassembled.
Ø Remove the two 3/8” flat head cap screws and Conelok nuts, one on each side of the crawler pad – see Figure 2-5.11
CAUTION
Ø Drive the two crawler pins out of the crawler pad using a ¾” diameter bolt or rod.
Personnel should stay clear of the chain during separation to avoid injury when the chain is disconnected.
10. Unblock the loose length of chain, lower it onto the mine bottom and attach a pull chain or cable to the end of the chain
11. Lay the pull chain to the rear of the miner and attach it to a vehicle or other method of traction.
12. Pull the cable until the crawler chain assembly is tensioned, then slowly pull the crawler chain until it has rotated the tram drive sprocket, gearing and motor and is free to slide off the crawler frame.
13. Pull the remainder of the crawler chain clear of the crawler frame and away from the machine.
On miners equipped with tram brakes, the chain cannot safely be dragged free of the tram drive sprocket without risking damage to the brake and drive system. In this case, the following procedure should be used:
14. Restore power to the miner.
15. If the radio transmitter is used to control the machine, set the tram speed selection to LOW TRAM and, using small tram lever movements, jog the tram control FORWARD while maintaining a light tension on the pull chain until the chain runs clear of the tram drive sprocket. If the pendant is used to control the machine, the TRAM button will automatically provide LOW TRAM speed, and the button can be used to jog the tram drive forward.
16. Complete the removal of the chain as in Step 11 above.
An alternate method for freeing the crawler chain in the presence of a locked tram brake is to use a Port-a Pack to applyhydraulic pressure to the brake to release it – see Section 3 for more details.
1. The miner should be in the same condition as for removing a crawler chain, that is, miner chassis raised and securely blocked, gathering head full up and blocked, cutting head resting on gathering head, and conveyor in its lowest position.
Switch all machine circuit breakers to “off” and disconnect and lock out the machine trailing cable at the power center. Failure to comply with this warning could result in serious injury or death.
Ensure that the grease pressure in the crawler chain take-up cylinder is relieved (crawler chain removal, step 6) and that the cylinder and take-up roller are fully collapsed.
2. Lay the crawler chain on the mine bottom under the crawler frame and extending forward in front of the miner. The grousers should be on the bottom side on the mine bottom.
Be sure grousers are in the correct direction before installing the chain onto the machine. Check the parts book for your 30m miner to verify correct direction.
3. Attach a pull cable to the rear end of the crawler chain.
NOTICE
4. Feed the loose end of the pull cable around the drive sprocket and into the upper crawler chain return deck. Continue feeding the pull cable forward until it is out in the open at the front of the crawler frame and past the take-up roller. Run the cable forward to where it can be attached to a vehicle or other traction device.
Again, if the miner is equipped with tram brakes, the chain must be powered onto the machine by the tram system. Alternatively, the brake must be released by hydraulic pressure so that the chain can be dragged into the machine.
5. Slowly pull the crawler chain into position on the drive sprocket so that the sprocket teeth engage the pockets in the first crawler pad. Continue pulling the chain slowly as it engages the rest of the exposed sprocket teeth and moves forward on the upper crawler chain return deck. Pull the end of the chain clear of the take-up roller until it can drape over the roller.
6. Block the bottom of the chain near the front as shown in Figure 25.12.
7. Remove the pull cable and mate the two ends of the chain using the twin connecting pins and securing them with two 3/8” x 1-1/4” flat head socket head cap screws and Conelok nuts.
8. Install the two 3/8” flat head cap screws and Conelok nuts (one on each side of the pad).
9. Check to see that the needle valve on the grease take-up cylinder has been closed.
Take-up Cylinder Fully Collapsed
10. Pump grease into the take-up cylinder until the proper chain sag is achieved (see Figure 2-5.13).
Figure 2-5.12 Chain Blocking Prior to Connection
Nominal take-up position for new chain = 1” ahead of
Full take-up
Proper sag for new installation is approximately 3”
crawler chain removal – constanttension hydraulic take-up option
In the case of a used or worn chain, if the take-up cylinder has reached its maximum travel and can no longer properly tension the crawler chain, a link must be removed from the chain.
For 30M miners equipped with a hydraulic-type crawler chain take-up, the following procedure is for removing a crawler chain:
1. Place the machine in a position where there is sufficient side room to work and enough space available to pull the chain off.
2. Lower the stabilizer shoe and the cutting head to raise the entire machine so the crawler chain may be removed. Securely block the miner chassis. The machine blocking cannot be in the way of the crawler chain.
Improper blocking of the miner chassis can cause serious injury or loss of life.
3. Raise the gathering head to its maximum up position and securely block it.
4. Lower the cutting head to rest on the gathering head.
Switch all machine circuit breakers to “off” and disconnect and lock out the machine trailing cable at the power center. Failure to comply with this warning could result in serious injury or death.
5. Lower the conveyor to its down position.
6. Bleed off hydraulic oil in the constant-tension take-up cylinder behind the crawler chain idler roller (see Figure 2-5.14). This is done by opening the vent side of the tee-fitting on the back end of the cylinder. Be sure that the cylinder collapses to relieve tension in the crawler chain.
Figure 2-5.13 Proper New Crawler Chain Sag
Ground Line
IMPORTANT
Take-Up
Take-Up
½” x 1” Socket Head Cap Screw (6 total) End
Crawler
Idler
Take-Up
7. Disconnect the crawler chain assembly at a convenient location near the tram drive gear case.
Ø Select the crawler link to be disassembled.
The end of the chain just forward of where it will be separated should be blocked to minimize its fall when it is disconnected – see figure 2-5.10.
Ø Remove the two 3/8” flat head cap screws and Conelok nuts, one on each side of the crawler pad – see Figure 2-5.11
Ø Drive the two crawler pins out of the crawler pad using a ¾” diameter bolt or rod.
Personnel should stay clear of the chain during separation to avoid injury when the chain is disconnected.
8. Unblock the loose length of chain, lower it onto the mine bottom and attach a pull chain or cable to the end of the chain
9. Lay the pull chain to the rear of the miner and attach it to a vehicle or other method of traction.
10. Pull the cable until the crawler chain assembly is tensioned, then slowly pull the crawler chain until it has rotated the tram drive sprocket, gearing and motor and is free to slide off the crawler frame.
11. Pull the remainder of the crawler chain clear of the crawler frame and away from the machine.
Figure 2-5.14 Crawler Chain Take-Up
NOTICE
On miners equipped with tram brakes, the chain cannot safely be dragged free of the tram drive sprocket without risking damage to the brake and drive system. In this case, the following procedure should be used:
12. Restore power to the miner.
13. If the radio transmitter is used to control the machine, set the tram speed selection to LOW TRAM and, using small tram lever movements, jog the tram control FORWARD while maintaining a light tension on the pull chain until the chain runs clear of the tram drive sprocket. If the pendant is used to control the machine, the TRAM button will automatically provide LOW TRAM speed, and the button can be used to jog the tram drive forward.
14. Complete the removal of the chain as in Step 11 above.
An alternate method for freeing the crawler chain in the presence of a locked tram brake is to use a Port-a Pack to applyhydraulic pressure to the brake to release it – see Section 3 for more details.
1. Position and prepare the miner according to the first six (6) steps under CRAWLER CHAIN REMOVAL.
2. Separate the crawler chain at the top of the take-up roller (see Figure 2-5.15).
3. Remove the take-up assembly by placing a strap or chain around both sides of the idler roller and sliding it forward until it clears the frame.
crawler take-up roller removal
Take –Up Cylinder Fully
Separation Point
Chain Blocking
Mine Bottom
Figure 2-5.15 Chain Separation for Idler Roller Removal
CAUTION
crawler take-up roller installation
Blocks should be placed under the take-up assembly so that it does not fall from the take-up yoke. Personnel should stay clear of the unit when it is pulled from the yoke.
4. If necessary, the hydraulic take-up cylinder can now be removed. Be sure to disconnect the oil line to the back of the cylinder before removal.
1. If the take-up cylinder has been removed, re-install it into its end mount. Block the cylinder until it is in a horizontal position.
2. Apply a thin coating of grease to the top and bottom take-up slide areas of the crawler frame.
3. Verify proper oil fill on the inside of the take-up roller housing. Place the assembly on its side with the roller shaft vertical. Remove both pipe plugs visible on the side of the roller. Pour gear oil into one hole until it runs out the other hole.
4. Position the crawler take-up assembly in front of the slide area of the crawler frame.
5. Slide the assembly into the main frame, then rearward until it stops against the piston of the hydraulic take-up cylinder or the grease take-up cylinder
CAUTION
Ensure that the piston end of the take-up cylinder fits properly into the take-up plug in the roller assembly (see figure 2-5.14).
6. Connect the hydraulic oil or grease line to the back end of the takeup cylinder.
7. Reconnect the crawler chain.
8. Unblock the chain and check for proper chain tension (see Figure 2-5.13). If the miner is equipped with a grease-type take-up, adjust the shims until the required sag is achieved.
9. If the miner has a constant-tension hydraulic take-up, apply power to the miner so that the constant-tension take-up cylinder is pressurized for checking proper chain sag (see again Figure 25.13).
10. Raise the cutting head and gathering head, then remove the gathering head blocking.
11. Lower the gathering head and the cutting head to remove the main frame blocking.
12. Check the machine operation.
system
Dust collector systems on 30M miners will vary greatly, depending on the customer’s specifications and mining conditions. These variations include:
F Dusty air pickup arrangement
Ø Single-side pickup (usually on the LH side).
Ø RH and LH pickup using a crossover pickup duct.
F Exhaust air arrangement
Ø Single-side exhaust (usually on the LH side).
Ø Exhaust-air crossover duct providing for optional RH or LH discharge.
The dust collector described here will be a typical arrangement using a crossover pickup duct with a rear crossover duct with optional RH or LH discharge. Such an arrangement is shown in Figure 2-6.1.
Consult the parts book for your particular 30m miner for details of the dust collector on your machine.
Cleanout Door
Pickup Duct
Scrubber
Figure 2-6.1 Dust Collector Assembly
Hinged Closure Door
removal of the pick-up duct
In the illustration of Figure 2-6.1, a pickup duct mounted on the cutting head support frame collects dusty air through a slotted intake opening on the underside of the RH and LH sides of the duct. Removable doors on the top surface of each side of the duct permit removal of the cutting head motor driveshaft on each side so that the crossover duct need not be removed for maintenance on the cutting head A cleanout door on the RH side of the duct enables the use of a wash down hose to clear accumulated debris from the duct.
On the LH side, airflow is directed rearward into the main intake duct, or scrubber box assembly With the cutting head and crossover duct moving up and down during cutting operations, the junction of the crossover and main intake ducts is connected by a hinged closure door.
The forward portion of the scrubber box assembly contains a water spray bar immediately ahead of a stainless steel filter screen. The incoming dusty air is wetted by the water spray and then passes through the filter screen to remove the larger dust particles. Much of the wetted dust flowing through the screen will tend to drop to the bottom of the duct where it runs into the sump under the demister box. Dust particles remaining in the airflow will pass through the demister box where multiple curved baffle plates collect the moisture and drain it into the sump.
A water pump evacuates the dirty water from the sump and pipes it to the conveyor where it is dumped. There are provisions for backflushing the sump to clear out debris when it becomes excessive.
Behind the demister box is the axial vane scrubber fan assembly
The exhaust air from the fan can go in one of two directions, depending on the direction of the ventilating air in the working section If a LH discharge is required, a blocking door (see Figure 2-6 6) is removed from the LH diffuser assembly, while a similar RH diffuser door (see Figure 2-6.7) would be installed. Likewise, a RH discharge would require the RH diffuser door to be removed and the LH blocking door installed.
Major subassemblies of the dust collector which can be removed as a unit are the pickup duct, the scrubber box assembly and the scrubber fan.
Figures 2-6.2 and 2-6.3 show details of the pickup duct and the hinged closure door The pickup duct is attached to the cutting head frame by a series of hex head cap screws across the front edge of the duct, and at a mounting block on each side underneath the duct.
The removal process follows:
1. Tram the machine to a suitable work area.
CAUTION
Be sure that the work area is under supported roof out of the way of other machinery. Use a pry bar to check the roof and ribs around the work area and remove loose material as necessary for safety.
Cutting Head
Underside Attachment
Top Attachment Screws (ten ¾” x 1-
Underside Attachment
Top Attachment
Underside Attachment
Blocks (two ¾” x 2-1/4” Hex Head Cap Screws per side)
2-6.2 Crossover Duct Details
2. Lower the gathering head to the mine bottom and lower the cutting head until it rests solidly on the gathering head frame.
Pickup Duct
Crossover Duct Hinged Closure
Hinged Closure
Figure
WARNING
Switch all machine circuit breakers to “off” and disconnect and lock out the machine trailing cable at the power center. Failure to comply with this warning could result in serious injury or death.
3. Remove any machine covers adjacent to the pickup duct.
4. Disconnect any water lines leading to internal water sprays (see Figure 2-6.2) if applicable.
5. Remove the cotter pin from the hinge pin of the hinged door closure, remove the hinge pin and lift the closure door free of the dust collector.
Closure Door Hinge Closure Door
Top Attach Screws
Protective Angle
Pickup Duct
Bottom Attachment Blocks
Cutting Head Frame
Plate Attachment
Hinged Closure Plate
6. Remove the four 5/8” x ¾” hex head cap screws which secure the small hinged closure plate to the edge of the pickup duct, and remove the plate.
7. Attach a lifting device securely to the pickup duct.
The pickup duct weighs about 1,700 lbs. Failure to properly secure the lifting device may result in an accident which could cause serious injury or loss of life.
8. Remove the ¾” x 1-1/4” hex head cap screws from the top front edge of the pickup duct.
9. Remove the four ¾” x 2-1/4” hex head cap screws from the underside of the pickup duct on each side.
10. The pickup duct is now free to be lifted off the cutting head frame.
Figure 2-6.3 Hinged Closure Door Details
Closure
(four 5/8” x ¾” Hex Head
removal of the scrubber box The entire scrubber box, from the front interface with the pickup duct back to the fan, must be removed in one piece (see Figure 2-6.4). Again, as dust collectors vary from one miner to another, the scrubber box will vary in size and, to a minor extent, in shape. Attachment of the scrubber box to the miner chassis will also vary in location.
The scrubber box in Figure 2-6.4 shows attachment points under the front of the duct, in the inner wall of the duct, and at the bottom on the demister section. The points of attachment of your particular miner will be illustrated in the Parts Book
The removal procedure is as follows:
1. With the miner in a safe working location and with all power and circuit breakers turned off, remove all covers, rub rails or other items which might impede removal of the scrubber box.
2. Disconnect the water line to the spray bar.
3. Disconnect the water hose connections for evacuating and backflushing the sump box.
Scrubber Box to Fan Attachment
4. Attach a lifting device securely to the scrubber box.
Spray Bar Filter Screen
Top of Duct Opened to Expose Filter Screen & Demister Blades
Attachment to Frame Attachment to Frame
Attachment to Frame
Figure 2-6.4 Scrubber Box Details
Scrubber Box to Fan Attachment
Demister and Sump Side Doors Omitted Sump Strainer
Machine Centerline
DANGER
DANGER
The scrubber box assembly can weigh from 1,500 lbs to 3,000 lbs Failure to properly secure the lifting device may result in an accident which could cause serious injury or loss of life.
5. Place blocking securely under the forward end of the fan unit.
The fan is held in place by the attachment cap screws to the scrubber box at its front end and held captive in place at the back end only by a pair of split circular frame members. Once the scrubber box is disconnected, there is nothing to retain the fan in position on its front end. Failure to block the fan securely at its front end may result in an accident which could cause serious injury.
6. Loosen, but do not remove, the ½” x 1-1/4” hex head cap screws around the perimeter of the fan-to-scrubber box attachment flange. In the dust collector described in this section, there are 24 such cap screws. This number will vary depending on the size of the scrubber box, which in turn depends on the capacity of the dust collector. Check the Parts Book for your particular 30M miner for the correct details of these mating screws.
7. Once the screws are loosened, check for binding between the scrubber and the fan, and adjust the fan blocking as needed to free up any binding.
8. Apply tension to the lifting device and check to see that the scrubber box is being lifted at approximately its center of gravity If not, adjust the position of the lifting device so that when lifted, the scrubber box can be raised without undue shifting or pivoting.
DANGER
removal of the axial vane fan
Undue shifting or pivoting of the scrubber box could dislodge the fan from its blocking. This might result in an accident which could cause serious injury or loss of life.
9. Lift the scrubber box clear of the miner.
The axial vane fan unit can be removed by itself. As described in the previous discussion, the fan is held in place by cap screws attaching it to the scrubber box at its front end and held captive in place at the back end by a split circular frame. This is illustrated in Figure 2-6.5, which shows the fixed inner fan attachment frame and the removable outer fan attachment frame.
To remove the fan assembly, do the following:
1. Remove all covers in the area of the fan assembly.
2. Block the fan securely.
3. Disconnect all electrical lines to the fan.
DANGER
Failure to block the fan securely at its front end may result in an accident which could cause serious injury.
4. Remove the four ¾” x 2” socket head cap screws holding the outer fan attachment frame and remove the frame.
5. Attach a lifting device to the fan assembly.
6. Loosen, but do not remove, the ½” x 1-1/4” hex head cap screws around the perimeter of the fan-to-scrubber box attachment flange. In the dust collector described in this section, there are 24 such cap screws. This number will vary depending on the size of the scrubber box, which in turn depends on the capacity of the dust collector. Check the Parts Book for your particular 30M miner for the correct details of these mating screws.
7. Once the screws are loosened, check for binding between the scrubber and the fan, and adjust the fan blocking as needed to free up any binding.
8. Apply tension to the lifting device and check to see that the fan assembly is being lifted at approximately its center of gravity If not, adjust the position of the lifting device so that when lifted, the fan assembly can be withdrawn sideways from the split frame cavity without undue shifting or pivoting.
9. Remove the fan assembly.
Figure 2-6.5 View Looking Rearward at Rear Fan Attachment Frame
Fan Assembly
¾” x 2” Hex Head
Outer Fan Attachment Frame (removable)
Inner Fan Attachment Frame (part of Main Frame)
Main Frame
removal of the left hand diffuser assembly
A diffuser assembly at the LH rear of the miner diffuses the exhaust airflow from the fan. The diffuser assembly may require removal to clear debris or for repairs.
Figure 2-6.6 shows the diffuser installation. To remove the diffuser,
1. Attach a lifting device securely to the diffuser.
2. Loosen, but do not remove, the nine (9) ¾” x 1-3/4” socket head cap screws and the single ¾” x 2-1/4” socket head cap screw as shown in Figure 2-6.6.
CAUTION
The diffuser weighs nearly 400 lbs. If the lifting device is not securely attached, an accident may occur which could cause serious injury.
Blocking Door
¾” x 2-1/4” Socket Head Cap Screw (1) ¾” x 1-3/4” Socket Head Cap Screws (9)
LH Diffuser Assembly
Main Frame Structure
Figure 2-6.6 LH Diffuser Assembly
3. Once the screws are loosened, check for binding between the diffuser and the main frame and adjust tension on the lifting device as necessary.
4. Remove the LH diffuser assembly.
servicing the rear crossover duct and right hand diffuser
The dust collector described in this section has a rear crossover duct to provide optional RH or LH discharge of exhaust air, as shown in Figure 2-6.7.
Several features can be seen:
Ø The blocking door in the LH diffuser assembly which, for illustration purposes, is shown partially removed.
Cleanou Rear Towing
Airflow Cleanout
Ø A corresponding blocking door, the RH diffuser door, shown on the RH side. One of these doors, or the other, would be used to discharge exhaust air on the RH or LH side, depending on the direction of ventilating airflow in the working section.
Ø The RH diffuser door is secured in place by two (2) ¾” x 1-1/4” hex head cap screws.
Ø Airflow guide plates on the RH side to help direct airflow out and toward the rear of the miner.
Ø Several cleanout holes on the top and rear surfaces of the crossover duct. These are to enable the clearing of coal fines which will inevitably collect in the duct.
LH Blocking Door (partially
RH Diffuser
Figure 2-6.7 Rear Crossover ¾” x 1-1/4” Hex
basic hydraulics Basic hydraulic laws deal with force, energy transfer, work, and power. They relate to two conditions that are found in a hydraulic system: pressure and flow. Each one performs a specific function.
Pressure pushes or exerts a force, technically, "force per unit area", or "pounds per square inch" (psi). Pressure equals a force in pounds divided by the area in square inches, or
Pressure = Force/Area
Example:
A force of 100 pounds is exerted over an area of 1 square inch. The pressure equals 100 pounds per square inch (psi).
Total F = 100 pounds
Area A = 1 sq in.
Pressure P = 100 pounds/1 sq in = 100 psi
Flow is fluid in motion and causes a secondary turbulent motion. The principle measurements for flow are velocity and flow rate. Velocity is the average speed of a fluid past a given point, usually measured in feet per minute (fpm). Flow rate is the measure of a volume of fluid passing a point in a given unit of time. The flow rate of this volume of fluid is measured in gallons per minute (gpm).
Pumps are normally rated in gallons per minute. If a cylinder in a system requires 10 gallons of oil to move it through its full stroke, then the time required to provide full stroke using a 10-gallon per minute, pump is:
10 gal. cylinder capacity /10 gpm pump output = 10/10 min. = 1 min.
Oil velocity is considered when sizing hydraulic hoses Small hoses increase oil speed to maintain the flow rate created by the pump. Conversely, larger hoses decrease oil velocity Higher oil velocities increase friction and turbulence, which in turn increase oil temperature and restriction to flow, or pressure losses. Low oil velocities decrease turbulence and therefore reduce friction and pressure losses due to friction. Thus, replacing a hose with smaller-diameter one would increase turbulence, temperature and pressure loss in that hose.
hydraulics
The key components in a machine’s hydraulic system are (1) an oil tank or reservoir to hold the oil supply, (2) hydraulic oil or other suitable fluid to transmit the power, (3) a pump to move the oil or fluid, (4) a relief valve to control or limit system pressure, (5) a control valve to direct flow, and (6) an actuator (generally a hydraulic cylinder or hydraulic motor) which transforms hydraulic power to mechanical motion.
Before machine start-up, the oil in the tank is at rest. At this time, normal atmospheric pressure (through a tank breather) acts on the oil surface. When the machine starts and the pump is activated, the mechanical action of the pump creates a vacuum in the pump suction line connected to the tank The vacuum allows atmospheric pressure to force oil through the suction line into the pump. This primes the pump and allows the mechanical action of the pump to force oil into the hydraulic system.
Failure to maintain the hydraulic system can result in damage to its components.
Basic maintenance considerations for efficient machine hydraulics require that you:
Keep all breathers clean and free of obstructions so as to maintain atmospheric pressure in the tank.
Maintain a sufficient oil level in the tank to satisfy all flow requirements in the system.
Maintain an airtight, leak-free, pump suction to keep air from being ingested into the pump.
Repair any leaks in the system as soon as practical after they are detected.
The pump is designed to move fluid; it does not pump pressure. Pressure in the system is caused by a resistance to flow produced by restrictions in the hydraulic system. All system components have some resistance to flow Hydraulic actuators, which power the various machine functions, are the major components causing this resistance.
A relief valve protects each major circuit so that system pressure will not exceed the rating of its components. To ensure that everything works correctly and in proper sequence, relief valve pressure settings closely match the load requirements. In addition, most of the subcircuits have separate relief valves, or other pressure control valves, in them.
Never change relief valve pressure adjustments without a pressure gage installed in the circuit.
Never set a relief valve to exceed DBTs stated maximum pressure for that particular valve.
system overview
The pressure settings given in this manual for the various valves may vary from one 30m miner to another. Consult the hydraulic schematic for your particular machine The schematic can be found in the envelope at the back of the parts book.
Most 30M miners have a two-section, external gear-type, fixed displacement hydraulic pump assembly Each single-stage section consists of two closely meshed gears inside a tightly fitted housing. As the gears rotate away from the inlet, a partial vacuum draws fluid into the pump. The fluid travels around the housing in space between the gear teeth and the housing. When the fluid reaches the meshing gear teeth, it is forced to exit the pump through the outlet port and into the hydraulic system.
Hydraulic power for all hydraulically-actuated functions originates with the pump assembly This includes power for cylinders, hydraulic motors, control valves, and pilot valves. This dual pump assembly is made up of two hydraulic pump sections designated A1 and A2. The pump and its electric drive motor are mounted within the LH or RH crawler frame, behind the crawler take-up assembly and forward of the tram motor.
The pump assembly (see Figure 3-2.1) is driven through a quill shaft adapter by a 55-HP AC drive motor. The tandem pumps are driven clockwise (facing the pump shaft) at a nominal speed of 1,760 RPM.
Hydraulic oil enters from near the center bottom of the tank (see Figure 3-2.2) via a 2.5” suction pipe and hose before entering the A1 and A2 pump sections.
2-Section Hydraulic Pump Pump & Motor Mounting
Figure 3-2.1 Hydraulic Pump Drive Assembly
AC Drive Motor
Quill Shaft Adapter
Hollow Motor Shaft
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