1、SERIES 1000-05 MAINTENANCE TRAINING 100005系列钻机的维护培训,VALLEY LONGWALL DRILLING,SECTION 1 INTRODUCTION 第一部分 简介,OBJECTIVES教学目的,To give the trainee a theoretical and practical understanding of the maintenance and repair of the hydraulic circuits of the VLD SERIES 1000-05 Directional Drill Rig. 在VLD100005
2、系列定向钻机的液压循环回路方面给学员一个理论和实践上的维护和修理的理解,SCOPE范围 Theory and demonstration.理论和演示 Oral examination.口头测试 Practical examination.实践测试 Managers authorisation管理者的权威,OUTCOME成果,At the completion of this training session the trainee will have a working knowledge of the hydraulic circuitry, in order to properly mai
3、ntain and repair, the VLD SERIES 1000 Directional Drill Rig safely. 完成这段培训后，学员将具备液压循环系统工作的知识，能够合理的进行VLD1000系列定向钻机的培训和维护 The trainee will be able to demonstrate his understanding through a practical demonstration. 学员能够通过实践演示来反映他的知识的掌握,5,EXPO 1展示1,The SERIES 1000 Directional Drill Rig is an electric/h
4、ydraulic track mounted drill rig, used for directional and rotational drilling in underground mines 这1000系列定向钻机是电液的轨道钻机，用于地下煤矿开采的定向和旋转钻进,Personal Protection Equipment 个人防护器具,Hearing protection听力保护 Eye Protection视力保护 Cap Lamp矿灯帽 Self Rescuer自救器 Hard Hat安全帽 Reflective clothing and/or vests护胸背心 Steel C
5、ap Boots矿靴 Long hair tied back or in hair net头发整理 Gloves手套,WARNING SIGNAGE 危险警示,MAJOR COMPONENTS: 主要组成元器件,The following covers the following components 下面的元件： FILTRATION过滤器 ROTATION UNIT旋转单位 ROD CLAMP钻杆夹持器 FEED FRAME给进装置 STABILIZATION稳定性 TRACTION牵引 WATER PUMP 水泵 HYDRAULIC PUMPS液压泵 ELECTRIC MOTOR电动马达
6、,Filtration - HIGH PRESSURE HYDRAULIC OIL FILTERS. 过滤高液压油过滤器,High Pressure Filters are located on the following circuits: 高压过滤器位于下列油路位置 Main Pump 主泵 Water Hydraulic Pump水液压泵 Auxiliary Pump辅助泵 Rod Clamp 钻杆夹持器 Rotation Unit 回转装置 NOTE: Clogging indicators only operate when fluid passes through them. 注意
7、：当流体通过他们时，堵塞指示器工作 Change filters every 3 Months or sooner if indicated by clogging indicators 每3个月更换一次过滤器，或如堵塞指示器显示就马上更换,Filtration - HIGH PRESSURE HYDRAULIC OIL FILTERS.,Components consist of: 由下类组成 Filter clogging indicator堵塞指示器 Filter head过滤头 Filter element过滤单元 Screw in bowl螺丝刀拧进缸筒 Bypass valve旁通
8、阀IMPORTANT: Ensure O-ring is correctly seated before tightening bowl 要点：在上紧压槽之前，保证O型正确密封,Filtration - HIGH PRESSURE HYDRAULIC OIL FILTERS.,Changing the Element更换过滤单元 ! Switch off hydraulic system, isolate machine.关掉液压系统，隔离机器 Remove Drain Plug 拔开排液塞 Unscrew Bowl 拧开压槽 Remove Element & examine 打开过滤单元并检
9、查 Exchange Element更换单元 Clean Bowl清洗压槽 Examine filter Sealing Surfaces and Thread检查过滤器密封表面和螺纹 Check O-rings & Backup rings检查O型圈和垫圈 Lightly lubricate thread sealing surfaces and the o-ring and element with clean oil.用干净油轻轻润滑螺纹密封表面和O型密封圈和过滤单元 Place filter carefully onto spigot 小心将过滤器放入套管 Screw in filte
10、r bowl fully, till firm.拧上过滤槽，拧紧 Screw in oil drain plug.拧上排油塞 Unscrew filter bowl by turn.打开过滤槽 转动1/4圈 Start hydraulic system and check for leaks启动液压系统，检查渗漏情况,Filtration - LOW PRESSURE HYDRAULIC OIL FILTERS. 过滤低压过滤油器,Low Pressure Filters are located on the hydraulic tank and filter:低压过滤器位于液压缸内 Main
11、 Return主回路 Case Drain Returns 排油路 NOTE: Clogging indicators only operate when fluid passes through them. 注意：当液压油通过时，堵塞指示器才工作 Change filters every 3 Months or sooner if indicated by clogging indicators 每3个月更换，或遇到堵塞报警，立即更换,Filtration - LOW PRESSURE HYDRAULIC OIL FILTERS.,Clogging indicator.堵塞指示器 Lid.盖
12、子 Element.过滤网 Filter body.过滤体,Filtration - LOW PRESSURE HYDRAULIC OIL FILTERS.,Changing the Element Low pressure filter .更换过滤网低压过滤器 ! Switch off hydraulic system, isolate machine.关掉液压系统，切断机器电源 Loosen four retaining bolts on top of filter 在过滤器顶部松开固定螺栓 Remove lid 挪开盖子 Extract the element 抽出过滤网 Retain
13、for examination 固定检查 Place new element into body 体内放进新过滤网 Replace the O-Ring.更换O型密封圈 Replace lid, retaining bolts and tighten.更换压盖，固定螺栓，上紧 Examine old element for excessive particle content. Take action if excessive.检查旧的过滤网是否过多的微颗粒，如果过多，采取办法,ROTATION UNIT旋转动力头,OIL AND LUBRICATION油和润滑Change the oil i
14、n the rotation unit gearbox after 150 hours of use on a newly purchased machine.新购设备使用150小时后更改旋转头变速箱内的机油 Drain whilst the oil is warm当油热时排油 Keep sample of the oil for analysis. 保留油作分析 Replace the drain plug and refill (refer to manual for recommended oil). 替换排油塞，再注油（参考手册推荐的的油） Remove the breather pl
15、ug挪开通气塞 Fill the gearbox until the oil begins to run out of the level plug hole 变速箱内注油直到油过插孔水平 Replace the level plug and tighten and replace the breather plug.更换插孔杆，上紧通气塞 The grease points on the rotation unit should be greased at the beginning of each shift (refer daily/weekly 103 service sheets).
16、 在每个班运行开始时，旋转头上注油孔要充足油脂（每台、每周 103个服务单）,Drain Plug排油塞,Gear Box Level Plug 齿轮象水平塞,Rotation unit grease points (2 of 3 shown) 旋转头注油孔,ROTATION UNIT旋转头,Filler Breather Cap 过滤通气帽,ROTATION UNIT/ROD CLAMP旋转头/钻杆夹持器 Jaw set replacement/卡瓦爪更换,Remove the top cap holder by removing three bolts located on the fro
17、nt of the rotation unit 通过拧旋转头前面的三个螺栓卸开顶盖 NOTE: The jaw set can only be replaced with the chuck in the open position. 注意：卡盘在打开位置情况下瓦爪才能被替换,ROTATION UNIT/ROD CLAMP Jaw set replacement,Remove the three bolts. 拧开三个螺栓,ROTATION UNIT/ROD CLAMP Jaw set replacement,Remove the cap holder卸开顶盖,ROTATION UNIT/RO
18、D CLAMP Jaw set replacement,Remove the jaw set.卸开卡瓦 Clean the jaw set with a wire brush to remove grit. 用刷子清洗卡瓦,ROTATION UNIT/ROD CLAMP Jaw set replacement,Clean the rotation jaw bowl. 清洗旋转卡瓦套 Check for wear in the bowl before re-installing the jaw set 在安装卡瓦之前检查瓦套的磨损,ROTATION UNIT/ROD CLAMP Bowl and
19、 Spring replacement 瓦套和弹簧更换,ROTATION UNIT/ROD CLAMP Bowl and Spring replacement,The springs (item 3.33) can only be replaced with the chuck in the closed position. 弹簧（3.33项）只能在卡盘封闭的情况下更换,ROTATION UNIT/ROD CLAMP Bowl and Spring replacement,Remove the top cap holder (item 3.15) by removing the three b
20、olts (item 3.27). 通过卸开三个螺栓(3.27项)来卸开顶盖帽(3.15项),ROTATION UNIT/ROD CLAMP Bowl and Spring replacement,Remove the jaw set (item 3.19) 卸开卡瓦（3.19项）,ROTATION UNIT/ROD CLAMP Bowl and Spring replacement,Remove the top cap adaptor (item 3.14) by removing the nine bolts (item 3.28).拧开9个螺栓（3.28)来卸开顶盖适配器 (3.14),
21、ROTATION UNIT/ROD CLAMP Bowl and Spring replacement,Remove the six bowl retaining bolts (item 3.25), the three long bolts (item 3.26) and the three spacers (item 3.16).卸开6个固定螺栓(3.25)，三个长螺栓(3.26)，三个隔板(3.16),ROTATION UNIT/ROD CLAMP Bowl and Spring replacement,Remove bowl (item 3.17)卸开缸筒（3.17）,ROTATION
22、 UNIT/ROD CLAMP Bowl and Spring replacement,Remove the springs (item 3.33) from the housing (item 3.12) and clean the spring seat area.从套内(3.12)卸开弹簧 清洗弹簧座(3.33),ROTATION UNIT/ROD CLAMP Bowl and Spring replacement,Refit the new spring set (item 3.33).重新安装新的弹簧(3.33项),ROTATION UNIT/ROD CLAMP Bowl and S
23、pring replacement,Clean the inside of the housing (item 3.12), regrease the inside surface and install the bowl. 清理套内(3.12)，表面加黄油，安装缸筒,ROTATION UNIT/ROD CLAMP Bowl and Spring replacement,Ensure the bolt holes are aligned and install the long bolts (item 3.26) without the spacers没有隔板下确保螺栓孔对齐安装长螺栓(3.2
24、6),ROTATION UNIT/ROD CLAMP Bowl and Spring replacement,Tighten the long bolts until the bowl has compressed the springs (item 3.33), install the short bolts (item 3.25) and tighten to 70Nm. 上紧长螺栓直到缸筒压缩到弹簧(3.33)，安装短螺栓(3.25)上紧到70KN,ROTATION UNIT/ROD CLAMP Bowl and Spring replacement,Remove the long bo
25、lts (item 3.26), fit the spacers (item 3.16) and tighten to 70Nm. 卸开长螺栓(3.26),安装隔板(3.16)上紧到70KN,ROTATION UNIT/ROD CLAMP Bowl and Spring replacement,Install the top cap adaptor (item 3.14), fit the nine bolts (item 3.28) and tighten up to 70Nm. 安装顶帽适配器(3.14项)，安装9个螺栓(3.28)上紧到70Nm,ROTATION UNIT/ROD CLA
26、MP Bowl and Spring replacement,Place the jaw set into the top cap holder. 将卡瓦装进盖套内,ROTATION UNIT/ROD CLAMP Bowl and Spring replacement,Reinstall the top cap holder (item 3.15), refit the bolts and tighten the bolts to 250Nm. 再安装盖帽(3.15)再安装螺栓上紧到250Nm,ROTATION UNIT/ROD CLAMP Bowl and Spring replacemen
27、t,Operate the drill to ensure correct operation. 操作钻机确保正确操作,ROTATION UNIT/ROD CLAMP Bowl and Spring replacement,Questions?问题？,HYDRAULIC CHUCK CYLINDER,Locate the piston (item 3.4) over the actuator sleeve (item 3.1). 将活塞(3.4)搁置再动力环(3.1)上,HYDRAULIC CHUCK CYLINDER液压卡盘缸套,Install thrust bearing assembly
28、 (item 3.5) into the piston Note: The thrust bearing assembly only fits one way. The thrust washer with the larger inner diameter should fit into the piston, then the roller race, greased and placed against it. The thrust washer with the smaller inner diameter is a tap fit onto the actuator sleeve.
29、安装止推轴承体到活塞上，注意：止推轴承只能一种方法安装，止推垫圈和大的内圈安装进活塞上，滚珠轴承座圈上黄油后安上。止推轴承带上小内径轻安到动环上,HYDRAULIC CHUCK CYLINDER,Screw the actuator sleeve ring (item 3.9) onto the actuator sleeve and tighten. Install the two nylon plugs (item 3.10) and the two grub screws (items 3.23) with a small quantity of Loctite thread locke
30、r 262. Tighten the grub screws. 拧上动环(3.9)到动环套上上紧，安装2个尼龙塞(3.10)两个螺钉(3.23)带上插销固定，拧紧螺钉,HYDRAULIC CHUCK CYLINDER,Fit the roll pins (item 3.8) to the piston (item 3.4); fit the Seal (item 3.6) and the wear ring (item 3.7). Lightly grease the surfaces and the seals. Locate the piston to the adaptor flange
31、. 在活塞(3.4)上插上滚销(3.8)，安上密封和磨损环。轻抹油脂和密封。将活塞放到适配器缘上,HYDRAULIC CHUCK CYLINDER,Fit the seal (item 3.2) and the wear ring (item 3.3) into the cylinder (item 3.13) lightly grease the inside surfaces and the seal. 将密封和磨损环安进缸体内，在内表面和密封上轻抹油脂,HYDRAULIC CHUCK CYLINDER,Fit the cylinder over the piston assembly,
32、insert the SHCS (item 3.29) and torque to 120Nm. 将缸套安到活塞体上，塞进SHCS,扭矩达到120Nm,HYDRAULIC CHUCK CYLINDER,Install the V ring (item 3.22), oil seals (items 3.31) and the spacers (item 3.18) in the spring housing (item 3.12).安装V型环、油封、和弹簧套内的隔离器,HYDRAULIC CHUCK CYLINDER,Screw the spring housing (item 3.12) o
33、nto the drive sleeve. 将弹簧套拧到驱动轴套上去,HYDRAULIC CHUCK CYLINDER,Refit the spring set (item 3.33).整修弹簧设置(3.33),HYDRAULIC CHUCK CYLINDER,Clean the inside of the housing (item 3.12). Regrease the inside surface and install the bowl. 清理套内里，内表面上油脂安装套,HYDRAULIC CHUCK CYLINDER,Ensure the bolts holes are aligne
34、d; install the long bolts (item 3.26) without the spacers. 确保螺栓孔对齐，安装长螺栓没有衬垫,HYDRAULIC CHUCK CYLINDER,Tighten the long bolts until the bowl has compressed the springs (item 3.33), install the short bolts (item 3.25) and tighten to 70Nm. 紧长螺栓，直到轴套压缩到弹簧，安装短螺栓，紧到70Nm,HYDRAULIC CHUCK CYLINDER,Remove the
35、 long bolts (item 3.26), fit the spacers (item 3.16) and tighten to 70Nm. 拆调长螺栓，装上衬垫，紧到70Nm,HYDRAULIC CHUCK CYLINDER,Install the top cap adaptor (item 3.14), fit the nine bolts and washers (items 3.28 and 3.30) and tighten to 70Nm. 安装顶帽适配器，安上9个螺栓，垫圈，紧到70Nm,HYDRAULIC CHUCK CYLINDER,Place the jaw set
36、into the top cap holder. Reinstall the top cap holder (item 3.15), refit the bolts and tighten the bolts to 200Nm. 将钳夹放进顶帽母上，重新安展顶帽母，安上螺栓，上紧到200Nm,HYDRAULIC CHUCK CYLINDER,Operate the drill to ensure correct operation. 操作钻机确保正确运转,HYDRAULIC CHUCK CYLINDER,Note: Grease lubrication points on the rotati
37、on unit every half hour for the first shift after rebuilding the rotation unit gearbox. 注意：旋转装置齿轮箱子重装后，第一班运行每半小时在旋转装置的润滑孔加油脂一次,HYDRAULIC CHUCK CYLINDER,Questions?问题？,ADJUSTING SPINDLE END PLAY,Spindle end play must be carried out whenever the spring bowl has been removed, or inspections have found i
38、t to be loose. 无论是弹簧套卸调，还是检查发现是松动的，锭子端允许必须完成,ADJUSTING SPINDLE END PLAY,Use wooden block, bump the drive sleeve at each end. It should move approximately 4mm through the gear box assembly. 用木块，在端部敲驱动轴套，应该移动大约4mm，穿过齿轮箱,ADJUSTING SPINDLE END PLAY,Use wooden block, bump the drive sleeve at each end. It
39、 should move approximately 4mm through the gear box assembly. 用木块，在端部敲驱动轴套，应该移动大约4mm，穿过齿轮箱,ADJUSTING SPINDLE END PLAY,Remove the bushing retainer (item 1.5), bearing retainer (item 1.3) and the lock nut (item 1.4) from the spindle.,ADJUSTING SPINDLE END PLAY,Take a wooden block and bump the drive sl
40、eeve at the lock nut end.,ADJUSTING SPINDLE END PLAY,Fit the hydraulic chuck cylinder to the adaptor flange, fit the SHCS and tighten to 120 Nm. Note: for details on assembling the hydraulic cylinder. 液压夹持器油缸安装到连接器法栏上，安装SHCS，紧到120Nm.注意安装液压油缸的细节,ADJUSTING SPINDLE END PLAY,Screw the spring housing (it
41、em 3.12) onto the drive sleeve. 将弹簧套拧到驱动轴套上,ADJUSTING SPINDLE END PLAY,The spring housing (item 3.12) must sit tight against the clamp ring (item 1.13). Bump the drive sleeve at the lock nut end while turning the spring housing clockwise. This will make sure all the drive sleeve is taken up in the s
42、pring housing. 弹簧套必须和卡环压紧了，在锁母端敲驱动轴，同时顺时针旋转弹簧套。这将确保驱动套能装到弹簧套上,ADJUSTING SPINDLE END PLAY,The rear of the spring housing must sit against the V-Ring on the face of the chuck cylinder, if it is too tight remove the housing and add shims (item 3.11) then refit the housing, ensuring the contact of the V
43、-Ring against the housing. Note Excessive load on the V-Ring will result in failure of the V-ring. 弹簧套的尾部必须坐在夹持器油缸的V型环上，如果太紧，卸掉套，加上薄垫片，然后重新安装套，保证V型环和套紧密接触，注意:V型圈上的载荷过大，将导致V型圈的失效,ADJUSTING SPINDLE END PLAY,Back off the spring housing on the spindle 1/3 of a turn anti-clockwise until the key-ways line
44、 up. Insert the three keys (item 2). 逆时针将锭子上的弹簧套退回到一周的1/3，直到钥匙口对齐，插入三把钥匙。,ADJUSTING SPINDLE END PLAY,Install the bearing retainer (item 1.13) to the rear of the sleeve and tighten to 240 Nm. This will force the spring housing tight against the clamp ring. If this is not done the chuck assembly will
45、be running loose on the drill head causing premature failure and extensive damage. 将轴承保持器安装到缸筒的尾部，紧到240Nm，迫使弹簧套压紧卡环。如果没压紧，动力头夹持器会转松，导致过早和过度损伤,ADJUSTING SPINDLE END PLAY,Install the retainer locknut (item 1.4) onto the drive sleeve and lock in place with the SHCS (item 1.33). 用SHCS将保持锁母安装到驱动轴套并锁上,ADJ
46、USTING SPINDLE END PLAY,Questions?问题？,Drill Head Maintenance钻机头部维护,After the initial run in period of the drill head assembly it is important to maintain the chuck assembly, spindle and the bearing assembly in a pre-load condition. 在钻机头安装阶段，初始运行之后，重要的是维持卡盘体、方钻杆和轴承体处在一个预载荷状态 Spindle pre-load is adjus
47、ted by shimming the bearing cones. The chuck assembly pre-load is adjusted as per the bearing retainers on the spindle. 通过契轴承锥子来对方钻杆加预载荷 Pre-load must be checked after the first 300 hrs of operational use and every 2500 hours thereafter during normal operating conditions. If however, drilling condit
48、ions are severe, pre-load must be checked more frequently.在正常操作条件下，第一300小时使用和此后的每2500小时预载荷必须核对。然而如果钻进条件不好，预载荷应更勤核对。 To check the pre-load place a screwdriver between the chuck housing and the cylinder (item 9 & 23) and try to move the housing. If the housing moves, then you have lost pre-load. Tight
49、en the bearing retainer lock nuts (item 19). If you still have movement after, a complete overhaul must be carried out. 为了检测预应力，在夹持套和油缸之间放置一个螺丝起子，卸掉夹持套。如果夹持套活动了，旧卸掉了预应力了。上紧轴承保持器锁母。如果仍然动，必须进行完整的大修,Feed Frame Cylinders/给进框架,Striping instructions of the cylinders as per following pages.,The cylinders u
50、sed in this machine are provided as a set. If a cylinder shows signs of failure both cylinders should be removed and serviced as a pair. 本机器提供一对液压缸，如果一个油缸出现问题信号，两个油缸应该卸下，一对修理。 Should the parts be found to be damaged and require replacement return the cylinders to the manufacturer. The cylinders that are used in the feed frame are of the balanced type. 发现部件损坏，需要替换，将油缸返回到制造厂内，给进装置内使用的油缸是平衡型的。,
