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BucyrusAmerica,Inc. 2045WestPikeStreet Telephone:724-743-1200 Houston,PA15342 Fax:724-743-1201 Internet:www.bucyrus.com OperationManual Bucyrus - ContinuousMiner Model - 25M0 Doc.No.:A6474X332 BI000959

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ThismanualisintendedtoprovideGENERALproductinformationfor theModel25M0ContinuousMiner.Theillustrations,descriptionsand procedurescontainedinthispublicationapplyonlytoTHISmachine. BucyrusAmerica,Inc.reservestherighttorevisemodelsanddesigns withoutpriornotice.

ThisContinuousMinerwasmanufacturedundertheguidelines,proceduresandrequirementssetforthinthesalesorderspecification.

Atthecompletionofthemanufacturingprocess,thisunitwasissuedthe appropriateapprovalnumbersandnameplatesindicatingitmetthe technicalrequirementsoftheseregulatoryagencies.Anychangetothe designorstructureofthisunit,withouttheconsentofBucyrusAmerica, Inc.andtheseregulatoryagencies,oranyrepairorreplacementof partscontrarytoBucyrusAmerica,Inc.’sinstructions,mayinvalidate theseapprovalsandrenderthisunitunsafetooperate.

StrictcompliancewithallFederalandStateMininglaws,regulations andpracticesregardingthesafeoperationandmaintenanceofundergroundminingequipmentandstrictadherencetotheinstructionsinthis manualisnecessaryforthepersonalsafetyofthoseworkingonor aroundthisunit.

Whilethismanualattemptstoanticipatethemostimportantoperations andmaintenanceneedsforthisunit,unforeseencircumstancesmay arisethathavenotbeenaddressedinthismanual.Ifanyconcernsor questionsarise,pleasecontactyourBucyrusAmerica.Inc.Service Representative immediately.

Thisworkcontainsinformationprotectedundertradesecretandother intellectualpropertylaws,andisprotectedundertheU.S.Copyright Actof1976,asamended.Thisworkisprovidedunderlicenseandthe licenseisnon-transferable.Distributionandaccessislimitedonlyto authorizedpersonnel.Disclosure,reproduction,distributionorunauthorizedusemaybeaviolationoffederalandstatelawsandmaysubjecttheunauthorizedusertocriminalliability.

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________________________________________________ Tableofcontents A6474X355 VPSS/0 ©BUCYRUSAMERICA,INC. Tableofcontents

Aboutthismanual Aboutthismanual .................................................................. 1.3 Beforestartingtowork 1.3 Whoisthisoperatingmanualintendedfor? ........................ 1.3 Whatisthepurposeofthisoperatingmanual? 1.4 Charactersandsymbols...................................................... 1.5

Yoursafety Yoursafety .............................................................................. 2.3 Personnel 2.4 Operation ........................................................................ 2.4 Installationandrepair 2.4 Operatingconditions............................................................ 2.5 Intendeduse 2.5 Unauthorizeduse............................................................ 2.5 Safetyinstructions 2.7 Generalrules: 2.7 Storageandtransport 2.8 Pre-startinspection 2.8 Installationandstart-up 2.9 Operation 2.9 Stopping 2.10 Maintenanceandrepair 2.10 Overviewofthesafetyinstructions 2.15 Chapter3:Storageandtransport 2.15 Chapter4:Installation 2.15 Chapter5:Operation 2.16 Chapter6:Technicaldata 2.31 3. Storageandtransport Storageandtransport............................................................ 3.3 Storage 3.3 Storageofthemachineandspareparts......................... 3.3 Long-termstorageofsparecomponents 3.4 Transport.............................................................................. 3.5 Loadunits:dimensionsandweights 3.5 Transportenvironment.................................................... 3.6 4. Installation Installation............................................................................... 4.3 Pointstoobservepriortoinstallation 4.3 Whoisallowedtocarryoutinstallation?......................... 4.3 Whichtoolsarerequiredforinstallation? 4.3 Notesoninstallation........................................................ 4.4 Pre-installationchecklist 4.5 Safetyfeatures................................................................ 4.6 BI000959

5. Operation

Tableofcontents _________________________________________________ Bucyrus – Model25M0ContinuousMiner ©BUCYRUSAMERICA,INC.

Operation................................................................................. 5.3 HowtooperatetheContinuousMiner................................. 5.3 WhoisallowedtooperatetheContinuousMiner 5.3 Whencanoperationbestarted?..................................... 5.3 Machinedescription 5.4 Controlsandindicators........................................................ 5.4 Machinecontrolsystem 5.19 Redzone 5.26 Safetyprecautionsforundergroundoperation 5.31 Trammingsafetyrules 5.31 Startingprocedure 5.32 Shutdownprocedure 5.34 Trammingtheminer 5.35 Cutterheadoperation 5.37 Conveyoroperation 5.38 Scrubbermotoroperation 5.39 Areaandheadlightoperation 5.32 Firesuppressioninradioremoteoperation 5.40 Conveyorraise/lower/left/rightinradioremoteoperation 5.40 Stabilizercylinderraise/lowerinradioremoteoperation 5.41 Shearup/downinradioremoteoperation 5.41 Gatheringheadraise/floatinradioremoteoperation 5.41 Breakeron/offinradioremoteoperation............................5.42 Typicalcuttingsequence 5.43 Miningoperations................................................................5.45 Mechanicalassemblies 5.50 Hydraulicsystem.................................................................5.57 Watersystem 5.89 Electricalsystem.................................................................5.99 Instructionsonthemaintenance 5.135 Importantnotes............................................................5.135 Beforemaintenance 5.135 Torquevalues ..............................................................5.136 Lubricants,fluidsandcapacities 5.137 Specificlubricationandmaintenanceinstructions............5.141 Everyshift 5.141 Everythirdshift(daily) 5.143 Weekly 5.148 Monthly 5.152 Everythreemonths 5.158 Everysixmonths 5.161 Adjustmentprocedures 5.164 Settinghydraulicpressures 5.164 Loadholdingvalve 5.165 Pilotpumpcircuitrelief 5.166 Maincontrolvalve........................................................5.168 Portrelief 5.169 Tramtrack....................................................................5.171 Tailshim 5.176 Chaintension...............................................................5.179 Mechanical 5.179 Greasetake-up....................................................5.181 Cuttermotorfeedback 5.183 BI000959

________________________________________________ Tableofcontents A6474X355 VPSS/0 ©BUCYRUSAMERICA,INC. Instructionsonreplacementofwearparts........................5.186 Cutterhead(boom)assembly 5.186 Boompivotpin .............................................................5.190 Shearcylinder 5.193 Centercutterdrum.......................................................5.198 Endcutterdrum 5.202 Drumdrivemotor .........................................................5.204 Drumdrivegearcase 5.210 Gatheringheadassembly............................................5.212 Gatheringheaddrivemotor 5.218 Gatheringheadgearcase ...........................................5.223 Gatheringheadfootshaft 5.229 Gatheringheadliftcylinder 5.232 CLA 5.235 CLAtipreplacement 5.238 Trammotor 5.239 Tramprimaryplanetarygear 5.244 Tramsecondaryplanetarygear 5.247 Tramcase 5.252 Tramreachgearset 5.257 Tramsprocket 5.265 Tramtrackfrontidler 5.272 Frontidlertake-upcylinder 5.276 Hydraulicpump 5.278 Hydraulicpumpmotor 5.281 Scrubberfan/motor 5.284 Stabilizercylinder 5.287 Swivelpinassembly.....................................................5.290 Tailroller 5.292 Conveyorchainreplacement.......................................5.294 Duo-coneseals 5.395 Bearings.......................................................................5.301 Bevelgears 5.307 Gearsandgearfailures ...............................................5.308 Lockwirefasteners 5.310 Specialfasteners .........................................................5.310 Self-lockingscrews 5.310 Locknuts.......................................................................5.311 Componentsubstitution 5.312 Troubleshootingprocedures.............................................5.313 Typicalhydraulicproblems 5.314 Contaminantsinhydraulicsystems 5.315 Specifichydrauliccircuits 5.316 Multi-functionfailure 5.316 Oiltankfill 5.317 Cutterheadraise 5.317 Cutterheadlower 5.317 Gatheringheadraise 5.318 Gatheringheadfloat 5.318 Conveyorraise 5.318 Conveyorlower....................................................5.319 Conveyorswing 5.319 Stabilizerraise .....................................................5.319 Stabilizerlower 5.319 ........................................................................................ BI000959

Tableofcontents _________________________________________________ Bucyrus – Model25M0ContinuousMiner ©BUCYRUSAMERICA,INC. Generalsafetyprocedureforshutdown.......................5.320 Excessivenoise 5.321 Excessiveheat .............................................................5.322 Incorrectflow 5.323 Incorrectpressure ........................................................5.324 Faultyoperation 5.325 Restartingchecklist......................................................5.326 Watersystem 5.327 Bearings .......................................................................5.329 Electricalsystem 5.330 6. Technicaldata Technicaldata .........................................................................6.3 Tighteningtorques................................................................6.5 Permissiblemedia 6.7 Lubricationfluidsandgreases.........................................6.7 7. Foryourinformation Foryourinformation...............................................................7.3 Ourservice 7.3 Serviceaddress...............................................................7.3 BI000959

_______________________________________________________________ Aboutthismanual BI000959

________________________________________________________________ BI000959

applicableoperatingmanual machinetype

Aboutthismanual

Thischapterprovidesimportantinformationmakingiteasierforyouto usethismanual.Youwillalsobegiveninformationonthestructureof themanualandthesymbolsandcharactersused.

Beforestartingtowork

Takecaretoensurethattheoperatingmanualavailabletoyouis applicableforthetypeofequipmentormachineused.

Thisoperatingmanualisintendedfor:

BucyrusModel25M0ContinuousMiner SerialNo.:N/A

andisonlypermittedtobeusedforequipmentofthistype.

newoperationmanual

Theoperatingmanualmustbeaccessibleatalltimestoallpersons workingonorwiththemachine.Itshould,ifpossible,alwaysbe availableattheplaceofoperation.

Sendforanewoperationmanualimmediatelyifthepresentmanualis nolongercompleteorhasbecomeillegible.

Whoisthisoperatingmanualintendedfor?

Thisoperatingmanualisintendedforthosepersonswhoworkwithor onthemachine.Everypersonworkingonthefaceorintheintersectionbetweenfaceandentryorintheentrymustreadthisoperating manual.

Thisincludespersonswho:

■ areinchargeoftransport

■ performassembly/disassemblywork

■ operatethemachine

■ eliminatefaults

■ performdailyroutineworkonthefaceorintheentry

■ performmaintenancework

■ performrepairwork

supervisorypersonnelwho:

■ initiateand/orsupervisetheactivitiesjustindicated.

________________________________________Beforestartingtowork A6474X332 VPSS/1 1.3 ©BUCYRUSAMERICA,INC.

BI000959

cost-effectiveness

Whatisthepurposeofthisoperatingmanual?

Thisoperatingmanualisintendedtohelpyouworkefficientlyand safelywithourproduct.Itcontainsimportantinformationonallthe activitiesrelatedtothemachine.

Readthisoperatingmanualcompletelyandatease.Payspecialattentiontothesafetyinstructions.Trytomemorizetheappearanceandthe meaningofthesafetyandinstructionsymbols.

service safety

Ifanydetailsarenotclearlyunderstood,pleasecontactourservice department.Ourserviceaddressisgiveninthechaptertitled“Foryour information”.

Readthechapter“Foryoursafety”withspecialattention.Thechapter containsimportantinformationindicatingpossiblehazards.Observe theinformationgivenandfollowtheproceduralinstructions.

Beforestartingtowork ________________________________________ 1.4

–

©BUCYRUSAMERICA,INC.

Bucyrus

Model25M0ContinuousMiner

BI000959

Charactersandsymbolsused

Thefollowingcharactersandsymbolsareusedforsafetyinstructions andimportantinformationintheoperatingmanual.

Trytomemorizethesymbolsandtheirmeanings.

DANGER!

Pointsinthetextmarkedwiththissymboldrawyourattentionto immediatelyimpendingdanger.Possibleconsequencesare: veryseriousinjuryorevendeath.

WARNING!

Thesepointscontaininformationondangeroussituations.Possibleconsequencesare:veryseriousinjuryorevendeath.

CAUTION!

Thissymboldrawsattentiontodangeroussituations.Possible consequencesare:lighttomoderatelyseriousinjuriesandmachinedamage.

NOTICE!

Pointsinthetextmarkedwiththissymboldrawattentiontoharmfulsituations.Possibleconsequencesare:damagetothemachineordamageintheimmediatevicinity.

IMPORTANT!

Pointsinthetextmarkedwiththissymbolcontainusefultipsand informationintendedtofacilitateworkforyou.Theydonotwarn aboutharmfulordangeroussituations.

■ Itemsinlistsaremarkedwithbullets.

– Pointsinsub-listsaremarkedwithalongdashatthestartof theline.

 Pointsintextmarkedinthiswaydescribeindividualoperations. Followtheseinstructionsstepbystep.Theywillhelpyoucarryout yourworkfasterandmoreimportantly,safer.

BI000959

Beforestartingtowork ________________________________________ 1.6

Bucyrus – Model25M0ContinuousMiner

_______________________________________________________________

BI000959

Yoursafety

• Thank you very much for reading the preview of the manual.

• You can download the complete manual from: www.heydownloads.com by clicking the link below

• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.

CLICK HERE TO DOWNLOAD THE COMPLETE MANUAL