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First Issue Date: 2008
Revision Date: 06/04/2011
Prepared by Ron Spencer Documentation
Checked by
Approved by
Revision No. 01
This document is the property of Bucyrus Australia. It shall not be copied or reproduced in any way what so ever and/or passed on to any third party without the written authority of Bucyrus Australia.
Copyright © Bucyrus Australia. All paper copies are uncontrolled.
Disclaimer:
Bucyrus has made every effort to ensure that all instructions contained within this document are accurate and safe, and cannot accept liability for any resulting injury, damage or loss to persons or property arising from the use thereof or otherwise. Contact Bucyrus Australia to obtain the latest updates for this document.
This manual is intended to provide basic operation information on BUCYRUS 30M3 series continuous miners. Additional information can be obtained by referring to the Parts Book supplied with your machine, or by contacting your local BUCYRUS Australia representative. The illustrations, descriptions and procedures contained in this manual pertain to the machine as it was originally manufactured and delivered to your mine and when the manual was approved for printing.
While this manual attempts to anticipate the most important operations and maintenance needs for this equipment, unforeseen circumstances may arise that have not been addressed in this manual. If any concerns or questions arise, please contact your BUCYRUS Australia Service Representative immediately.
ALL applicable Notes, Cautions and Warnings listed in this Manual are to be included in the support documents following the same format as defined below.
Follow Notes, Cautions and Warnings found in the handout.
NOTE: Indicates a procedure or condition that is essential for the operator to know.
CAUTION: Indicates an action or condition that, if not followed, could cause damage to the vehicle or other equipment.
WARNING: Indicates an action or condition that, if not followed, could cause injury to the operator or other personnel.
Operating procedures are written with the intention of being correct. If you do notice errors within the procedures, it is an important part of our company’s Quality Processes that we be notified quickly so that any problem can be corrected.
The machine should be regularly checked for any defects or hazards and rectified where possible or dealt with according to mine specific action plans.
It is essential that all personnel are clear of machine prior to start once operating all personnel to be clear of conveyor boom and cutter head. Operator must be aware of his location to avoid crush potential.
Never put yourself or any other person in any position that should machine fail to respond correctly or if in normal operation creates a position whereby no escape is possible.
“One fraction of a second of carelessness can result in a lifetime of suffering for yourself or other team members”.
To understand this statement is the beginning of effective safe work practices.
• Safety risks are created when you shortcut Standard Procedures.
• Machinery is like a loaded gun - even if it is not running or is switched off.
• When doing tests with the machine on running:
Stop machine and isolate to set up test. Stand clear and observe test. Stop machine and isolate before disconnecting test.
• When repairing, replacing or fitting heavy components: Use blocks, and supports to prevent components tipping, sliding or moving out of position.
• When working under the heads, shovel or tail: Make sure that safety stops are securely in place at all times.
• When testing the machine in any way: Ensure that personnel are clear of the machine at all times when testing.
All safety procedures shall comply with mine specific and relevant Mine Managers Rules and particularly any documents relating to the use and maintenance of Remote Control Continuous Miners.
Isolation Procedures
Below is an example of a generic isolation procedure which is common to some coal mines throughout NSW and QLD.
NOTE: Mine Specific Isolation Procedures are to be adhered to and take precedence over example isolation procedures mentioned in this document.
The 12 steps must include consideration of the following actions:
1. Identify all plant or equipment and their energy sources that require isolation
• Identify all primary energy sources and confirm that the isolation point e.g. switches, circuit breakers, de-contactors, whole current isolators, battery isolators, valves etc., you isolate are the correct ones for the plant or equipment. Where appropriate refer to schematic diagrams to confirm that the isolator will give complete isolation.
• Identify any associated plant or equipment that could create a hazard.
• Isolation can only be achieved by isolating the plant or equipment from all sources of energy. While the plant or equipment may be electrically isolated, other sources of energy must be considered e.g. hydraulic/water/air pressure, gravitational energy (continuous miner head or loader bucket in the air, conveyor counterweights) etc.
• Determine the type of isolation that you will require (Individual, Group, High Voltage) and apply as required
• Check to see if any specific isolation procedures apply to that equipment or circuit.
2. Advise relevant parties
• Notify all people who will be affected by the isolation to ensure no safety or operational problems will be created.
• Where necessary advise operators that the plant or equipment is to be isolated to allow for machines to be left in a safe position prior to isolating.
3. Isolate and secure energy sources
• Isolate primary isolator in an approved manner or using site procedures and/or manufacturers recommended instructions e.g., operate whole current isolator, remove plug, close valve etc. Shedding of loads prior to operating primary isolator may need to be considered in some instances.
• Isolate or secure/control all secondary energy sources. For example:
• bleed off stored hydraulic or pneumatic pressure from pressure vessels, accumulators etc,
• Release stored energy such as springs, conveyor belt tension, etc.
• secure/barricade/chock elevated equipment or material hang-up in chutes, truck bodies etc
• Chock machinery and equipment to prevent unplanned movement.
• Do not use auxiliary devices for isolation e.g., push buttons, control circuit devices, emergency stop buttons, key-switches, conveyor lanyards, etc. except where these remote isolator devices control an approved (to relevant Australian Standard) whole of current isolation device e.g. Motorised lanyard controls on conveyors to AS1755.
4. Apply Personal Danger Tags / Locks, or Permit Danger Tags / Locks
• A Personal Danger Tag or lock is to be placed on the appropriate isolation point/s by a competent person.
• In the case of a permit:
• a Permit Danger Tag / Lock is to be placed on the relevant isolation point/s by the Authorised Isolator after the Permit Holder has raised the appropriate permit
• All members of the work party shall sign onto, or attach their Personal Danger Tag or lock to the appropriate permit after checking the work they are performing is covered by the Permit.
• Any visitor requiring to place a Personal Danger Tag or lock or sign onto a permit can only do so under direct supervision of a competent person or Permit Holder
NB. Depending on the circumstances, it may be necessary to reverse steps 4 & 5 eg. When access to switchboards is necessary for verification purposes and a tag or lock will prevent entry.
5. Verify the effectiveness of the isolation
All isolations must be checked to verify the isolation has been effective by:
• Testing the test equipment is in good operating condition and is set to correct scale eg. Pressure gauges, non-contact voltage detector multi-meters etc
• Checking the operation of test equipment before and after isolation
• Test the isolation has been effective by:
• Checking for the presence of voltage for electrical isolations
• Attempting to start the equipment. Eg. mobile equipment/machinery
• Opening valves in pipelines
• Confirming secondary energies are secured eg. Chocks etc.
Check for test methods that may have been developed and approved for use for various isolations.
6. Commence Work
• Carry out the required tasks.
• Monitor work area for any new introduced hazards
7. Complete Work
• Complete all tasks related to the isolation.
8. Check Work
• Review all work that has been carried out to confirm the work-area has been left in a safe condition e.g. Guards and covers are back in position etc.
• Attach an Out of Service Tag to the plant or equipment isolation point if it is not safe or ready for service.
9. Clear Area
• Ensure all persons working on the affected plant or equipment have completed their tasks and are clear of the work area.
• Confirm area associated with restoring energy has been cleared i.e. remove rubbish from rotating parts, roll up hoses, removal of spare or replaced parts etc.
10. Remove Personal Danger Tags / Locks, or Permit Danger Tags / Locks
• Remove Personal Danger Tags / Locks associated with the work being done. Each person to remove only their own Personal Danger Tag / Lock.
• In the case of a Permit, each individual is to sign off all permits, or remove Personal Danger Tag / Lock, associated with the Permit. The Permit Holder may then cancel the Permit.
• Visitors may only remove their own Personal Danger Tags / Locks or sign off a Permit under the direct supervision of a Competent Person/Permit Holder.
11. Restore Energy
• Advise all relevant or affected parties of your intention to restore energy.
• Restore energy to the plant or equipment in accordance with the operation’s energy restoration procedures.
12. Check Operation
• Tests run the plant or equipment to confirm that the work carried out has been successful and that the plant or equipment is operating normally.
• Attach an Out of Service Tag to the plant or equipment isolation point if it is not safe or ready for service, or testing is required using approved procedures.
• Attach an Information Tag if required
• Fill out shift report of status and works completed and communicate details of work undertaken to all relevant persons.
Before commencing work near or under auger head - fit head stops as shown in photo. Stops (L) (R) is carried on board machine.
1. Also isolate main circuit breaker, traction, conveyor and cutter breakers and tag prior to working in this area. Procedure for fitting head stops are as follows:
• Isolate cutter circuit breaker – conveyor circuit breaker – traction circuit breaker
NOTE: Refer to Mines Remote Control Operations for Continuous Miners.
• With an operator by your side, start the machine, lower the gathering head to the floor and raise the auger head to a suitable height to fit stops.
• Carefully slide stops into cutter head areas Left and Right hand sides.
• With Miner still running slowly lower auger head onto the manufactured stops ensuring to take the weight of the auger head.
WARNING: Isolate Miner as per Mines isolation procedures.
Before commencing work in or around conveyors ensure the conveyor stop bar is used. Ensure conveyor is rested on conveyor stop before any work is commenced. Also isolate and tag machine prior to any work in this area. Procedure for fitting conveyor stop is as follows:
• Isolate CONVEYER, CUTTER head and TRACTION circuit breakers.
• With operator by your side, start the machine
NOTE: Refer to Mines Remote Control Operations Continuous Miner – RCCM rev.doc.
• Raise the conveyor to a suitable height to slide the stop horizontally (3.3).
• Check that the sliding bolt is secure and locked into place.
• Lower the conveyor onto stop.
WARNING: Isolate Miner as per Mines Isolation Procedures.
Climb on and off the miner only where steps or grab irons are provided. Use both hands when mounting and dismounting and face the vehicle. Never get on or off a moving continuous miner, and never jump off a continuous miner.
• Climb up and down the ladders by facing the ladder.
• Never climb down with your back facing the ladder rungs.
• Be very careful on the bottom steps, especially in muddy conditions.
• Always maintain three point contacts.
NOTE:Use access platforms when performing maintenance or bolting
• 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.