Technical Manual
© Bucyrus All Rights Reserved
R
BI619026
BUCYRUS
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DBT America________________________________________________ 2045 WEST PIKE STREET HOUSTON, PA 15342-1010 Internet: www.dbtamerica.com Operation Manual DBT- CONTINUOUS MINER ® Model - 25M Series Doc. No.: 03-29-05 BI619026
preface
This manual is intended to provide basic operating information on DBT 25M Series class continuous miners. Additional information can be obtained by referring to the Parts Book supplied with your machine, or by contacting your local DBT representative. The illustrations, descriptions and procedures contained in this manual pertained to the machine as it was originally manufactured and delivered to your mine, and when the manual was approved for printing. DBT reserves the right to discontinue or revise machine models at any time, or change specifications, designs or procedures, without notice and without incurring obligations.
The machine was manufactured under the guidelines, procedures and requirements of the appropriate government regulatory agencies. At the completion of manufacturing, this machine was issued the appropriate approval numbers and nameplates indicating that it met the technical requirements of the appropriate agencies. Any change to the design or structure of this machine, without the consent of DBT and these agencies, may void these approvals and render the machine illegal or dangerous for use.
Strict compliance with all local and national laws, regulations and practices regarding the safe operation and maintenance of underground mining equipment is necessary to ensure the personal safety of those working on, or around, this machine.
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 DBT America Service Representative immediately
This work contains information protected under trade secret and other intellectual property laws, and is protected under the U. S. Copyright Act of 1976, as amended. This work is provided under license and the license is non-transferable. Distribution and access is limited only to authorized personnel Disclosure, reproduction, distribution or unauthorized use may be a violation of federal and state laws and may subject the unauthorized user to criminal liability.
__________________________________________________________ Table of contents _________________________________________________
BI619026
Table of contents
________________________________________________ Table
_______________________________________________________________ DBT – 25M SERIES CONTINUOUS MINER © VUVR / 03
of contents
ABOUT THIS MANUAL 1.0 right operating manual 1.3 type 1.3 new operating manual 1.3 efficiency 1.4 service 1.4 safety 1.4 YOUR SAFETY 2.0 state of the art 2.3 further operating manuals 2.3 safety precautions for operating the continuous miner 2.4 training 2.4 operating conditions 2.5 storage and transport 2.6 pre-start inspection 2.6 operation 2.6 inspection 2.6 maintenance 2.6 instruction and safety 2.6 operator’s compartment 2.6 canopy 2.6 stopping 2.7 operator’s compartment 2.7 parking 2.7 securing 2.7 replacing components 2.7 original parts 2.7 lifting 2.7 handling hydraulic fluids 2.7 permissible hoses 2.8 STORAGE AND TRANSPORT 3.0 corrosion protection 3.3 no direct exposure to sunlight 3.3 short term storage 3.3 BI619026
Table
contents _________________________________________________ ________________________________________________________________ DBT – DASH SERIES CONTINUOUS MINER © © DBT AMERICA 2005 long term storage 3.3 plastic deformation 3.3 random sample inspection 3.4 natural aging 3.4 HFA fluids 3.4 before transport 3.5 temperature below freezing 3.5 electrical and electronic components 3.5 INSTALLATION 4.0 special tools 4.3 general safety rules 4.4 general safety maintenance 4.5 lubricate every shift 4.7 inspect daily 4.7 lubricate weekly 4.7 lubricate daily 4.7 check daily 4.7 replace when necessary 4.8 electric motor maintenance 4.8 every month 4.8 electrical motor maintenance 4.10 every three months 4.10 every six months 4.10 annually 4.10 notes on installation 4.11 installation plan 4.11 superbolt installation and specifications 4.12 tightening procedures 4.12 loosening procedures 4.13 lubricants 4.14 safety features 4.16 panic strip (s) 4.16 canopy 4.16 antifreeze measures for oil cooler 3.5 BI619026
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________________________________________________________________ DBT – DASH SERIES CONTINUOUS MINER © © DBT AMERICA 2005 ________________________________________________
Fire suppression 4.16 Guards and covers 4.16 Circuit breaker reset 4.16 OPERATION 5.0 Cutter head assembly 5.3 Boom pivot pin 5.4 Drum drive torque limiting switch 5.5 Drum drive motor—dash-0 & dash-1 5.5 Drum drive motor—dash-2 & dash-3 5.6 Shear cylinder—dash-0, dash-1 & dash-2 5.7 Shear cylinder—dash-3 5.8 Cutter drums—dash-0 5.8 Center cutter drums 5.8 End cutter drums 5.9 Main cutter drums 5.9 Cutter drums installation / removal—dash-1 5.10 Center cutter drum 5.10 End cutter drum 5.11 Main cuter drum 5.11 Cutter drums installation / removal—dash-2 5.12 End cutter drums 5.13 Center cutter drum 5.14 End cutter drum 5.14 Gear case installation / removal—dash-0 5.15 Gear case installation / removal—dash-1 5.16 Gear case installation / removal—dash-2 & 3—see figures 21 & 22 5.17 Figure 21 5.18 Figure 22 5.19 Cutter boom gear case—dash-2 & 3 5.20 Gathering head assembly installation / removal—see figure 14 & 15 5.21 CLA installation / removal—see figure 16 5.22 Gathering head motor installation / removal 5.23 Foot shaft installation / removal 5.23 Gear case installation / removal 5.24 Lift cylinder installation / removal—see figure 23 5.25 Tractor frame assembly—see figure 1 5.26 Tram primary planetary gear installation / removal—see figure 3 5.27 BI619026
Table of contents
__________________________________________________________ Table of contents _________________________________________________ tram secondary planetary gear installation / removal—see figure-4 5.28 tram case installation / removal 5.29 stabilizing cylinder installation / removal—see figure-7 5.30 tram sprocket assembly installation / removal—see figure-8 5.31 tram track adjustment—see figure-9 5.32 tram track front idler installation / removal—see figure-10 5.34 front idler take-up jack assembly 5.35 hydraulic pump installation / removal—see figure 12 5.35 hydraulic pump motor installation / removal—see figure 13 5.36 conveyor assembly installation / removal—see figure 38 & 39 5.37 swing cylinder installation / removal—see figure-40 5.38 swivel pin installation / removal—see figure-41 5.39 tail roller installation / removal—see figure-42 5.40 tail shim adjustment—see figure-43 5.40 lift cylinder installation / removal—see figure-44 5.41 chain installation / removal—see figure-45 5.42 chain tension adjustment—see figure-46 5.42 scrubber system—see figure-47 5.44 scrubber cleaning—see figure-48 5.45 fan motor assembly—see figure-49 5.45 power schematic—see figures 50, 51, 52, 56, 57 & 58 5.46 motor overloads 5.46 motor control 5.47 motor contactors—see figure-67 5.47 cutter motor feedback 5.47 radio control schematic—see figure-53 5.48 tram dead man—see figure-54 5.48 methane monitor 5.49 low oil level 5.49 e-stop bypass—see figure-55 5.49 battery back-up 5.49 scrubber fan 5.49 cutter motor feedback adjustment—see figure-59 5.50 armature voltage—see figures 60 & 61 5.51 BI619026
________________________________________________________________ DBT – DASH SERIES CONTINUOUS MINER © © DBT AMERICA 2005 ________________________________________________ Table of contents transmitter—see figures 64 & 65 5.53 battery charger 5.53 permissibility 5.53 troubleshooting 5.54 dual systems 5.54 diagnostic display 5.55 component change out 5.55 TECHNICAL DATA 6.0 tractor frame assemblies—figure-1 6.4 tractor frame-tractor motor—figure-2 6.5 tram preliminary planetary gear—figure-3 6.6 tram secondary planetary gear—figure-4 6.7 tram case—figure-5 6.8 tram case—figure-6 6.9 stabilizing cylinder—figure-7 6.10 tram sprocket—figure-8 6.11 tram track adjustment—figure-9 6.12 tram track front idler—figure-10 6.13 front idler take-up jack—figure-11 6.14 hydraulic pump—figure-12 6.15 hydraulic pump motor—figure-13 6.16 gathering head—figure-14 6.17 gathering head assembly—figure-15 6.18 gathering head CLA installation / removal—figure-16 6.19 gathering head motor installation / removal—figure-17 6.20 gathering head foot shaft installation / removal—figure-18 6.21 foot shaft assembly—figure-19 6.22 gathering head gear case installation / removal—figure-20 6.23 gathering head gear case assembly—figure-21 6.24 gathering head gear case assembly—figure-22 6.25 gathering head lift cylinder installation / removal—figure-23 6.26 cutter head assemblies—figure-24 6.27 cutter head book assemblies—figure-25 6.28 radio remote control—see figures 62, 70 & 71 5.52 receiver, power supply and module traction case—see figure-69 5.52 diagnostic display—see figure-63 5.53 BI619026
Table of contents _________________________________________________ ________________________________________________________________ DBT – DASH SERIES CONTINUOUS MINER © © DBT AMERICA 2005 cutter head—dash 0, 1 & 2 boom pivot pin—figure-26 6.29 cutter head—dash-3 boom pivot pin—figure-27 6.30 cutter head dash 2 & 3 drum drive torque limiting clutch—figure-28 6.31 cutter head dash 2 & 3 drum drive motor—figure-29 6.32 cutter head—dash 0 & 1 drum drive motor—figure-30 6.33 cutter head—dash 0, 1 & 2—figure-32 6.34 cutter head—dash 3 shear cylinder—figure-33 6.35 cutter boom—dash 0 cutter drums—figure-34 6.36 cutter boom—dash 1 cutter drums 6.37 cutter boom—dash 2 cutter drums—figure-36 6.38 cutter doom—dash 3 drums—figure-37 6.39 conveyor—figure-38 6.40 conveyor—figure-39 6.41 swing cylinder—figure-40 6.42 swivel pin—figure-41 6.43 tail roller—figure-42 6.44 tail shim—figure-43 6.45 FOR YOUR INFORMATION 7.0 our service 7.3 service addresses 7.3 BI619026
_______________________________________________________________ _______________________________________________________________ 1 About this manual ________________________________________________________________ 1.0 VUVR / 03___DBT – 25M SERIES CONTINUOUS MINER © BI619026
______________________________________________________________ _____________________________________________________________ BI619026
About this manual
This chapter contains important information, which will simplify work with this manual for you. In addition, it contains information about the structure of the manual and on the characters and symbols used.
Before starting work
If you use an operating manual which has not been written for your conveyor type, you will endanger yourself and others. Ensure that the data on the Continuous Miner corresponds to those in this operating manual.
This operating manual belongs to:
DBT America—Dash Series Continuous Miner
Serial No.: 02-14-05
The operating manual is to be used only for the Dash Series Continuous Miners.
An operating manual for the conveyor must always be available at the place of operation. Send for a new manual immediately if the present manual is no longer complete or has become illegible.
Who is this operating manual intended for?
This operating manual is intended for all persons working with or on the Continuous Miner
All persons working at the face, at the edge of the face or in the entry must have read this operating manual.
This includes persons:
¾ responsible for transport,
¾ developing the raise,
¾ carrying out erection / disassembly,
¾ operating the conveyor,
¾ eliminating faults,
¾ carrying out daily routine work at the face or in the entry,
¾ carrying out maintenance operations,
¾ carrying out repairs.
supervisory persons:
¾ instructing and/or
¾ supervising
the above activities.
___________________________________________
_____________________________________________________________ DBT – 25M SERIES CONTINUOUS MINER © VUVR / 03 1.3 © DBT AMERICA 2005
About this manual
BI619026
right operating manual type new operating manual
What is the purpose of this operating manual?
This operating manual is intended to help you work efficiently and safely with our product. It contains important information on all the activities related to the Dash Series Continuous Miners.
Read this operating manual completely and carefully In particular, pay attention to the safety instructions.
Note the appearance and meaning of the safety and warning symbols.
If any points are not clear, please contact our Service Department. You will find our Service address in chapter 7 ”For your information”.
Pay particular attention to the chapter ”Your Safety”. It contains important information drawing your attention to possible sources of danger. Observe the information and follow the instructions contained in this operating manual.
Characters and symbols used
The following characters and symbols are used for safety instructions and important information in the operating manual. Pay particular attention to these points.
Points in the text marked with this symbol draw your attention to immediately impending danger. Possible consequences are: very serious injury or even death.
These points contain information on dangerous situations. Possible consequences are: Very serious injury or even death.
This symbol draws attention to dangerous situations. Possible consequences are: Light to moderately serious injuries and machine damage.
Points in the text marked with this symbol draw attention to harmful situations. Possible consequences are: Damage to the conveyor or damage in the immediate vicinity.
Points in the text marked with this symbol contain useful tips and information intended to facilitate work for you. They do not warn about harmful or dangerous situations.
¾ Points in sub-lists are marked with a square at the start of the line describe individual work steps. Follow these instructions step-by-step.
________________________________________________________________ 1.4 VUVR / 03____________DBT – 25M SERIES CONTINUOUS MINER © © DBT AMERICA 2005
About this manual_____________________________________________
C CAUTION DANGER WARNING NOTICE IMPORTANT efficiency service safety BI619026
• 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
CLICK HERE TO DOWNLOAD THE COMPLETE MANUAL
