Issuu

BucyrusAmerica,Inc. 2045WestPikeStreet Telephone:724-743-1200 Houston,PA15342 Fax:724-743-1201 Internet:www.bucyrus.com OperationManual Bucyrus - ContinuousMiner Model - 25M1AC Doc.No.:A6474X331 BI000958

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ThismanualisintendedtoprovideGENERALproductinformationfor theModel25M1ACContinuousMiner.Theillustrations,descriptions andprocedurescontainedinthispublicationapplyonlytoTHISmachine.BucyrusAmerica,Inc.reservestherighttorevisemodelsand designswithoutpriornotice.

ThisContinuousMinerwasmanufacturedundertheguidelines,proceduresandrequirementsoftheU.S.FederalCoalMineHealthand SafetyAct,CodeofFederalRegulations,Title30,Chapter1,Subpart0, Part75forundergroundcoalmines,andotherapplicablenon-U.S. regulatoryagencystandards.

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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© BUCYRUSAMERICA,INC. ALLRIGHTSRESERVED

________________________________________________ Tableofcontents A6474X331 SUSV/00 ©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.................................................... 3.8 4. Installation Installation............................................................................... 4.3 Pointstoobservepriortoinstallation 4.3 Whoisallowedtocarryoutinstallation?......................... 4.3 Whichtoolsarerequiredforinstallation? 4.3 Notesoninstallation........................................................ 4.4 Pre-installationchecklist 4.5 Safetyfeatures................................................................ 4.6 BI000958

5. Operation

Tableofcontents _________________________________________________ Bucyrus – Model25M1ACContinuousMiner ©BUCYRUSAMERICA,INC.

Operation................................................................................. 5.3 HowtooperatetheContinuousMiner 5.3 WhoisallowedtooperatetheContinuousMiner........... 5.3 Whencanoperationbestarted? 5.3 Controlsandindicators........................................................ 5.4 Redzone 5.24 Safetyprecautionsforundergroundoperation ...................5.29 Trammingsafetyrules 5.29 Startingprocedure ..............................................................5.30 Shutdownprocedure 5.32 Trammingtheminer............................................................5.33 Cutterheadoperation 5.35 Conveyoroperation.............................................................5.36 Scrubbermotoroperation 5.37 Areaandheadlightoperation..............................................5.39 Firesuppressioninradioremoteoperation 5.38 Conveyorraise/lower/left/rightinradioremoteoperation 5.38 Stabilizercylinderraise/lowerinradioremoteoperation 5.39 Shearup/downinradioremoteoperation 5.39 Gatheringheadraise/floatinradioremoteoperation 5.39 Breakeron/offinradioremoteoperation 5.40 Typicalcuttingsequence 5.41 Miningoperations 5.43 Mechanicalassemblies 5.48 Hydraulicsystem 5.55 Watersystem 5.87 Electricalsystem 5.98 Instructionsonthemaintenance 5.125 Importantnotes 5.125 Beforemaintenance.....................................................5.125 Torquevalues 5.126 Lubricants,fluidsandcapacities..................................5.127 Specificlubricationandmaintenanceinstructions 5.128 Everyshift ....................................................................5.131 Everythirdshift(daily) 5.133 Weekly .........................................................................5.138 Monthly 5.141 Everythreemonths......................................................5.148 Everysixmonths 5.151 Adjustmentprocedures.....................................................5.154 Settinghydraulicpressures 5.154 Loadholdingvalve.......................................................5.155 Pilotpumpcircuitrelief 5.156 Maincontrolvalve 5.158 Portrelief 5.159 Tramtrack 5.161 Tailshim 5.166 Chaintension 5.168 Hydraulic 5.168 Cuttermotorfeedback 5.169 BI000958

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SUSV/00 ©BUCYRUSAMERICA,INC. Instructionsonreplacementofwearparts........................5.172 Cutterhead(boom)assembly 5.172 Boompivotpin .............................................................5.176 Shearcylinder 5.181 Centercutterdrum.......................................................5.186 Endcutterdrum 5.190 Drumdrivemotor .........................................................5.192 Drumdrivegearcase 5.197 Gatheringheadassembly............................................5.199 Gatheringheaddrivemotor 5.205 Gatheringheadgearcase ...........................................5.210 Gatheringheadfootshaft 5.216 Gatheringheadliftcylinder 5.219 CLA 5.222 CLAtipreplacement 5.225 Trammotor 5.226 Tramprimaryplanetarygear 5.231 Tramsecondaryplanetarygear 5.234 Tramcase 5.239 Tramreachgearset 5.244 Tramsprocket 5.252 Tramtrackfrontidler 5.259 Frontidlertake-upcylinder 5.263 Hydraulicpump 5.265 Hydraulicpumpmotor 5.267 Scrubberfan/motor 5.271 Stabilizercylinder 5.274 Swivelpinassembly.....................................................5.277 Tailroller 5.279 Conveyorchainreplacement.......................................5.281 Duo-coneseals 5.282 Bearings.......................................................................5.288 Bevelgears 5.294 Gearsandgearfailures ...............................................5.295 Lockwirefasteners 5.297 Specialfasteners .........................................................5.297 Self-lockingscrews 5.297 Locknuts.......................................................................5.298 Componentsubstitution 5.299 Superbolts....................................................................5.299 Troubleshootingprocedures 5.303 Typicalhydraulicproblems 5.304 Contaminantsinhydraulicsystems 5.305 Specifichydrauliccircuits 5.306 Multi-functionfailure 5.307 Oiltankfill 5.307 Cutterheadraise 5.307 Cutterheadlower 5.307 Gatheringheadraise 5.308 Gatheringheadfloat 5.308 Conveyorraise.....................................................5.308 Conveyorlower 5.309 Conveyorswing ...................................................5.309 Stabilizerraise 5.309 Stabilizerlower.....................................................5.309 BI000958

Tableofcontents A6474X331

Tableofcontents _________________________________________________ Bucyrus – Model25M1ACContinuousMiner ©BUCYRUSAMERICA,INC. Generalsafetyprocedureforshutdown.......................5.310 Excessivenoise 5.311 Excessiveheat .............................................................5.312 Incorrectflow 5.313 Incorrectpressure ........................................................5.314 Faultyoperation 5.315 Restartingchecklist......................................................5.316 Watersystem 5.317 Bearings .......................................................................5.319 Electricalsystem 5.320 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 BI000958

_______________________________________________________________ Aboutthismanual BI000958

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applicableoperatingmanual machinetype

Aboutthismanual

Thischapterprovidesimportantinformationmakingiteasierforyouto usethismanual.Youwillalsobegiveninformationonthestructureof themanualandthesymbolsandcharactersused.

Beforestartingtowork

Takecaretoensurethattheoperatingmanualavailabletoyouis applicableforthetypeofequipmentormachineused.

Thisoperatingmanualisintendedfor:

BucyrusModel25M1ACContinuousMiner 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 A6474X331 SUSV/00 1.3 ©BUCYRUSAMERICA,INC.

BI000958

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 – Model25M1ACContinuousMiner

BI000958

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.

________________________________________Beforestartingtowork A6474X331 SUSV/00 1.5 ©BUCYRUSAMERICA,INC.

BI000958

Beforestartingtowork ________________________________________

1.6

©BUCYRUSAMERICA,INC. BI000958

Bucyrus – Model25M1ACContinuousMiner

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BI000958

Yoursafety

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furtheroperatingmanuals

Yoursafety

Thischapterprovidesvitalinformationforyoursafety.Payspecialattentiontothischapter.Thesafetyinstructionsandrulesofprocedure willhelpyoutoavoidhazardoussituationsandtoperformthenecessaryworkassafelyaspossible.

Themachinehasbeenmanufacturedinaccordancewiththestateof theartandgenerallyrecognizedsafetystandardsandregulations. Youandotherscan,nevertheless,beexposedtodangeroussituations e.g.asaresultofenvironmentalinfluences,machinedamageoroperatorerrors.

Donotmakeanyalterationsormodificationswhichcouldimpairthe safetyofthemachine.AllmodificationsandchangesmustbeapprovedbyBucyrusAmerica,Inc.andanyappropriateregulatory agency.

UseonlyoriginalsparepartsfromBucyrusAmerica,Inc.Notethatthe useofpartsfromothermanufacturerswillvoidthewarranty.

Inadditiontothisoperatingmanualbesuretoalsoobservetherespectivelegalprovisionsandregulationsinyourcountry.

Observethesafetyandaccidentpreventionregulations

■ ofthemine,

■ ofthemineinspector,and

■ oftheminingsupervisoryauthorities.

Readtheoperatingmanualsofthecomponentsrequiredforoperation, e.g.ofgearboxes,electricmotors,radioremotes,etc.,carefullyand thoroughly.Clarifyanyquestions before startingwork.

stateoftheart

BI000958

Personnel

Operation

Themachinemayonlybeoperatedbyqualified,trainedpersonnel.

Themachineisonlyallowedtobeoperatedbyqualifiedpersonnelwho canprovideproofofhavingbeentrainedonthisunit.

Readingoftheoperationmanual,especiallythechapteronsafety,shall constituteapartofthistraining.

Youmusthaveadequateknowledgeofthe

■ mechanics,

■ hydraulics,and

■ controlengineering andmustbeabletoprovethisknowledge.

Installationandrepair

Asafundamentalrule,installationandrepairworkmayonlybecarried outbypersonnelwhohavebeenadequatelytrainedfortheseparticular requirements.

Installationandrepairworkon:

■ safetycomponents(pressurereliefvalves,extinguishers,etc.)

■ theelectrics(motors,controllers,etc.)

■ thehydraulics(controls,cylinders,etc.)

mayonlybecarriedoutbyserviceengineersfromBucyrusAmerica, Inc.orbyspeciallyqualifiedpersonnelofthemine.

Personnel ___________________________________________________

2.4

Bucyrus – Model25M1ACContinuousMiner

training BI000958

Operatingconditions

Intendeduse

TheContinuousMinerhasbeendesignedandmanufacturedforthe extractionofcoal,phosphate,potash,salt,tronaandothermedium hardnessminerals.

Intendedusesinclude:

■ extractionofcoal,phosphate,potash,salt,tronaandothermedium hardnessminerals

■ loadingthematerialslistedaboveontoahaulagesystemorshuttle car,ordumpingitontothegroundforloadingatalatertime

■ operationongradesoflessthan10degrees

Unauthorizeduse

Applicationsnotexpresslylistedasintendedusesareunauthorized usesandarenotallowedtobeperformedwiththemachine.

■ thetransportofpersons

■ stonedevelopmentorextraction

BucyrusAmerica,Inc.acceptsnoliabilityforanydamageresulting fromanysuchunauthorizeduse.

BI000958

Operatingconditions __________________________________________

2.6 Bucyrus – Model25M1ACContinuousMiner

• 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