BucyrusAmerica,Inc. 4041WurnoRoad Telephone:540-980-4530 Pulaski,VA24301 Fax:540-994-3763 Internet:www.bucyrus.com OperationManual Bucyrus - ContinuousMiner Model - 35M3 Doc.No.:A6474X309 BI000933
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ThismanualisintendedtoprovideGENERALproductinformationfor theModel35M3ContinuousMiner.Theillustrations,descriptionsand procedurescontainedinthispublicationapplyonlytoTHISmachine. BucyrusAmerica,Inc.reservestherighttorevisemodelsanddesigns withoutpriornotice.
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 A6474X309 VUSV/0 ©BUCYRUSAMERICA,INC. Tableofcontents
Aboutthismanual Aboutthismanual 1.3 Beforestartingtowork 1.3 Whoisthisoperatingmanualintendedfor? 1.3 Whatisthepurposeofthisoperatingmanual? 1.4 Charactersandsymbols 1.5
1.
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 2.27
Storageandtransport Storageandtransport............................................................ 3.3 Storage ................................................................................ 3.3 Storageofthemachineandspareparts 3.3 Long-termstorageofsparecomponents........................ 3.4 Transport 3.5 Liftingpoints.................................................................... 3.6
Installation Installation............................................................................... 4.3 Pointstoobservepriortoinstallation 4.3 Whoisallowedtocarryoutinstallation?......................... 4.3 Whichtoolsarerequiredforinstallation? 4.3 Notesoninstallation........................................................ 4.4 Pre-installationchecklist 4.5 Safetyfeatures................................................................ 4.6 BI000933
2.
3.
4.
5. Operation
Tableofcontents _________________________________________________ Bucyrus – Model35M3ContinuousMiner ©BUCYRUSAMERICA,INC.
Operation..............................................................................5.3 HowtooperatetheContinuousMiner 5.3 WhoisallowedtooperatetheContinuousMiner 5.3 Whencanoperationbestarted? 5.3 Controlsandindicators 5.4 Operatingprocedures 5.36 Redzone 5.36 Safetyprecautionsforundergroundoperation 5.41 Trammingsafetyrules 5.41 Startingprocedure 5.43 Shutdownprocedure 5.45 Trammingtheminer 5.46 Cutterheadoperation 5.48 Conveyoroperation 5.49 Scrubbermotoroperation 5.51 Areaandheadlightoperation.....................................5.52 Firesuppression(optional) 5.53 Shearup/down ...........................................................5.53 Gatheringheadraise/float 5.53 Stabilizercylinderraise/lower.....................................5.53 Conveyorraise/lowerandswingleft/right 5.54 Trammingwithpendantcontrols................................5.55 Typicalcuttingsequence 5.57 Miningoperations.......................................................5.59 Mechanicalassemblies 5.65 Hydraulicsystem...............................................................5.71 Watersystem 5.107 Electricalsystem...............................................................5.119 Instructionsonthemaintenance 5.145 Importantnotes............................................................5.145 Beforemaintenance 5.145 Torquevalues 5.147 Lubricants,fluidsandcapacities 5.147 Specificlubricationandmaintenanceinstructions 5.153 Everyshift 5.153 Everythirdshift(daily) 5.157 Weekly 5.164 Monthly 5.168 Everythreemonths 5.174 Everysixmonths 5.180 Instructionsontheadjustmentprocedures.......................5.183 Pilot/auxiliarypumpcircuitrelief 5.185 Maincontrolvalve........................................................5.186 Tramtrack 5.190 Tailshim.......................................................................5.195 Conveyorchaintension 5.198 Sumptramming............................................................5.199 BI000933
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VUSV/0 ©BUCYRUSAMERICA,INC. Replacementofwearparts 5.201 Cutterhead(boom)assembly 5.201 Cutterheadassemblyremoval/installation 5.202 Shearcylinder 5.206 Centercutterdrum 5.211 Endcutterdrum.......................................................5.214 Drumdrivemotor 5.217 Drumdrivegearcase..............................................5.223 Gatheringheadassembly 5.226 Gatheringheadassemblyremoval/installation.......5.227 Gatheringheaddrivemotor 5.232 Gatheringheadgearcase ......................................5.235 Gatheringheadfootshaft 5.232 CLA .........................................................................5.235 CLAtipreplacement 5.245 Gatheringheadliftcylinder .....................................5.246 Crawlerassembly 5.250 Trammotor..............................................................5.251 Tramcase 5.256 Crawlerchain..........................................................5.261 Tramtrackfrontidler 5.265 Conveyorassembly 5.268 Conveyorchain 5.269 Conveyorassemblyremoval/installation 5.273 Dischargeconveyor 5.277 Tailroller 5.282 Troubleshootingprocedures 5.285 Typicalhydraulicproblems 5.286 Contaminantsinhydraulicsystems 5.287 Specifichydrauliccircuits 5.288 Generalsafetyproceduresforshutdown 5.292 Excessivenoise 5.293 Excessiveheat 5.294 Incorrectflow 5.295 Incorrectpressure........................................................5.296 Faultyoperation 5.297 Restartingchecklist......................................................5.298 Watersystem 5.299 Electricalsystem..........................................................5.301 Bearings 5.304 Controlsystem.............................................................5.305 Errorcodes 5.305 Faultcodes..............................................................5.327 BI000933
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Tableofcontents _________________________________________________ Bucyrus – Model35M3ContinuousMiner ©BUCYRUSAMERICA,INC. 6. Technicaldata Technicaldata .........................................................................6.3 Tighteningtorques 6.5 Permissibledata 6.7 Lubricationfluidsandgreases 6.7 7. Foryourinformation Foryourinformation 7.3 Ourservice...........................................................................7.3 Serviceaddress 7.3 BI000933
_______________________________________________________________ Aboutthismanual BI000933
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applicableoperatingmanual machinetype newoperationmanual
Aboutthismanual
Thischapterprovidesimportantinformationmakingiteasierforyouto usethismanual.Itcontainesinformationonthestructureofthemanualandthesymbolsandcharactersused.
Beforestartingtowork
Takecaretoensurethattheoperatingmanualavailabletoyouisapplicableforthetypeofequipmentormachineused.
Thisoperatingmanualisintendedfor:
BucyrusModel35M3ContinuousMiner SerialNo.:N/A
andisonlypermittedtobeusedforequipmentofthistype.
Theoperatingmanualmustbeaccessibleatalltimestoallpersons workingonorwiththemachine.Itshould,ifpossible,alwaysbeavailableattheplaceofoperation.
Sendforanewoperationmanualimmediatelyifthepresentmanualis nolongercompleteorhasbecomeillegible.
Whoisthisoperatingmanualintendedfor?
Thisoperatingmanualisintendedforthosepersonswhoworkwithor onthemachine.Everypersonworkingonthefaceorintheintersectionbetweenfaceandentryorintheentrymustreadthisoperating manual.
Thisincludespersonswho:
■ operatethemachine
■ areinchargeoftransport
■ performassembly/disassemblywork
■ find/fixfaults
■ performdailyroutineworkatthefaceorintheentry
■ performmaintenancework
■ performrepairwork
supervisorypersonnelwho:
■ initiateand/orsupervisetheactivitiesjustindicated.
________________________________________Beforestartingtowork A6474X309 VUSV/0 1.3 ©BUCYRUSAMERICA,INC.
BI000933
service safety
Whatisthepurposeofthisoperatingmanual?
Thisoperatingmanualisintendedtohelpyouworkefficientlyand safelywithourproduct.Itcontainsimportantinformationonalltheactivitiesrelatedtothemachine.
Readthisoperatingmanualcompletelyandatease.Payspecialattentiontothesafetyinstructions.Trytomemorizetheappearanceandthe meaningofthesafetyandinstructionsymbols.
Ifanydetailsarenotclearlyunderstood,pleasecontactourservicedepartment.Ourserviceaddressisgiveninthechaptertitled“Foryour information”.
Readthechapter“Foryoursafety”withspecialattention.Thechapter containsimportantinformationindicatingpossiblehazards.Observe theinformationgivenandfollowtheproceduralinstructions.
Beforestartingtowork ________________________________________ 1.4
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©BUCYRUSAMERICA,INC.
Bucyrus
Model35M3ContinuousMiner
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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 A6474X309 VUSV/0 1.5 ©BUCYRUSAMERICA,INC.
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Beforestartingtowork ________________________________________ 1.6
©BUCYRUSAMERICA,INC. BI000933
Bucyrus – Model35M3ContinuousMiner
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Yoursafety
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stateoftheart
Yoursafety
Thischapterprovidesvitalinformationforyoursafety.Payspecialattentiontothischapter.Thesafetyinstructionsandrulesofprocedure willhelpyoutoavoidhazardoussituationsandtoperformthenecessaryworkassafelyaspossible.
Thismachinehasbeenmanufacturedinaccordancewithstateofthe artandgenerallyrecognizedsafetystandardsandregulations. Youandotherscan,nevertheless,beexposedtodangeroussituations e.g.asaresultofenvironmentalinfluences,machinedamageoroperatorerrors.
alterations
Donotmakeanyalterationsormodificationswhichcouldimpairthe safeoperationandmaintainabilityofthemachine.Allmodifications andchangesmustbeapprovedbyBucyrusandallappropriateregulatoryagencies.
UseonlyoriginalsparepartsfromBucyrus.Notethattheuseofparts fromothermanufacturerswillvoidthewarranty.
Inadditiontothisoperatingmanualbesuretoalsoobservetherespectivelegalprovisionsandregulationsinyourcountry.
Observethesafetyandaccidentpreventionregulations
■ ofthemine,
■ ofthemine’sinspectors,and
■ oftheminingsupervisoryauthorities.
furtheroperatingmanuals
Readtheoperatingmanualsofthecomponentsrequiredforoperation, e.g.ofgearboxes,electricmotors,radioremotes,etc.,carefullyand thoroughly.Clarifyanyquestions before startingwork.
__________________________________________________ Personnel A6474X309 VUSV/0 2.3 ©BUCYRUSAMERICA,INC.
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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.)
mayonlybecarriedoutbyserviceengineersfromBucyrusorbyspeciallyqualifiedpersonnelofthemine.
Personnel ___________________________________________________
2.4
©BUCYRUSAMERICA,INC.
Bucyrus – Model35M3ContinuousMiner
training BI000933
Operatingconditions
Intendeduse
TheContinuousMinerhasbeendesignedandmanufacturedforspecificuses.Intendedusesinclude:
■ extractionofcoal,phosphate,potash,salt,trona,andothermediumhardnessminerals
■ loadingthematerialslistedaboveontoahaulagesystemorshuttle car,ordumpingitontothegroundforloadingatalatertime
■ operationongradesoflessthan10degrees
Unauthorizeduse
Applicationsnotexpresslylistedasintendedusesareunauthorized usesandarenotallowedtobeperformedwiththemachine.
■ thetransportofpersons
■ stonedevelopmentorextraction
BucyrusAmerica,Inc.acceptsnoliabilityforanydamageresulting fromanysuchunauthorizeduse.
_________________________________________ Operatingconditions A6474X309 VUSV/0 2.5 ©BUCYRUSAMERICA,INC.
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Operatingconditions __________________________________________
2.6
©BUCYRUSAMERICA,INC. BI000933
Bucyrus – Model35M3ContinuousMiner
• 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
