BucyrusAmerica,Inc. 4041WurnoRoad Telephone:540-980-4530 Pulaski,VA24301 Fax:540-994-3763 Internet:www.bucyrus.com OperationManual Bucyrus - ContinuousMiner Model - 25C Doc.No.:A6474X308 BI000932
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ThismanualisintendedtoprovideGENERALproductinformationfor theModel25CContinuousMiner.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 A6474X308 Rev.0 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 Permissiblehoses 2.12 3. Storageandtransport Storageandtransport............................................................ 3.3 Storage 3.3 Storageofthemachineandspareparts 3.3 Long-termstorageofsparecomponents 3.4 Transport 3.5 Weights........................................................................... 3.5 Beforetransport 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 BI000932
1.
2.
5. Operation
Tableofcontents _________________________________________________ Bucyrus – Model25CContinuousMiner
Operation................................................................................. 5.3 HowtooperatetheContinuousMiner 5.3 WhoisallowedtooperatetheContinuousMiner 5.3 Whencanoperationbestarted? 5.3 Controlsandindicators 5.4 Redzone 5.30 Safetyprecautionsforundergroundoperation 5.35 Trammingsafetyrules 5.38 Radioremoteoperation 5.36 Startingprocedure 5.37 Shutdownprocedure 5.39 Trammingtheminer 5.40 Cutterheadoperation 5.42 Conveyoroperation 5.43 Scrubbermotoroperation 5.44 Areaandheadlightoperation..............................................5.45 Firesuppressioninradioremoteoperation 5.46 Conveyorboomcontrol.......................................................5.46 Stabilizercylinderraise/lowerinradioremoteoperation 5.47 Shearup/downinradioremoteoperation...........................5.47 Gatheringheadraise/floatinradioremoteoperation 5.47 Breakeron/offinradioremoteoperation............................5.48 E-stopbypass 5.49 Typicalcuttingsequence ....................................................5.50 Miningoperations 5.52 Mechanicalassemblies.......................................................5.57 Hydraulicsystem 5.65 Watersystem......................................................................5.97 Electricalsystem 5.107 Instructionsonthemaintenance.......................................5.127 Importantnotes 5.127 Beforemaintenance 5.127 Torquevalues 5.129 Lubricants,fluidsandcapacities 5.129 Specificlubricationandmaintenanceinstructions 5.133 Everyshift 5.133 Everythirdshift(daily) 5.137 Weekly 5.144 Monthly 5.148 Everythreemonths 5.154 Everysixmonths..........................................................5.159 Instructionsontheadjustmentprocedures 5.163 Settinghydraulicpressures..........................................5.163 Loadholdingvalve 5.164 Pilotpumpcircuitreliefvalve .......................................5.165 Tramtrack 5.167 Tailshim.......................................................................5.172 Chaintension 5.175 Sumptramming(cuttermotorfeedback) .....................5.176 BI000932
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A6474X308 Rev.0 Replacementofwearparts 5.183 CANsolenoid 5.183 ACdriveencoder 5.188 Tractiondrive 5.194 Cutterhead(boom)assembly 5.199 Boompivotpin .............................................................5.203 Shearcylinder 5.205 Centercutterdrum.......................................................5.210 Endcutterdrum 5.216 Drumdrivemotor .........................................................5.219 Drumdrivetorquelimitingclutch 5.223 Drumdrivegearcase...................................................5.227 Gatheringheadassembly 5.231 Gatheringheaddrivemotor.........................................5.236 Gatheringheadgearcase 5.242 Gatheringheadfootshaft ............................................5.248 Gatheringheadliftcylinder 5.251 CLA..............................................................................5.254 CLAtipreplacement 5.257 Trammotor...................................................................5.258 Tramprimaryplanetarygear 5.264 Tramsecondaryplanetarygear 5.267 Tramcase 5.271 Tramreachgearset 5.276 Tramsprocket 5.284 Tramtrackfrontidler 5.291 Frontidlertake-upcylinder 5.295 Hydraulicpump 5.297 Hydraulicpumpmotor 5.300 Scrubberfan/motor 5.304 Stabilizercylinder 5.306 Swivelpinassembly 5.309 Tailroller 5.312 Chainreplacement 5.314 Duo-coneseals............................................................5.315 Bearings 5.321 Bevelgears..................................................................5.327 Gearsandgearfailures 5.328 Lockwirefasteners......................................................5.330 Specialfasteners 5.330 Self-lockingscrews ......................................................5.330 Locknuts 5.331 Troubleshootingprocedures.............................................5.333 Typicalhydraulicproblems 5.334 Contaminantsinhydraulicsystems .............................5.335 Specifichydrauliccircuits 5.336 Multi-functionfailure 5.336 Oiltankfill 5.337 Cutterheadraise 5.337 Cutterheadlower 5.337 Gatheringheadraise 5.338 Gatheringheadfloat 5.338 Conveyorraise 5.338 Conveyorlower 5.339 BI000932
Tableofcontents
Tableofcontents _________________________________________________ Bucyrus – Model25CContinuousMiner Conveyorswing 5.339 Stabilizerraise 5.339 Stabilizerlower 5.339 Generalsafetyproceduresforshutdown 5.340 Excessivenoise 5.341 Excessiveheat..................................................................5.342 Incorrectflow 5.343 Incorrectpressure.............................................................5.344 Faultyoperation 5.345 Restartingchecklist...........................................................5.346 Watersystem 5.347 Bearings............................................................................5.349 Electricalsystem 5.350 ACtractionsystem............................................................5.353 Inverterfaultandwarningcodes 5.353 Rectifierfaultandwarningcodes.................................5.357 ACtractionsysteminterfacingconnectors andcabling...................................................................5.359 Controlsystempinouts 5.361 Solenoidfaultandwarningcodes.....................................5.367 RTDcorrespondingtemperaturevalues 5.370
Technicaldata Technicaldata 6.3 Tighteningtorques............................................................... 6.5 Permissibledata 6.7 Lubricationfluidsandgreases........................................ 6.7 7. Foryourinformation Foryourinformation .............................................................. 7.3 Ourservice 7.3 Serviceaddress .............................................................. 7.3 BI000932
6.
_______________________________________________________________ Aboutthismanual BI000932
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applicableoperatingmanual
machinetype newoperationmanual
Aboutthismanual
Thischapterprovidesimportantinformationmakingiteasierforyouto usethismanual.Youwillalsobegiveninformationonthestructureof themanualandthesymbolsandcharactersused.
Beforestartingtowork
Takecaretoensurethattheoperatingmanualavailabletoyouis applicableforthetypeofequipmentormachineused.
Thisoperatingmanualisintendedfor:
BucyrusModel25CContinuousMiner SerialNo.:N/A
andisonlypermittedtobeusedforequipmentofthistype.
Theoperatingmanualmustbeaccessibleatalltimestoallpersons workingonorwiththemachine.Itshould,ifpossible,alwaysbe availableattheplaceofoperation.
Sendforanewoperationmanualimmediatelyifthepresentmanualis nolongercompleteorhasbecomeillegible.
Whoisthisoperatingmanualintendedfor?
Thisoperatingmanualisintendedforthosepersonswhoworkwithor onthemachine.Everypersonworkingonthefaceorintheintersectionbetweenfaceandentryorintheentrymustreadthisoperating manual.
Thisincludespersonswho:
■ areinchargeoftransport
■ performassembly/disassemblywork
■ operatethemachine
■ eliminatefaults
■ performdailyroutineworkonthefaceorintheentry
■ performmaintenancework
■ performrepairwork
supervisorypersonnelwho:
___________________________________________ Beforestartingtowork A6474X308 Rev.0 1.3
■ initiateand/orsupervisetheactivitiesjustindicated. BI000932
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
Bucyrus – Model25CContinuousMiner
BI000932
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.
___________________________________________ Beforestartingtowork A6474X308 Rev.0 1.5
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Beforestartingtowork ____________________________________________
1.6
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Bucyrus – Model25CContinuousMiner
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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.
______________________________________________________ Personnel A6474X308 Rev.0 2.3
stateoftheart
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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.)
mayonlybecarriedoutbyserviceengineersfromBucyrusAmerica, Inc.orbyspeciallyqualifiedpersonnelofthemine.
Personnel _______________________________________________________
2.4
Bucyrus – Model25CContinuousMiner
training BI000932
Operatingconditions
Intendeduse
ThisContinuousMinerhasbeendesignedandmanufacturedforthe 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.
_____________________________________________ Operatingconditions A6474X308 Rev.0 2.5
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Operatingconditions _____________________________________________
2.6
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Bucyrus – Model25CContinuousMiner
• 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
