BucyrusAmerica,Inc. 4041WurnoRoad Telephone:540-980-4530 Pulaski,VA24301 Fax:540-994-3763 Internet:www.bucyrus.com OperationManual Bucyrus - ContinuousMiner Model - 25M3 Doc.No.:A6474X356 BI000979
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ThismanualisintendedtoprovideGENERALproductinformationfor theModel25M3ContinuousMiner.Theillustrations,descriptionsand procedurescontainedinthispublicationapplyonlytoTHISmachine. BucyrusAmerica,Inc.reservestherighttorevisemodelsanddesigns withoutpriornotice.
ThisContinuousMinerwasmanufacturedundertheguidelines,proceduresandrequirementssetforthinthesalesorderspecification.
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 BI000979
________________________________________________ Tableofcontents A6474X356 VESS/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 2.31
Storageandtransport Storageandtransport............................................................ 3.3 Storage 3.3 Storageofthemachineandspareparts 3.3 Long-termstorageofsparecomponents........................ 3.4 Transport 3.5 Beforetransport .............................................................. 3.8
Installation Installation 4.3 Pointstoobservepriortoinstallation 4.3 Whoisallowedtocarryoutinstallation?......................... 4.3 Whichtoolsarerequiredforinstallation? 4.3 Notesoninstallation 4.4 Pre-installationchecklist 4.5 Safetyfeatures................................................................ 4.6 BI000979
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3.
4.
5. Operation
Tableofcontents _________________________________________________ Bucyrus – Model25M3ContinuousMiner ©BUCYRUSAMERICA,INC.
Operation................................................................................. 5.3 HowtooperatetheContinuousMiner 5.3 WhoisallowedtooperatetheContinuousMiner........... 5.3 Whencanoperationbestarted? 5.3 Machinedescription 5.4 Controlsandindicators 5.4 Redzone.............................................................................5.25 Safetyprecautionsforundergroundoperation 5.30 Trammingsafetyrules 5.30 Startingprocedure 5.31 Shutdownprocedure 5.33 Trammingtheminer 5.34 Cutterheadoperation 5.36 Conveyoroperation 5.37 Areaandheadlightoperation 5.38 Firesuppressioninradioremoteoperation........................5.39 Shearup/downinradioremoteoperation 5.40 Gatheringheadraise/floatinradioremoteoperation 5.40 Stabilizercylinderraise/lowerinradioremoteoperation 5.40 Breakeron/offinradioremoteoperation............................5.42 Typicalcuttingsequence 5.43 Miningoperations................................................................5.45 Mechanicalassemblies 5.50 Hydraulicsystem.................................................................5.56 Watersystem 5.90 Electricalsystem.................................................................5.101 Instructionsonthemaintenance 5.142 Importantnotes............................................................5.142 Beforemaintenance 5.142 Lubricants,fluidsandcapacities..................................5.144 Specificlubricationandmaintenanceinstructions 5.148 Everyshift 5.148 Everythirdshift(daily) 5.150 Weekly 5.156 Monthly 5.159 Everythreemonths 5.166 Everysixmonths 5.170 Instructionsontheadjustmentprocedures 5.173 Pilot/auxiliarypumpcircuitrelief 5.175 Maincontrolvalve 5.177 Tramtrack 5.180 Tailshim 5.185 Chaintension 5.188 Mechanical 5.188 Greasetake-up....................................................5.190 Hydraulic 5.192 Cuttermotorfeedback .................................................5.193 BI000979
________________________________________________ Tableofcontents A6474X356 VESS/0 ©BUCYRUSAMERICA,INC. Replacementofwearparts 5.196 Cutterhead(boom)assembly 5.196 Boompivotpin 5.200 Shearcylinder 5.205 Centercutterdrum 5.210 Endcutterdrum ...........................................................5.214 Drumdrivemotor 5.218 Drumdrivetorquelimitingclutch 5.224 Drumdrivegearcase 5.229 Gatheringheadassembly............................................5.234 Gatheringheaddrivemotor 5.239 Gatheringheadgearcase ...........................................5.244 Gatheringheadfootshaft 5.250 Gatheringheadliftcylinder..........................................5.253 CLA 5.256 CLAtipreplacement ....................................................5.259 Trammotor 5.260 Tramprimaryplanetarygear........................................5.265 Tramsecondaryplanetarygear 5.268 Tramcase....................................................................5.273 Tramreachgearset 5.278 Tramsprocket 5.286 Tramtrackfrontidler 5.293 Frontidlertake-upcylinder ..........................................5.297 Hydraulicpump 5.299 Hydraulicpumpmotor 5.302 Fanmotorremoval/installation 5.305 Stabilizercylinder 5.308 Swivelpinassembly 5.310 Tailroller 5.312 Chainreplacement 5.314 Duo-coneseals 5.315 Bearings 5.321 Bevelgears 5.327 Gearsandgearfailures ...............................................5.328 Specialfasteners 5.330 Superbolts....................................................................5.332 Troubleshootingprocedures 5.336 Typicalhydraulicproblems ..........................................5.337 Contaminantsinhydraulicsystems 5.338 Specifichydrauliccircuits.............................................5.339 Multi-functionfailure 5.339 Oiltankfill ............................................................5.340 Cutterheadraise 5.340 Cutterheadlower ................................................5.340 Gatheringheadraise 5.341 Gatheringheadfloat ............................................5.341 Conveyorraise 5.342 Conveyorlower....................................................5.342 Conveyorswing 5.342 Stabilizerup 5.342 Stabilizerdown 5.342 BI000979
Tableofcontents _________________________________________________ Bucyrus – Model25M3ContinuousMiner ©BUCYRUSAMERICA,INC. Generalsafetyproceduresforshutdown 5.343 Excessivenoise 5.344 Excessiveheat 5.345 Incorrectflow 5.346 Incorrectpressure 5.347 Faultyoperation ...........................................................5.348 Restartingchecklist 5.349 Watersystem 5.350 Electricalsystem 5.352 Bearings.......................................................................5.356
Technicaldata Technicaldata 6.3 Tighteningtorques 6.5 Permissibledata 6.7 Lubricationfluidsandgreases 6.7
Foryourinformation Foryourinformation...............................................................7.3 Ourservice 7.3 Serviceaddress 7.3 BI000979
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7.
_______________________________________________________________ 1 Aboutthismanual BI000979
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applicableoperatingmanual machinetype
Aboutthismanual
Thischapterprovidesimportantinformationmakingiteasierforyouto usethismanual.Youwillalsobegiveninformationonthestructureof themanualandthesymbolsandcharactersused.
Beforestartingtowork
Takecaretoensurethattheoperatingmanualavailabletoyouisapplicableforthetypeofequipmentormachineused.
Thisoperatingmanualisintendedfor:
BucyrusModel25M3ContinuousMiner SerialNo.:N/A
andisonlypermittedtobeusedforequipmentofthistype.
newoperationmanual
Theoperatingmanualmustbeaccessibleatalltimestoallpersons workingonorwiththemachine.Itshould,ifpossible,alwaysbeavailableattheplaceofoperation.
Sendforanewoperationmanualimmediatelyifthepresentmanualis nolongercompleteorhasbecomeillegible.
Whoisthisoperatingmanualintendedfor?
Thisoperatingmanualisintendedforthosepersonswhoworkwithor onthemachine.Everypersonworkingonthefaceorintheintersectionbetweenfaceandentryorintheentrymustreadthisoperating manual.
Thisincludespersonswho:
■ areinchargeoftransport
■ performassembly/disassemblywork
■ operatethemachine
■ find/fixfaults
■ performdailyroutineworkonthefaceorintheentry
■ performmaintenancework
■ performrepairwork
supervisorypersonnelwho:
■ initiateand/orsupervisetheactivitiesjustindicated.
_______________________________________ Beforestartingtowork A6474X356 VESS/0 1.3 ©BUCYRUSAMERICA,INC.
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cost-effectiveness
Whatisthepurposeofthisoperatingmanual?
Thisoperatingmanualisintendedtohelpyouworkefficientlyand safelywithourproduct.Itcontainsimportantinformationonalltheactivitiesrelatedtothemachine.
Readthisoperatingmanualcompletelyandatease.Payspecialattentiontothesafetyinstructions.Trytomemorizetheappearanceandthe meaningofthesafetyandinstructionsymbols.
service safety
Ifanydetailsarenotclearlyunderstood,pleasecontactourservicedepartment.Ourserviceaddressisgiveninthechaptertitled“Foryour information”.
Readthechapter“Foryoursafety”withspecialattention.Thechapter containsimportantinformationindicatingpossiblehazards.Observe theinformationgivenandfollowtheproceduralinstructions.
Beforestartingtowork ________________________________________ 1.4
©BUCYRUSAMERICA,INC.
Bucyrus – Model25M3ContinuousMiner
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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 A6474X356 VESS/0 1.5 ©BUCYRUSAMERICA,INC.
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Beforestartingtowork ________________________________________ 1.6
©BUCYRUSAMERICA,INC. BI000979
Bucyrus – Model25M3ContinuousMiner
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2 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 A6474X356 VESS/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.)
mayonlybecarriedoutbyserviceengineersfromBucyrusAmerica, Inc.orbyspeciallyqualifiedpersonnelofthemine.
Personnel ___________________________________________________
2.4
©BUCYRUSAMERICA,INC.
Bucyrus – Model25M3ContinuousMiner
training BI000979
Operatingconditions
Intendeduse
TheContinuousMinerhasbeendesignedandmanufacturedforspecificuses.Intendedusesinclude:
■ extractionofcoal,phosphate,potash,salt,trona,andothermediumhardnessminerals
■ loadingthematerialslistedaboveontoahaulagesystemorshuttle car,ordumpingitontothegroundforloadingatalatertime
■ operationongradesoflessthan10degrees
Unauthorizeduse
Applicationsnotexpresslylistedasintendedusesareunauthorized usesandarenotallowedtobeperformedwiththemachine.
■ thetransportofpersons
■ stonedevelopmentorextraction
BucyrusAmerica,Inc.acceptsnoliabilityforanydamageresulting fromanysuchunauthorizeduse.
_________________________________________ Operatingconditions A6474X356 VESS/0 2.5 ©BUCYRUSAMERICA,INC.
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Operatingconditions __________________________________________
2.6
©BUCYRUSAMERICA,INC. BI000979
Bucyrus – Model25M3ContinuousMiner
• 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