CAT Bucyrus Continuous Miner 35M3 Operation Manual BI001567 – PDF DOWNLOAD

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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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5. Operation

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.

service safety

Whatisthepurposeofthisoperatingmanual?

Thisoperatingmanualisintendedtohelpyouworkefficientlyand safelywithourproduct.Itcontainsimportantinformationonalltheactivitiesrelatedtothemachine.

Readthisoperatingmanualcompletelyandatease.Payspecialattentiontothesafetyinstructions.Trytomemorizetheappearanceandthe meaningofthesafetyandinstructionsymbols.

Ifanydetailsarenotclearlyunderstood,pleasecontactourservicedepartment.Ourserviceaddressisgiveninthechaptertitled“Foryour information”.

Readthechapter“Foryoursafety”withspecialattention.Thechapter containsimportantinformationindicatingpossiblehazards.Observe theinformationgivenandfollowtheproceduralinstructions.

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.

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

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.

Bucyrus – Model35M3ContinuousMiner

Operatingconditions

Intendeduse

TheContinuousMinerhasbeendesignedandmanufacturedforspecificuses.Intendedusesinclude:

■ extractionofcoal,phosphate,potash,salt,trona,andothermediumhardnessminerals

■ loadingthematerialslistedaboveontoahaulagesystemorshuttle car,ordumpingitontothegroundforloadingatalatertime

■ operationongradesoflessthan10degrees

Unauthorizeduse

Applicationsnotexpresslylistedasintendedusesareunauthorized usesandarenotallowedtobeperformedwiththemachine.

■ thetransportofpersons

■ stonedevelopmentorextraction

BucyrusAmerica,Inc.acceptsnoliabilityforanydamageresulting fromanysuchunauthorizeduse.

cordonoffworkingarea

movingparts

Safetyinstructions

Generalrules

Alwaysworkwithfullconcentration.

Familiarizeyourselfwithyourworkingenvironment.

Alwayswearyourpersonalprotectiveequipment.Thisalsoincludes earprotectorsasthenoiseemittedbyotherequipmentintheareamay attimesexceed85db(A).

Informyourcolleaguesof

■ yourexactlocation,

■ theworkyouareperforming,and

■ thetimethatyouwillprobablyrequire.

Startthemachineonlywhenitisinagoodandsafeoperatingcondition andallprotectivedevices,e.g.emergencystopdevices,machinestop buttons,coverplates,etc.arecorrectlyinstalled.

Observetheacousticandopticalstart-upwarningsofthemachine.

Observethesymbolplatesonthemachine.

Presstheemergencystopbuttonimmediatelyintheeventoffaultor irregularitiesinoperation.Reportanyirregularitiestoyoursuperiorso thatnecessarymeasurescanbetakenimmediately.

Disconnect,lockout,andtagthepowersystemwhileperforming:

■ maintenance

■ inspection

■ repairwork

FollowallMine,State,andFederalregulationsregardinglockout/tag outprocedures.

Cordonoffyourworkingareawidelyforthemachine.

Neverallowpartsofyourbodytocomebetweenpartswhichcould move,suchase.g.:

■ chains,flights,andchainsprockets

■ pivotpoints

■ crawlerassembliesandconveyors

■ cutterandgatheringheadassemblies

Safetyinstructions

Storageandtransport

Maintaintheprescribedstorageperiodsandobservetheinstructions forstorage.

Donotstorematerialsorpartsinthetravelwayorinyourworking area.

Informthepersonsinvolvedabouttheintendedtransportrouteandthe anticipateddurationofthetransport.

Ensurethatthetransportsafetydevicesarecorrectlyfitted.

Fixallmovingpartswithtransportlocks. Neverstandunderunsupportedpartsorsuspendedloads.

Connecttheliftingequipmentonlytothepointsofattachmentprovided forthatpurpose.Observethedifferentloadlimitsoftheattachment points.Alsoobservetheinstructionsonthetransportsheet.

Onlyusemeansofattachmentwhichareingoodconditionandhave beendesignedfortheloadstobehandled.

Forroundcomponentsusetransportstraps,only.Neverusechainsor steelcablesforthispurpose.

Donotdamagethetreatedorpolishedsurfacesofshafts,sealingsurfaces,etc.

Whenusingmobilehandlingsystemsfortransportmakesurethatthe centerofgravityisaslowaspossible.

Pre-startinspection

Readthisentiremanualbeforeattemptingtooperatethismachine. Inspectthemachineandhaveanymalfunctioning,brokenormissing partscorrectedorreplacedbeforeuse.

Verifythatallmaintenancehasbeenperformed.

Verifythatallinstructionandsafetytagsareinplaceandreadable. Theseareasimportantasanyotherequipmentonthemachine.

Installationandstart-up

Oninclinedfacessecureallcomponentpartsbychains,e.g.tothe support.

Whenworkingwithoils,greasesandotherchemicalsubstances,observethesafetyregulationsapplicabletotheproduct.SafetyregulationscanbefoundonthecontainerorontheMaterialSafetyData Sheet(MSDS)fortheproduct.

Disposeofcleaningrags,etc.whichhavebeensoiledwithoil,grease orotherchemicalsubstancesinanenvironmentallysafemanner.

Whenstartingupmachine,donotoperateanycontrolslocatedinside theoperator’scompartment(optional)fromoutsidethecompartment.

Followthestartingprocedureinstructionsintheoperationsmanual. Donotoperateanylevers,pedalsorcontrolsifanyoneisinthered zone.(SeeRedZoneinChapter5ofthismanual)

Operation

Operatethemachineonlyifyouhaveaprofoundknowledgeofthe controlelementsandtheirfunctions.Itisnecessarythatyouhave beentasktrainedontherespectiveContinuousMiner.

Beforestart-up,ensurethattherearenopersonsorobstructionsin yourlineoftravelorinthearticulationareawhensteeringtheunit.

Checkthatallprotectivedevicesareinstalledonthemachineandfunctionproperly.

Useextremecautionwhentravelinginclosequartersorincongested orblind-travelareas.

Nevercarrypassengers.Passengersmaybethrownoffthemachine orcrushedbetweenthemachineandoutsideobjects.

Alwaysfollowallsafetyrulesofeachparticularminewhenoperating themachine.

Ifproblemsormalfunctionsareencounteredwhileoperatingtheunit, themachinemustbeproperlyshutdownandtheproblemcorrected immediately.

trailingcableuncoupled andlockedandtaggedout

Stopping

Alwaysparktheunitonsolid,levelground.Ifthisisnotpossible,park theunitatarightangletotheslopetopreventaccidentalmovementof themachine.

Useproperflags,warningsorbarrierswhenparkinginareasoftraffic. Thereisauniquecodeswitchsetupwhichpermitseachoperatorto activateonlyhisdesignatedminer,allowingseveralremote-controlled minerstooperateinthesameareawithoutgettingtheirradiosignals crossed.Inaddition,animproperlydecodedradiosignalwillautomaticallyshut-offtheminer.Followthegeneralsafetynoticesandsafety recommendationslistedintheremotecontrolsystemguide.

Maintenanceandrepair

Besuretoobservetheprescribedmaintenanceandinspectionintervals.

Informthesupervisorypersonnelandthefacecrewofanymaintenance andrepairoperations.Givetheminformationontheintendedoperationsandtheanticipatedduration.

Beforeattemptinganyrepairs,a DANGER signmustbeattachedtothe appropriatecircuitatthepowerdistributionbox.Itismandatoryunder theUnitedStatesFederalLawthatthetrailingcablebeuncoupled, taggedandlocked-outfromthepowersourcetoprovidevisualevidencethattheminerisde-energized.

securing

Secureyourworkingareaoverawiderange,inordertoavoidendangeringotherpersons.

Disconnectthepowerfromthemachinetopreventunauthorizedand unintentionalrestarting.

Protectyourworkareaagainstfallingrocks.

Passdefectivecomponentsremovedonforservicingwithoutdelayin ordertopreventthesepartsbeingreinstalledelsewhere.

originalparts

methanemonitoring

Useonlysparepartswhichsatisfythespecifiedtechnicalrequirements. ThisisonlyensuredwithoriginalBucyrusspareparts.Pleasereferto thesparepartslistsorpartscatalogfortheordernumbers.

Beforeattemptinganyrepairsormaintenance,methaneairmonitoring mustbecompletedbeforeandduringtherepairandmaintenance.

lifting

Safetyinstructions

ForraisingtheContinuousMineruseonly:

■ cribblockswithadequateload-holdingcapacity.

■ hoists,jacksorcraneswithadequateload-carryingcapacity.

handlingofhydraulicfluids

Avoiddirectcontactbetweentheskinandhydraulicfluids.Hydraulic fluidcanpenetratetheskinandcauseseriousinfection.

Neverusehydraulicfluidforrinsingorcleaning.Hydraulicfluidrepresentsaveryseriousdangertohealth.

maintenance/repair

Onlypersonswhohaveandcandemonstrateaspecialknowledgeof hydraulicsareallowedtoworkonthehydraulicsystem.

Avoid,wheneverpossible,servicing,cleaningorexaminingthemachineincongestedareas.

Avoid,wheneverpossible,servicingorprovidingmaintenancetothe unitunlesstheappropriatesafetydevicesareplacedwhererecommendedtopreventaccidentalmovementoftheunit.

Donotaltertheelectricalorhydraulicsettingsfromthatindicatedinthis manualorassetatthefactory.

Alwaysreplacedamagedorlostdecalsandmetalinstructionplates. Disconnectthepowerwhenworkingwiththeelectricalsystem,orwhen weldingontheunittopreventelectricalshock.

Alwaysfollowallsafetyproceduresofeachparticularminewhenperformingmaintenance.

Itisimportantthatanyprocedurenotspecificallyrecommendedinthis guidebethoroughlyevaluatedfromthestandpointofsafetybeforeitis implemented.

Safetyinstructions

Someillustrationsinthismanualshowguardsorcoverpanelsremoved forpurposesofclarity.Neveroperateunitwithoutguardsorcoverpanelsinplace.

Carryoutavisualinspectionofallthehydrauliccomponentsatregular intervals.Inparticularcheckthat:

■ thehosesarenotpinchedortrapped.

■ thehoseshavenobubblesorblisters.

■ thehoseoroutersheathsofthehosearenotabnormallyrigidor hard.

■ theoutersheathofthehosesisnotdamaged.

■ theconnectorsaresecurelyinsertedintothesockets.

■ theconnectionsareleak-tight.

Ensurethatnodirtentersthehydraulicsystemduringrepairwork.Dirt inthehydraulicsystemcancauseseriousdamageinthewholesystem! Flushoutthehydrauliclinesthoroughlybeforeconnecting.

permissiblehoses

Ifhydraulichosecouplersaredifficulttodisconnectorcannotbedisconnected,thehydrauliclinemaystillbepressurized.Besuretodepressurizethelinebeforedisconnectingcouplers.

Securetheconnectorsofthehydraulicelementsonlywiththeproper couplingclamps.Alwaysfastentheclampscompletelyandwithboth sides.Neverusenails,wireorsimilarmaterialsforsecuring.

Afterfinishingrepairwork,checkallconnectorsandconnectionsfor leaksbeforepressurizingthesystemagain.

Useonlyhydraulichosesapprovedfortheprevailingpressures.

Donotuseanyhydraulichoseswithdamagedconnectorsorwornorings.

Replacehydraulichosesonlywithhosesofthesameorahigherquality.

Nevertrytoholdajumpinghydraulichose.Depressurizethelinein questionimmediately.

Nevertrytorepairdamagedhydraulichoses.

Replacehydraulichosesatthefirstsuspicionofdamage.

installinghydraulichoses

Installthehydraulichosesproperlybehindthebracketsandclamps providedforthem.

Alwaysinstallhydraulichosessothey:

■ alwayshavealittleslack.

■ arenottwisted.

Fig.2:Installinghydraulichoses,twisting

■ arenotbentdirectlybehindtheconnections. (distancemin.1.5xnominaldiameter).

Fig.3:Installinghydraulichoses,bending Right

Fig.1:Installinghydraulichoses,slack

Safetyinstructions

■ alwayshavealittleslack.

■ arenotkinked.

■ donothavetowithstandtensilestrains.

■ areprotectedagainstthermalradiation.

■ areaccessibleatalltimes.

Screwhydraulichosesintothesocketsonlybyhandandfingertighten. Nevertrytodrivethehydraulichosesinwithatoolasthiswilldamage theconnections.Usetheappropriateamountoftorquetoensurea properhosefit.

Wheninstallingthehydraulichoses,ensurethattheycannotbe:

■ tornout,

■ kinked,

■ crushed,

■ drivenoveror

■ twistedbymovementofthemachine.

Fig.4:Installinghydraulichoses,connectionsonmovingparts

Overviewofthesafetyinstructions

Thisisasummaryofallthesafetyinstructionswhichhavetobeobservedinthefollowingchapters.Thissummaryisintendedonlytogive youanoverviewofalltheinstructions.Insomecases,thereisnologicalrelationshipbetweentheindividualinstructions.

Chapter3:Storageandtransport

IMPORTANT!

Takecaretoinsurethatnewmaintenancesuppliesarestored separatelyfromexistingstockandthatremovaltakesplaceonthe “firstin,firstout”principle.

WARNING!

Useonlyloadhandlingdevicescomplyingwiththetechnicaland legalregulationsforthetransportofloads. Youcouldbeseriouslyinjuredorevenkilledbyfallingloads.

WARNING!

DonotusetheeyebolttoliftthecomponentANDitsrelatedassemblies.

Chapter4:Installation

CAUTION!

SeriousdamagecanbecausedtotheContinuousMinerasaresultofincorrectinstallation.TheunitshouldthereforeonlybeinstalledundertheinstructionofspecialistsfromBucyrus.

IMPORTANT!

Thesequenceofoperationsduringinstallationmustbeadaptedto theindividualconditionsprevailingatthesite.Beforestartingthe workadetailedlistofstepstobetakenwithrespecttotransport andassemblyshouldbepreparedandacorrespondingplan established.

NOTICE!

Themachinewasinspectedpriortoshipmentfromthefactoryto ensureproperfunctioningandinstallationofallcomponents. However,toensurethatnotransitdamagehasoccurred,thefollowingpre-startupchecksshouldbeperformed:

NOTICE!

Theoperatormustbecomefamiliarwithallthesafetyfeaturesand theirlocationonthemachinepriortoinstallationoroperation.

WARNING!

Ifeitherofthefiresuppressionactuators(optional)isactuated, thesystemmustbecompletelyrechargedwithdrychemicalsand expellants.

DANGER!

Donotoperatethemachinewithanyoftheguardsorcoversremoved.Youorotherpersonnelcouldbeseriouslyinjuredfrom movingorrotatingparts.

Chapter5:Operation

DANGER!

Incorrectoperationendangersyourselfandothers!Incorrectoperationofthemachineisoftenthecauseofveryseriousaccidents!Operatetheunitonlywhenyouhavebeensufficiently trainedonthemachineandhavereadandunderstoodthisoperatingmanual.Shouldanythingbeunclear,pleasecontactyourimmediatesupervisor.

NOTICE!

Beforebeginningcuttingoperations,carefullyunloadthetrailing cableprovidingenoughslackandplacingitwhereitallowsadequateclearanceforsafemaneuverabilityoftheminer.

DANGER!

TheContinuousMinerisradioremotecontrolledduringproductionoperations.Manualoperationviacontrolsattheoperator’s stationisnotpermittedforproductionoperation.Manualoperationisfortroubleshootingandmaintenanceundersupportedroof only.TrammingviatheEmergencytrampendantisonlypermitted insituationswhentheradioremotesystemisinoperable.OperatingtheContinuousMinerwithmanualorpendantcontrolsunder unsupportedroofmayresultinsevereinjuryordeath.

NOTICE!

Onceahydrauliccontrolvalvehandleisreleasedbytheoperator, theleverwillautomaticallyreturntothecentered(“HOLD”)position.

DANGER!

Powertothemachinemustalwaysbeisolatedtothetrailingcable atthesectionpowercenterbeforeeitherthevictorsocketisremovedorthemaincircuitbreakercaseisopened.Wheneverany workisperformedonthecontinuousminer,allmine,State,and Federalregulationsregardinglockout/tagoutofthemachine.

WARNING!

Radioremotecontrolsystemsaredangerous.Thecontinuous mineroperatorcannotoperatearemotesystemuntilheisproperlytrainedintheoperationofthesystem.Remotecontrolsystemssometimeshaveautomaticfeaturesofwhichuntrainedoperatorsandworkersarenotaware.

IMPORTANT!

Foroperatinginstructions,includingstarting,shuttingdown, tramming,andmining,usingtheremotecontrol,seetheOperating proceduressectionofthischapter.

IMPORTANT!

Thependantcontrolleranditsumbilicalcordshouldbestoredina protectedlocationontheworkingsection,awayfromtheminer,to preventdamage.

• 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.