BucyrusAmerica,Inc. 4041WurnoRoad Telephone:540-980-4530 Pulaski,VA24301 Fax:540-994-3763 Internet:www.bucyrus.com OperationManual Bucyrus - FULLDIMENSION ® ContinuousHaulageSystem Doc.No.: A6474X251
• 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
ThismanualisintendedtoprovideGENERALproductinformationfor theFULLDIMENSION® ContinuousHaulageSystem.Theillustrations, descriptionsandprocedurescontainedinthispublicationapplyonlyto thissystem.BucyrusAmerica,Inc.reservestherighttorevisemodels anddesignswithoutpriornotice.
Thishaulagesystemwasmanufacturedundertheguidelines,proceduresandrequirementsoftheU.S.FederalCoalMineHealthand SafetyAct,CodeofFederalRegulations,Title30,Chapter1,Subpart0, Part75forundergroundcoalmines,andotherapplicablenon-U.S. regulatoryagencystandards.
Atthecompletionofthemanufacturingprocess,thissystemwasissued theappropriateapprovalnumbersandnameplatesindicatingitmetthe technicalrequirementsoftheseregulatoryagencies.Anychangetothe designorstructureofthissystem,withouttheconsentofBucyrus America,Inc.andtheseregulatoryagencies,oranyrepairorreplacementofpartscontrarytoBucyrusAmerica,Inc.’sinstructions,mayinvalidatetheseapprovalsandrenderthissystemunsafetooperate.
StrictcompliancewithallFederalandStateMininglaws,regulations andpracticesregardingthesafeoperationandmaintenanceofundergroundminingequipmentandstrictadherencetotheinstructionsinthis manualisnecessaryforthepersonalsafetyofthoseworkingonor aroundthissystem.
Whilethismanualattemptstoanticipatethemostimportantoperations andmaintenanceneedsforthissystem,unforeseencircumstancesmay arisethathavenotbeenaddressedinthismanual.Ifanyconcernsor questionsarise,pleasecontactyourBucyrusAmerica,Inc.Service Representative immediately
Thisworkcontainsinformationprotectedundertradesecretandother intellectualpropertylaws,andisprotectedundertheU.S.Copyright Actof1976,asamended.Thisworkisprovidedunderlicenseandthe licenseisnon-transferable.Distributionandaccessislimitedonlyto authorizedpersonnel.Disclosure,reproduction,distributionorunauthorizedusemaybeaviolationoffederalandstatelawsandmaysubjecttheunauthorizedusertocriminalliability.
__________________________________________________________
© BUCYRUSAMERICA,INC. ALLRIGHTSRESERVED
________________________________________________ Tableofcontents A6474X251 SUVT/03 © B U C Y R U S A M E R I C A , I N C 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 2.9 Installationandstart-up 2.9 Operation 2.9 Maintenanceandrepair 2.10 Overviewofthesafetyinstructions 2.15 Chapter3:Storageandtransport 2.15 Chapter4:Installation....................................................2.15 Chapter5:Operation 2.16 Chapter6:Technicaldata..............................................2.23
Storageandtransport Storageandtransport 3.3 Storage 3.3 Storageoftheequipment 3.3 Transport 3.4 Dimensionsandweights................................................. 3.4 Beforetransport 3.5
Installation Installation............................................................................... 4.3 Pointstoobservepriortoinstallation 4.3 Whoisallowedtocarryoutinstallation 4.3 Whichtoolsarerequiredforinstallation.......................... 4.3 Notesoninstallation 4.4 Pre-installationchecklist 4.5 Safetyfeatures 4.6 Overviewofthecontinuoushaulagesystem....................... 4.8
1.
2.
3.
4.
5. Operation
Tableofcontents _________________________________________________ BUCYRUS – FULLDIMENSION®ContinuousHaulageSystem © B U C Y R U S A M E R I C A , I N C
Operation................................................................................. 5.3 Howtooperatethecontinuoushaulagesystem 5.3 Whoisallowedtooperatethecontinuoushaulage system? 5.3 Whencanconveyingbestarted? 5.3 Controlsandindicators 5.4 Operator’scompartment................................................. 5.4 Startingprocedure 5.12 General 5.12 Checklist 5.13 Operatingprocedures 5.15 Startingthepumpmotor 5.15 Startingtheconveyors(automaticmode) 5.15 Startingtheconveyors(individualmode) 5.16 Joggingtheconveyors 5.17 Tramming...............................................................5.17 Stoppingthepump 5.18 Pumpmotorreset 5.19 Conveyorlift 5.19 Cabandcanopy.....................................................5.19 Lights 5.19 Instructionsonthemaintenanceofthecontinuous haulagesystem 5.21 Importantnotes..............................................................5.21 Beforemaintenance 5.21 lubricants........................................................................5.23 Instructionsonthelubricationofthemobilebridge carrier(MBC)..................................................................5.24 Centrallubricationsystem 5.24 Specificlubricationprocedures..............................5.27 Every8hours 5.27 Daily 5.29 Everyweek 5.30 Afterfirst50hoursofservice 5.32 Every2weeks 5.33 Everymonth 5.36 Every3months 5.39 Every6months 5.40 Asrequired 5.41 Instructionsonthelubricationofthepiggyback conveyor(PIG) 5.42 Specificlubricationprocedures(PIG) 5.43 Daily 5.43 Everyweek 5.44 Every30hours.......................................................5.45 Every3to6months 5.46 Every6months......................................................5.47 InstructionsonthelubricationoftheRFMtaildolly 5.48 Specificlubricationprocedures(RFMtaildolly) ....5.49 Every8hours 5.49 Every24hours.......................................................5.49
________________________________________________ Tableofcontents A6474X251 SUVT/03 © B U C Y R U S A M E R I C A , I N C InstructionsonthelubricationoftheRFMpulley supportsection 5.50 Specificlubricationprocedures(RFMpulley supportsection) 5.51 Every8hours 5.51 Every6months......................................................5.51 InstructionsonthelubricationoftheintermediateRFM section 5.52 Specificlubricationprocedures(intermediateRFM section) ..................................................................5.53 Every6months 5.53 Inspectionofthemobilebridgecarrier...........................5.54 Inspectionofwearpartsonthemobilebridgecarrier 5.55 Inspectionoffiresuppressionsystemonthemobile bridgecarrier 5.55 Rechargeoffiresuppressionsystemonthemobile bridgecarrier 5.57 Rechargeinspectionoffiresuppressionsystemonthe mobilebridgecarrier 5.58 Inspectionofthepiggybackbridgeconveyor.................5.61 Inspectionofwearpartsonthepiggybackbridge conveyor 5.60 InspectionoftheRFM 5.61 Instructionsontheadjustmentproceduresonthemobile bridgecarrier 5.63 Conveyorchain 5.63 Crawlertrack 5.65 Instructionsontheadjustmentproceduresonthe piggybackbridgeconveyor 5.67 Conveyorchain 5.67 Instructionsonthereplacementofwearpartsonthe mobilebridgecarrier(MBC) 5.69 Conveyordrive 5.69 Driveshaft 5.70 Howtoremovethedriveshaft ........................5.71 Howtoinstallthedriveshaft 5.74 Driveshaftsprocket...............................................5.78 Howtoremovethedriveshaftsprocket 5.79 Howtoinstallthedriveshaftsprocket.............5.79 Howtoremovethedriveshaftsprocketfor fieldreplacement.............................................5.80 Conveyordrivemodule 5.82 Howtoremovetheconveyordrivemodule.....5.83 Howtoinstalltheconveyordrivemodule 5.84 Howtodisassembletheconveyordrive module 5.85 Howtoassembletheconveyordrivemodule .5.86 Tailshaft 5.88 Howtoremovethetailshaft............................5.89 Howtoinstallthetailshaft 5.89 Howtodisassemblethetailshaft 5.91 Howtoassemblethetailshaft 5.92
Tableofcontents _________________________________________________ BUCYRUS – FULLDIMENSION®ContinuousHaulageSystem © B U C Y R U S A M E R I C A , I N C Conveyorchain 5.93 Howtoassembletheconveyorchain sections 5.94 Howtoremovetheconveyorchainassembly 5.95 Howtoinstalltheconveyorchainassembly 5.96 Crawlertrack ......................................................... 5.98 Howtoassemblethecrawlertrackpads 5.99 Howtoremovethecrawlertrackpad assembly 5.99 Howtoinstallthecrawlertrackpad assembly 5.100 Crawlerdrivemodule ...........................................5.101 Howtodisassemblethecrawlerdrive module ..........................................................5.102 Howtoassemblethecrawlerdrivemodule 5.103 Crawlertake-upandidler.....................................5.104 Howtoremovethecrawlertake-upand idler ................................................................5.105 Howtoinstallthecrawlertake-upandidler 5.106 Instructionsonthereplacementofwearpartsonthe piggybackbridgeconveyor 5.107 Conveyordrive 5.107 Driveshaft 5.108 Howtoremovethedriveshaft.......................5.109 Howtoinstallthedriveshaft 5.111 Driveshaftsprockets 5.114 Howtoremovethedriveshaftsprockets 5.115 Howtoinstallthedriveshaftsprockets 5.115 Howtoremovethedriveshaftsprocketsfor fieldreplacement 5.116 Conveyordrivemodule 5.117 Howtoremovetheconveyordrivemodule 5.118 Howtoinstalltheconveyordrivemodule 5.119 Howtodisassembletheconveyordrive module...........................................................5.121 Howtoassembletheconveyordrivemodule5.121 Tailshaft...............................................................5.123 Howtoremovethetailshaft 5.124 Howtoinstallthetailshaft.............................5.124 Howtodisassemblethetailshaft 5.125 Howtoassemblethetailshaft.......................5.126 Conveyorchain 5.128 Howtoassembletheconveyorchain sections 5.129 Howtoremovetheconveyorchain assembly 5.130 Howtoinstalltheconveyorchainassembly..5.131
________________________________________________ Tableofcontents A6474X251 SUVT/03 © B U C Y R U S A M E R I C A , I N C Instructionsonthereplacementofhydrauliccomponents onthemobilebridgecarrier(MBC) 5.133 Hydrauliccomponents(MBC) 5.133 Tramhydrostaticpump 5.135 Howtodisassemblethehydrostaticpump drive...............................................................5.136 Howtoassemblethehydrostaticpumpdrive5.137 Trammotor 5.138 Howtoremovetrammotor 5.138 Howtoinstalltrammotor...............................5.138 Conveyorliftcylinders(inbyandoutby) 5.139 Howtoremoveconveyorliftcylinders ..........5.139 Howtoinstallconveyorliftcylinders 5.140 Canopycylinder...................................................5.141 Howtoremovecanopycylinder 5.141 Howtoinstallcanopycylinder .......................5.141 Troubleshootingprocedures 5.143 Hydraulicsystem(general)..................................5.144 Hydrauliccylinders 5.146 Hydraulicpump....................................................5.147 Valves 5.150 Errorcodes 5.151 Communicationfaults 5.152 Faultlogcodes..............................................5.152 Realtimecodes 5.155 6. Technicaldata Technicaldata......................................................................... 6.3 Componentsofthecontinuoushaulagesystem.................. 6.3 MobileBridgeCarrier(MBC) 6.3 PiggybackBridgeConveyor(PBC)................................. 6.4 PiggybackBridgeConveyor(PBC liquidcooled) 6.5 MBCdolly........................................................................ 6.5 RFMpulleysection 6.5 RFMintermediatesection............................................... 6.5 Taildolly 6.5 Tighteningtorques............................................................... 6.7 Permissiblemedia 6.13 Lubricationfluidsandgreases.......................................6.13 7. Foryourinformation Foryourinformation .............................................................. 7.3 Ourservice 7.3 Serviceaddress .............................................................. 7.3 Rebuildfacilityaddress 7.4
Tableofcontents _________________________________________________ BUCYRUS – FULLDIMENSION®ContinuousHaulageSystem © B U C Y R U S A M E R I C A , I N C
_______________________________________________________________ 1 Aboutthismanual
________________________________________________________________
applicableoperatingmanual machinetype
Aboutthismanual
Thischapterprovidesimportantinformationmakingiteasierforyouto usethismanual.Youwillalsobegiveninformationonthestructureof themanualandthesymbolsandcharactersused.
Beforestartingtowork
Takecaretoensurethattheoperatingmanualavailabletoyouisapplicableforthetypeofequipmentormachineused.
Thisoperatingmanualisintendedfor:
Bucyrus – FULLDIMENSION® ContinuousHaulageSystem SerialNo.:N/A
andisonlypermittedtobeusedforequipmentofthistype.
Theoperatingmanualmustbeaccessibleatalltimestoallpersons workingonorwiththemachine. Itshould,ifpossible,alwaysbeavailableattheplaceofoperation.
Sendforanewoperationmanualimmediatelyifthepresentmanualis nolongercompleteorhasbecomeillegible.
Whoisthisoperatingmanualintendedfor?
Thisoperatingmanualisintendedforthosepersonswhoworkwithor onthemachine.
Everypersonworkingonthefaceorintheintersectionbetweenface andentryorintheentrymustreadthisoperatingmanual.
Thisincludespersonswho:
■ areinchargeoftransport
■ preparetheriseheading
■ performassembly/disassemblywork
■ operatethemachine
■ eliminatefaults
■ performdailyroutineworkonthefaceorintheentry
■ performmaintenancework
■ performrepairwork
supervisorypersonnelwho:
■ initiateand/or
■ supervisetheactivitiesjustindicated.
_______________________________________ Beforestartingtowork A6474X251 SUVT/03 1.3 © B U C Y R U S A M E R I C A , I N C
newoperationmanual
cost-effectiveness
Whatisthepurposeofthisoperatingmanual?
Thisoperatingmanualisintendedtohelpyouworkefficientlyand safelywithourproduct.Itcontainsimportantinformationonalltheactivitiesrelatedtothemachine.
Readthisoperatingmanualcompletelyandatease.Payspecialattentiontothesafetyinstructions.Trytomemorizetheappearanceandthe meaningofthesafetyandinstructionsymbols.
service safety
Ifanydetailsarenotclearlyunderstood,pleasecontactourservicedepartment.Ourserviceaddressisgiveninthechaptertitled“Foryour information”.
Readthechapter“Foryoursafety”withspecialattention.Thechapter containsimportantinformationindicatingpossiblehazards.Observe theinformationgivenandfollowtheprocedural instructions
Beforestartingtowork ________________________________________ 1.4 BUCYRUS – FULLDIMENSION®ContinuousHaulageSystem © B U C Y R U S A M E R I C A , I N C
Charactersandsymbolsused
Thefollowingcharactersandsymbolsareusedforsafetyinstructions andimportantinformationintheoperatingmanual.
Trytomemorizethesymbolsandtheirmeanings.
DANGER!
Pointsinthetextmarkedwiththissymboldrawyourattentionto immediatelyimpendingdanger.Possibleconsequencesare: veryseriousinjuryorevendeath.
WARNING!
Thesepointscontaininformationondangeroussituations. Possibleconsequencesare:veryseriousinjuryorevendeath.
CAUTION!
Thissymboldrawsattentiontodangeroussituations.Possible consequencesare:lighttomoderatelyseriousinjuriesand machinedamage.
NOTICE!
Pointsinthetextmarkedwiththissymboldrawattentionto harmfulsituations.Possibleconsequencesare:damagetothe machineordamageintheimmediatevicinity.
IMPORTANT!
Pointsinthetextmarkedwiththissymbolcontainusefultipsand informationintendedtofacilitateworkforyou.Theydonotwarn aboutharmfulordangeroussituations.
■ Itemsinlistsaremarkedwithbullets.
– Pointsinsub-listsaremarkedwithalongdashatthestartof theline.
Pointsintextmarkedinthiswaydescribeindividualoperations. Followtheseinstructionsstepbystep.Theywillhelpyoucarryout yourworkfasterandmoreimportantly,safer.
_______________________________________ Beforestartingtowork A6474X251 SUVT/03 1.5 © B U C Y R U S A M E R I C A , I N C
Beforestartingtowork ________________________________________ 1.6 BUCYRUS – FULLDIMENSION®ContinuousHaulageSystem © B U C Y R U S A M E R I C A , I N C
_______________________________________________________________
2 Yoursafety
________________________________________________________________
furtheroperatingmanuals
Yoursafety
Thischapterprovidesvitalinformationforyoursafety. Payspecialattentiontothischapter.Thesafetyinstructionsandrules ofprocedurewillhelpyoutoavoidhazardoussituationsandtoperform thenecessaryworkassafelyaspossible.
Themachinehasbeenmanufacturedinaccordancewiththestateof theartandgenerallyrecognizedsafetystandardsandregulations. Youandotherscanneverthelessbeexposedtodangeroussituations e.g.asaresultofenvironmentalinfluences,machinedamageoroperatorerrors.
Donotmakeanyalterationsormodificationswhichcouldimpairthe safetyofthemachine.AllmodificationsandchangesmustbeapprovedbyBucyrusAmerica,Inc.
UseonlyoriginalsparepartsfromBucyrusAmerica,Inc.Notethatthe useofpartsfromothermanufacturerswillvoidtheguarantee.
Inadditiontothisoperatingmanualbesuretoalsoobservetherespectivelegalprovisionsandregulationsinyourcountry.
Observethesafetyandaccidentpreventionregulations:
■ ofthemine
■ oftheMinesInspectorateand
■ oftheminingsupervisoryauthorities
Pleasereadalsotheoperatingmanualsofthecomponentsrequiredfor operation,e.g.ofgearboxes,electricmotors,etc.,carefullyandthoroughly.Clarifyanyquestions before startingwork.
_________________________________________________ Yoursafety A6474X251 SUVT/03 2.3 © B U C Y R U S A M E R I C A , I N C
stateoftheart
• 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
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
© B U C Y R U S A M E R I C A , I N C
– FULLDIMENSION®ContinuousHaulageSystem
training
