BucyrusAmerica,Inc. 4041WurnoRoad Telephone:540-980-4530 Pulaski,VA24301 Fax:540-994-3763 Internet:www.bucyrus.com OperationManual Bucyrus - ContinuousMiner Model - 30M3L Doc.No.:A6474X352 BI000976
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ThismanualisintendedtoprovideGENERALproductinformationfor theModel30M3LContinuousMiner.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 BI000976
_________________________________________________ Tableofcontents A6474X352 VPSS/0 ©BUCYRUSAMERICA,INC. Tableofcontents
Aboutthismanual Aboutthismanual 1.2 Beforestartingtowork 1.2 Whoisthisoperatingmanualintendedfor? 1.2 Whatisthepurposeofthisoperatingmanual?....................1.3 Charactersandsymbols 1.4
Yoursafety Yoursafety 2.2 Personnel 2.3 Operation 2.3 Installationandrepair......................................................2.3 Operatingconditions 2.4 Intendeduse 2.4 Unauthorizeduse 2.4 Safetyinstructions 2.5 Generalrules 2.5 Storageandtransport 2.6 Pre-startinspection 2.6 Installationandstart-up 2.7 Operation 2.7 Stopping 2.8 Maintenanceandrepair 2.8 Overviewofthesafetyinstructions 2.13 Chapter3:Storageandtransport.................................. 2.13 Chapter4:Installation 2.13 Chapter5:Operation..................................................... 2.14 Chapter6:Technicaldata 2.28 3. Storageandtransport Storageandtransport.............................................................3.2 Storage 3.2 Storageofthemachineandspareparts 3.2 Long-termstorageofsparecomponents........................3.3 Transport 3.4 Liftingpoints ....................................................................3.5 4. Installation Installation 4.2 Pointstoobservepriortoinstallation 4.2 Whoisallowedtocarryoutinstallation?.........................4.2 Whichtoolsarerequiredforinstallation? 4.2 Notesoninstallation 4.3 Pre-installationchecklist 4.4 Safetyfeatures ................................................................4.5 BI000976
1.
2.
5. Operation
Tableofcontents _________________________________________________ Bucyrus – Model30M3LContinuousMiner ©BUCYRUSAMERICA,INC.
Operation ..............................................................................5.2 HowtooperatetheContinuousMiner 5.2 WhoisallowedtooperatetheContinuousMiner .............5.2 Whencanoperationbestarted? 5.2 Controlsandindicators 5.3 Machinecontrolsystem 5.11 Operatingprocedures........................................................5.25 Redzone 5.25 Safetyprecautionsforundergroundoperation 5.30 Trammingsafetyrules 5.30 Startingprocedure 5.31 Shutdownprocedure 5.33 Trammingtheminer 5.34 Cutterheadoperation 5.36 Blowingsystemoperation 5.37 Conveyoroperation ....................................................5.38 Areaandheadlightoperation 5.39 Firesuppression(optional) 5.40 Shearup/down 5.41 Gatheringheadraise/float ..........................................5.41 Stabilizercylinderraise/lower 5.41 Conveyorraise/lowerandswingleft/right...................5.42 Breaker“ON/OFF”inradioremote 5.43 Typicalcuttingsequence............................................5.44 Miningoperations 5.45 Mechanicalassemblies.....................................................5.50 Hydraulicsystem 5.57 Watersystem ....................................................................5.87 Electricalsystem 5.96 Instructionsonthemaintenance.......................................5.121 Importantnotes 5.121 Beforemaintenance 5.121 Torquevalues 5.123 Lubricants,fluidsandcapacities 5.124 Specificlubricationandmaintenanceinstructions 5.129 Everyshift 5.129 Everythirdshift(daily) 5.133 Weekly 5.142 Every2weeks 5.146 Monthly 5.148 Everythreemonths 5.154 Everysixmonths 5.161 Instructionsontheadjustmentprocedures 5.163 Pilot/auxiliarypumpcircuitrelief 5.165 Maincontrolvalve ........................................................5.166 Tramtrack 5.170 Tailshim.......................................................................5.175 Conveyorchaintension 5.178 Sumptramming............................................................5.179 BI000976
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VPSS/0 ©BUCYRUSAMERICA,INC. Replacementofwearparts 5.183 Cutterhead(boom)assembly 5.183 Cutterheadassemblyremoval/installation 5.184 Shearcylinder 5.187 Centercutterdrum 5.192 Endcutterdrum.......................................................5.195 Drumdrivemotor 5.197 Drumdrivegearcase 5.204 Gatheringheadassembly 5.207 Gatheringheadassemblyremoval/installation .......5.208 Gatheringheaddrivemotor 5.213 Gatheringheadgearcase.......................................5.216 Gatheringheadfootshaft 5.221 CLA..........................................................................5.224 CLAtipreplacement 5.226 Gatheringheadliftcylinder......................................5.227 Crawlerassembly 5.231 Trammotor..............................................................5.231 Tramcase 5.237 Crawlerchain...........................................................5.242 Tramtrackfrontidler 5.243 Conveyorassembly 5.249 Conveyorchain 5.250 Conveyorassemblyremoval/installation.................5.254 Dischargeconveyor 5.257 Tailroller 5.263 Troubleshootingprocedures 5.266 Typicalhydraulicproblems 5.267 Contaminantsinhydraulicsystems 5.268 Specifichydrauliccircuits 5.269 Generalsafetyproceduresforshutdown 5.273 Excessivenoise 5.274 Excessiveheat 5.275 Incorrectflow 5.276 Incorrectpressure ........................................................5.277 Faultyoperation 5.278 Restartingchecklist......................................................5.279 Watersystem 5.280 Electricalsystem ..........................................................5.282 Bearings 5.285 Controlsystem .............................................................5.287 Faultcodes 5.287 BI000976
A6474X352
Tableofcontents _________________________________________________ Bucyrus – Model30M3LContinuousMiner ©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 BI000976
_______________________________________________________________ 1 Aboutthismanual BI000976
applicableoperatingmanual
machinetype
Aboutthismanual
Thischapterprovidesimportantinformationmakingiteasierforyouto usethismanual.Itcontainsinformationonthestructureofthemanual andthesymbolsandcharactersused.
Beforestartingtowork
Takecaretoensurethattheoperatingmanualavailabletoyouisapplicableforthetypeofequipmentormachineused.
Thisoperatingmanualisintendedfor:
BucyrusModel30M3LContinuousMiner
andisonlypermittedtobeusedforequipmentofthistype.
newoperationmanual
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 A6474X352 VPSS/0 1.2 ©BUCYRUSAMERICA,INC.
BI000976
service safety
Whatisthepurposeofthisoperatingmanual?
Thisoperatingmanualisintendedtohelpyouworkefficientlyand safelywithourproduct.Itcontainsimportantinformationonalltheactivitiesrelatedtothemachine.
Readthisoperatingmanualcompletelyandatease.Payspecialattentiontothesafetyinstructions.Trytomemorizetheappearanceandthe meaningofthesafetyandinstructionsymbols.
Ifanydetailsarenotclearlyunderstood,pleasecontactourservicedepartment.Ourserviceaddressisgiveninthechaptertitled“Foryour information”.
Readthechapter“Foryoursafety”withspecialattention.Thechapter containsimportantinformationindicatingpossiblehazards.Observe theinformationgivenandfollowtheproceduralinstructions.
Beforestartingtowork ________________________________________ 1.3
©BUCYRUSAMERICA,INC.
Bucyrus – Model30M3LContinuousMiner
BI000976
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 A6474X352 VPSS/0 1.4 ©BUCYRUSAMERICA,INC.
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2 Yoursafety
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 A6474X352 VPSS/0 2.2 ©BUCYRUSAMERICA,INC.
BI000976
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 ___________________________________________________
2.3
©BUCYRUSAMERICA,INC.
Bucyrus – Model30M3LContinuousMiner
training BI000976
Operatingconditions
Intendeduse
TheContinuousMinerhasbeendesignedandmanufacturedforspecificuses.Intendedusesinclude:
■ extractionofcoal,phosphate,potash,salt,trona,andothermediumhardnessminerals
■ loadingthematerialslistedaboveontoahaulagesystemorshuttle car,ordumpingitontothegroundforloadingatalatertime
■ operationongradesoflessthan10degrees
Unauthorizeduse
Applicationsnotexpresslylistedasintendedusesareunauthorized usesandarenotallowedtobeperformedwiththemachine.
■ thetransportofpersons
■ stonedevelopmentorextraction
BucyrusAmerica,Inc.acceptsnoliabilityforanydamageresulting fromanysuchunauthorizeduse.
_________________________________________ Operatingconditions A6474X352 VPSS/0 2.4 ©BUCYRUSAMERICA,INC.
BI000976
general
Safetyinstructions
Generalrules
Alwaysworkwithfullconcentration.
Familiarizeyourselfwithyourworkingenvironment.
Alwayswearyourpersonalprotectiveequipment.Thisalsoincludes earprotectorsasthenoiseemittedbyotherequipmentintheareamay attimesexceed85db(A).
Informyourcolleaguesof
■ yourexactlocation,
■ theworkyouareperforming,and
■ thetimethatyouwillprobablyrequire.
safetyequipment
Startthemachineonlywhenitisinagoodandsafeoperatingcondition andallprotectivedevices,e.g.emergencystopdevices,machinestop buttons,coverplates,etc.arecorrectlyinstalled.
Observetheacousticandopticalstart-upwarningsofthemachine.
Observethesymbolplatesonthemachine.
Presstheemergencystopbuttonimmediatelyintheeventoffaultor irregularitiesinoperation.Reportanyirregularitiestoyoursuperiorso thatnecessarymeasurescanbetakenimmediately.
Disconnect,lockout,andtagthepowersystemwhileperforming:
■ maintenance
■ inspection
■ repairwork
Followallapplicableregulationsregardinglockout/tagoutprocedures. Cordonoffyourworkingareawidelyforthemachine.
movingparts
Neverallowpartsofyourbodytocomebetweenpartswhichcould move,suchas:
■ chains,flights,andchainsprockets
■ pivotpoints
■ crawlerassembliesandconveyors
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A6474X352 VPSS/0 2.5 ©BUCYRUSAMERICA,INC.
Safetyinstructions
noiseemissions
■ cutterandgatheringheadassemblies symbolplates emergencystop lock-outandtag
BI000976
cordonoffworkingarea
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.
Safetyinstructions____________________________________________ 2.6
©BUCYRUSAMERICA,INC.
Bucyrus – Model30M3LContinuousMiner
transportsafetydevice meansofattachment mobilehandlingequipment operation inspection maintenance instructionandsafetytags BI000976
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.
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A6474X352 VPSS/0 2.7 ©BUCYRUSAMERICA,INC.
Safetyinstructions
inclinedface environmentalacceptability
redzone controls training beforestart-up protectivedevices traveling passengers safetyrules problemsandmalfunctions BI000976
startingprocedures
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.Itismandatorythatthe trailingcablebeuncoupled,taggedandlocked-outfromthepower sourcetoprovidevisualevidencethattheminerisde-energized.Followallapplicableregulationsregardinglockout/tagout.
securing
Secureyourworkingareaoverawiderange,inordertoavoidendangeringotherpersons.
Disconnectthepowerfromthemachinetopreventunauthorizedand unintentionalrestarting.
Protectyourworkareaagainstfallingrocks.
Passdefectivecomponentsremovedonforservicingwithoutdelayin ordertopreventthesepartsbeingreinstalledelsewhere.
originalparts
methanemonitoring
Useonlysparepartswhichsatisfythespecifiedtechnicalrequirements. ThisisonlyensuredwithoriginalBucyrusspareparts.Pleasereferto thesparepartslistsorpartscatalogfortheordernumbers.
Beforeattemptinganyrepairsormaintenance,methaneairmonitoring mustbecompletedbeforeandduringtherepairandmaintenance.
Safetyinstructions____________________________________________ 2.8
©BUCYRUSAMERICA,INC.
Bucyrus – Model30M3LContinuousMiner
parking
radio BI000976
• 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
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