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ThismanualisintendedtoprovideGENERALproductinformationfor theModel25M0ContinuousMiner.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.

2. Yoursafety

3. Storageandtransport

4. Installation

7. Foryourinformation

Aboutthismanual

Thischapterprovidesimportantinformationmakingiteasierforyouto usethismanual.Youwillalsobegiveninformationonthestructureof themanualandthesymbolsandcharactersused.

Beforestartingtowork

Takecaretoensurethattheoperatingmanualavailabletoyouis applicableforthetypeofequipmentormachineused.

Thisoperatingmanualisintendedfor:

BucyrusModel25M0ContinuousMiner

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:

■ initiateand/orsupervisetheactivitiesjustindicated.

Beforestartingtowork

Whatisthepurposeofthisoperatingmanual?

Thisoperatingmanualisintendedtohelpyouworkefficientlyand safelywithourproduct.Itcontainsimportantinformationonallthe activitiesrelatedtothemachine.

Readthisoperatingmanualcompletelyandatease.Payspecialattentiontothesafetyinstructions.Trytomemorizetheappearanceandthe meaningofthesafetyandinstructionsymbols.

Ifanydetailsarenotclearlyunderstood,pleasecontactourservice department.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.

Beforestartingtowork

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.

training

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.

Operatingconditions

Intendeduse

TheContinuousMinerhasbeendesignedandmanufacturedforthe 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.

safetyequipment symbolplates machinestop

lock-outandtag-out

Safetyinstructions

Generalrules:

Alwaysworkwithfullconcentration.

Familiarizeyourselfwithyourworkingenvironment.

Alwayswearyourpersonalprotectiveequipment.Thisalsoincludes earprotectorsasthenoiseemittedbyotherequipmentintheareamay attimesexceed85db(A).

Informyourcolleaguesof

■ yourexactlocation,

■ theworkyouareperforming,and

■ thetimethatyouwillprobablyrequire.

Startthemachineonlywhenitisinagoodandsafeoperatingcondition andallprotectivedevices,e.g.MACHINESTOPdevices,coverplates, etc.arecorrectlyinstalled.

Observetheacousticandopticalstart-upwarningsofthemachine.

Observethesymbolplatesonthemachine.

PresstheMACHINESTOPbuttonimmediatelyintheeventoffaultor irregularitiesinoperation.Reportanypeculiaritytoyoursuperiorso thatnecessarymeasurescanbetakenimmediately.

Lock-out,tag-outanddisconnectthepowersystemwhileperforming:

■ maintenancework

■ inspectionwork

■ repairwork

cordonoffworkingarea movingparts

Cordonoffyourworkingareawidelyforthemachine.

Neverallowpartsofyourbodytocomebetweenpartswhichcould move,suchase.g.:

■ chains,flights,andchainsprockets

■ pivotpoints

■ cutterheadandloadinghead

■ 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.

Cleananyforeignmaterialfromtheoperator’scompartment.

Thismachinemaybeshippedfromthefactoryequippedwithaprotectivecab/canopy.Thecab/canopymustbesecurelyinplacebeforeoperatingtheunit.

Safetyinstructions

Installationandstart-up

Oninclinedfacessecureallcomponentpartsbychains,e.g.tothe support.

Whenworkingwithoils,greasesandotherchemicalsubstances,observethesafetyregulationsapplicabletotheproduct.

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.

Cleantheoperator’scompartmentatregularintervals.Ensurethatthe operatingsymbolsarelegibleinordertoavoidanyoperatorerrorsand resultingaccidents.

Neverclimbonto,orclimboutofthemachinewhileitisinmotion.

Donotoperatethemachinewithanypartofyourbodyoutsideofthe operator’scompartmentinordertopreventbodypartsfrombeing crushedbetweenthemachineandoutsideobjects.

Useextremecautionwhentravelinginclosequartersorincongested orblind-travelareas.

Nevercarrypassengers.Passengersmaybethrownoffthemachine orcrushedbetweenthemachineandoutsideobjects.

Alwaysfollowallsafetyrulesofeachparticularminewhenoperating themachine.

Ifproblemsormalfunctionsareencounteredwhileoperatingtheunit,it mustbeproperlyshutdownandtheproblemcorrectedimmediately.

Safetyinstructions

Stopping

Donotleavetheoperator’scompartmentwiththeunitrunning.Always properlyshutdowntheunitbeforeleavingtheoperator’scompartment.

Alwaysparktheunitonsolid,levelground.Ifthisisnotpossible,park theunitatarightangletotheslopetopreventaccidentalmovementof themachine.

Useproperflags,warningsorbarrierswhenparkinginareasoftraffic.

Thereisauniquecodeswitchsetupwhichpermitseachoperatorto activateonlyhisdesignatedminer,allowingseveralremote-controlled minerstooperateinthesameareawithoutgettingtheirradiosignals crossed.Inaddition,animproperlydecodedradiosignalwillautomaticallyshut-offtheminer.Followthegeneralsafetynoticesandsafety recommendationslistedintheremotecontrolsystemtroubleshooting guide.

Maintenanceandrepair

Besuretoobservetheprescribedmaintenanceandinspectionintervals.

Informthesupervisorypersonnelandthefacecrewofanymaintenance andrepairoperations.Givetheminformationontheintendedoperationsandtheanticipatedduration.

Beforeattemptinganyrepairs,a DANGER signmustbeattachedtothe appropriatecircuitatthepowerdistributionbox.Itismandatoryunder theUnitedStatesFederalLaw,thatthetrailingcablebeuncoupledand locked-outandtagged-outfromthepowersourcetoprovidevisual evidencethattheminerisde-energized.

Secureyourworkingareaoverawiderange,inordertoavoidendangeringotherpersons.

Disconnectthepowerfromthemachinetopreventunauthorizedand unintentionalrestarting.

Protectyourworkareaagainstfallingrocks.

Disconnectthepowerfrommachinetopreventfromrestartingbefore replacinganydefectivecomponents.

Passdefectivecomponentsremovedonforservicingwithoutdelayin ordertopreventthesepartsbeingreinstalledelsewhere.

Useonlysparepartswhichsatisfythespecifiedtechnicalrequirements. ThisisonlyensuredwithoriginalBucyrusAmerica,Inc.spareparts. Pleaserefertothesparepartslistsfortheordernumbers.

handlingofhydraulicfluids lifting

maintenance,repair

Safetyinstructions

ForraisingtheContinuousMineruseonly:

■ cribblockswithadequateload-holdingcapacity.

■ hoists,jacksorcraneswithadequateload-carryingcapacity.

Avoiddirectcontactbetweentheskinandhydraulicfluids.Hydraulic fluidcanpenetratetheskinandcauseseriousinfection.

Neverusehydraulicfluidforrinsingorcleaning.Hydraulicfluidrepresentsaveryseriousdangertohealth.

Onlypersonswhohaveandcandemonstrateaspecialknowledgeof hydraulicsareallowedtoworkonthehydraulicsystem.

Avoid,wheneverpossible,servicing,cleaningorexaminingthemachineincongestedareas.

Avoid,wheneverpossible,servicingorprovidingmaintenancetothe unitunlesstheappropriatesafetydevicesareplacedwhererecommendedtopreventaccidentalmovementoftheunit.

Donotaltertheelectricalorhydraulicsettingsfromthatindicatedinthis manualorassetatthefactory.

Alwaysreplacedamagedorlostdecalsandmetalinstructionplates.

Disconnectthepowerwhenworkingwiththeelectricalsystem,orwhen weldingontheunittopreventelectricalshock.

Alwaysfollowallsafetyproceduresofeachparticularminewhenperformingmaintenance.

Itisimportantthatanyprocedurenotspecificallyrecommendedinthis guidebethoroughlyevaluatedfromthestandpointofsafetybeforeitis implemented.

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Safetyinstructions ____________________________________________

Someillustrationsinthismanualshowguardsorcoverpanelsremoved forpurposesofclarity.Neveroperateunitwithoutguardsorcoverpanelsinplace.

Carryoutavisualinspectionofallthehydrauliccomponentsatregular intervals.Inparticularcheckthat:

■ thehosesarenotpinchedortrapped.

■ thehoseshavenobubblesorblisters.

■ thehoseoroutersheathesofthehosearenotabnormallyrigidor 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.

Safetyinstructions

installinghydraulichoses

Installthehydraulichosesproperlybehindthebracketsandclamps providedforthem.

Alwaysinstallhydraulichosessothey:

■ alwayshavealittleslack.

Fig.1:Installinghydraulichoses,slack Right Wrong

■ arenottwisted.

Fig.2:Installinghydraulichoses,twisting Right Wrong

■ arenotbentdirectlybehindtheconnections. (distancemin.1.5xnominaldiameter).

Fig.3:Installinghydraulichoses,bending Right Wrong

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.TheunitshouldthereforeonlybeinstalledundertheinstructionofspecialistsfromBucyrusAmerica, Inc.

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.

Overviewofsafetyinstructions

Chapter5:Operation

DANGER!

Incorrectoperationendangersyourselfandothers!Incorrectoperationofthemachineisoftenthecauseofveryseriousaccidents!Operatetheunitonlywhenyouhavebeensufficiently trainedonthemachineandhavereadandunderstoodthisoperatingmanual.Shouldanythingbeunclear,pleasecontactyourimmediatesupervisorortheirdesignee.

NOTICE!

Beforebeginningcuttingoperations,carefullyunloadthetrailing cableprovidingenoughslackandplacingitwhereitallowsadequateclearanceforsafemaneuverabilityoftheminer.

WARNING!

TheContinuousMinerisradioremotecontrolled.Manualoperationisgenerallyfortroubleshootingandmaintenanceunderroof support.OperatingtheContinuousMinermanualfromtheOperator’sstationmayresultinseriousinjuryordeath.

CAUTION!

MANUALONLY:TheContinuousMiner’stramandsteeringspeed isvariable.Thismeansthatthefartherthetramhandleis actuatedthefastertheContinuousMinerwilltravelorturn.The tramlevermustbemovedslowly.Movingthetramleverstoo quicklymayresultinsevereinjuryorlossofcontrol.

IMPORTANT!

Oncethetram/steeringcontrolleverisreleasedbytheoperator thecontrolleverautomaticallyreturnstothecentered(neutral) position.

WARNING!

ManualoperationoftheContinuousMinerisnotallowedforproductionoperationunlesstheminerhasanoperator’spitandcanopy.Manualoperationisgenerallyfortroubleshootingandmaintenanceunderroofsupport.OperatingtheContinuousMiner manuallyfromtheoperator’sstationmayresultinseriousinjury ordeath.

WARNING!

Themachinecircuitbreakerde-energizestheelectricalcontroller andmotors.However,electricalpowerisstillpresentinsidethe connectionboxtothecircuitbreaker.Ifthecircuitbreakerinside theconnectionboxrequiresservice,thetrailingcableshouldbe disconnectedfromthepowercenter.

WARNING!

Oncethebreakerhastripped,itwillnotstayinthe“ON”position withoutfirstbeingmovedtothe"RESET"position,andthento "ON".

WARNING!

Overviewofsafetyinstructions

Ifeitherofthefiresuppressionactuatorareactuated,thesystem mustbecompletelyrechargedwithdrychemicalsandexpellants.

WARNING!

BepreparedforasuddenstopwhentheE-stopisactuatedduringnormaltrammingofthemachine.

IMPORTANT!

Refertotheradioremotecontroloperationmanualsuppliedwith yourmachineforinformationregardingtheoperationofyour specificremotecontrol.

WARNING!

Failuretoreadandunderstandalloperatinginstructionsbefore startingtheContinuousMinercouldresultinseriousinjuryor deathtotheoperatororpersonsaroundthemachineorcause damagetothemachine.

WARNING!

Readallinstructionscarefullybeforeattemptingtostartoroperatemachine.

WARNING!

UnderstandthefunctionsofallcontrolsbeforestartingtheContinuousMiner.Readandfollowtheinstructionsonallwarning tagsonthemachine,observeallregulationsandsafetyprecautions.

WARNING!

NeveroperateaContinuousMinerwhichhasbeendamagedoris notoperatingproperly.AnypartoftheContinuousMinerwhich doesnotfunctionproperlycanbeahazard.Reportitimmediately toyoursupervisor.

WARNING!

BeforestartingtheContinuousMiner,makesurethatnooneisin theredzone(Fig.22throughFig.26).

NOTICE!

Inextremelycoldweather,allowmotorsandgearcasestoidle. Thiswillwarmthehydraulicoilsandlubricants.Stilloilsand greasescouldimmobilizethemachine.

IMPORTANT!

Apump“growl”meansnotenoughoilisreachingthepumps throughthesuctionlines.Ensurethepumpgetsprimedbefore continuingoperation.Alwayschecktheoillevel.

DANGER!

Improperpositioncouldresultininjuryordeathtotheoperator bycrushinghimagainsttheriborroofsupports.Itmayalso causehimtorunoverthetrailingcableordislodgetheroofsupports.

Overviewofsafetyinstructions _________________________________

WARNING!

Turningonthewatersprayspriortocuttingpreventstheaccumulationofdustandthegenerationofexcessiveheatwhichcould causeanignitionorexplosion.

WARNING!

TheContinuousMineristypicallyoperatedbyradioremotecontrol.Manualoperationisnotallowedforproductionoperation unlesstheminerhasanoperator’spitandcanopy.Manualoperationgenerallyisfortroubleshootingandmaintenanceunderroof support.

IMPORTANT!

Beforestart-up,checkthatdailymaintenancehasbeenperformed onthemachine.

WARNING!

Visuallycheckforotherpersonnelandverballyshoutawarning beforestartingthismachine.Makesureallpersonnelarecompletelyclearofthemachineandit’scomponentsandcheckthat anyloosematerial,tools,oilcansorotherobjectsareclearfrom theareabeforestartingthemachine.

IMPORTANT!

The“PUMPON”keymustbereleasedbefore“SHIFT”.If“SHIFT” isreleasedfirst,thepumpmotorwillshutoff.

WARNING!

Afterturningoffthepowertothemachine,neverwalkawayand leavetheradioremoteturnedon.Failuretoturntheremoteoff couldresultinanaccidentcausingseriousinjuryorlossoflife.

WARNING!

Trammingrequirescoolingwatertothetrammotors.Failureto coolthemotorswillresultinmotordamageandprematurefailure.

WARNING!

Adjustconveyorboomtoallowclearancefromroof,walls,and floor.Failuretodosowillresultindamagetotheconveyorboom.

WARNING!

Neverstartcutterheadmotorsunderaload.Startingmotorsunderloadmayresultinmotordamageorprematurefailure.

WARNING!

Warn“ALLCLEAR”beforestartingthecutterhead.Failuretodo somayresultinseriousinjuryordeath.

IMPORTANT!

Bothcuttermotorsdonotstartatthesametime.Thereisapreset timeddelaybetweentheleftcuttermotorstartingandtheright cuttermotorstarting.

IMPORTANT!

The“CUTTERON”keymustbereleasedbefore“SHIFT”.If “SHIFT”isreleasedfirst,thecuttermotorswillshutoff.

Overviewofsafetyinstructions

WARNING!

Warn“ALLCLEAR”beforestartingtheconveyor.Failuretodoso mayresultinseriousinjuryordeath.

IMPORTANT!

The“CONVON”keymustbereleasedbefore“SHIFT”.If“SHIFT” isreleasedfirst,theconveyormotorswillshutoff.

IMPORTANT!

The“FANON”keymustbereleasedbefore“SHIFT”.If“SHIFT”is releasedfirst,thefanmotorwillshutoff.

CAUTION!

Alwaysensureoperatorsafetywhileoperatingthemachine.

CAUTION!

Alwaysbealerttohazardousconditionsandtakecorrectiveactionasnecessary.

IMPORTANT!

Careshouldbetakennottostallcuttersonconveyorduringcuttingoperations.Severedamagetomotorsandgearboxescould occurifcuttersorconveyorarerepeatedlystalled.

IMPORTANT!

Tramislimitedintheforwarddirectionwhilethecuttersarerunningwiththecutterheadfeedbackcircuit.Asthecuttersbeginto cutthematerialfromthefacethesumpspeedwillautomatically slowthetramdowntopreventoversumpingthemachine.

IMPORTANT!

Inspectionofthebitsandbitblocksbeforethestartofeachshift willreducelaterproblems.Miningwithdull,bentorbrokenbit blocksincreasesdustandnoiselevels,aswellasputtingexcessivestrainonbothcutterandtramdrives.

WARNING!

Failuretomaintainthehydraulicsystemwillresultindamageto itshydrauliccomponentswhichwillresultinincreasedwearand prematurefailure.

IMPORTANT!

Schematicsmayvaryfromoneunittothenext.ConsulttheBucyrusAmerica,Inc.partsbookfortheschematicforyourmachine.

IMPORTANT!

Duringdisassemblyofcontrolvalves,giveparticularattentionto identificationofpartsforreassembly.Spoolsareselectivelyfitted tovalvebodiesandmustbereturnedtothesamebodiesfrom whichtheywereremoved.SpoolsareNOTinterchangeablebetweenvalvebodies.

Overviewofsafetyinstructions _________________________________

WARNING!

Donotsalvagespoolsorvalvebodiesforlaterusein“new”combinations.Impropercomponentsusedduringassemblymayappearasinternalleakage,ora"sticking"or"hangingup"ofthe spoolinthevalvebody.Incorrectsetswillresultinimproperoperationofthevalvesection,possiblycausingunexpectedmachine operationthatcouldresultinmachinedamageorinjurytopersonnel.

WARNING!

Donotrelyontheloadholdingvalvewhenworkingunderthecutterheadortheconveyor.Alwaysblocktheconveyororthecutter headifitmustbeelevated.Seriousinjuryordeathmayresult fromnotblockingtheload.

WARNING!

Theloadholdingvalvesonthecutterheadandconveyorcylinders arepresetandDONOTrequireadjustment.Adjustmentofthese valvemayresultinveryseriousinjuryorevendeath.

DANGER!

Theareaunderandaroundtheraisedcutterheadisdangerous. Securelyblocktheheadbeforeperformingmaintenanceonor belowit.Failuretoblocktheraisedcutterheadcouldresultin seriousinjuryorevendeath.

DANGER!

Theloadholdingvalveispreset. DONOTADJUSTIT.Ifitmalfunctions,replaceitimmediately.

IMPORTANT!

Whennotinuse,ensurethatthepowerfillsuctionhose istightly pluggedtopreventdirtandcontaminantsfromenteringthehydraulicsystemwhennotinuse.

IMPORTANT!

Thepowerfillisactivatedbyopeningtheballvalveandthenengagingconveyordownfunction.

IMPORTANT!

Neverruntheconveyorwithouttheneedlevalveclosed.Injuryor deathmayoccur.

IMPORTANT!

Youmustmanuallyresetthe2-way,2-positionwatervalvetoreset thedelugefirespraycircuit.

IMPORTANT!

Thebackupaccumulatormustmaintainaminimumpressureof 500psifor12minutesafterthepumphasbeende-energized.For maintenanceonthecircuit,loosenthefittingSLOWLYuntilthe pressureisreleased.

Overviewofsafetyinstructions

IMPORTANT!

Hangtrailingcablestopreventdamagefrommovingequipment!

WARNING!

Neverrunoveranunprotectedtrailingcable.Damagedcables shouldberepairedimmediately.

DANGER!

Neverhandleenergizedtrailingcablewithoutproperprotective equipment.Contactwithanenergizedtrailingcablewithcompromisedinsulationcouldresultindeathbyelectrocution.

WARNING!

Alwaysusecautionwhenstandingnearorcrossingtrailingcables.Thetrailingcablemaymoveasthemachinemoves.

IMPORTANT!

Ifthelowoilwarninglightcomesonwhenthecircuitbreakeris closed.Besuretofillthereservoirbeforestartingthemotors.

CAUTION!

Onlyqualifiedtechniciansshouldtroubleshoottheelectricalsystems.Touchingorshortingenergizedcomponentscancauseseriousinjuryordeath.

WARNING!

Beforeperformingmaintenanceonthemachinethecircuitbreaker mustbeinthe“OFF”positionandthepowershouldbedisconnectedatthemainpowersource.FollowallFederalandMine safetyregulationsforlockout/tagoutprocedures.Accidentalmachinemovementorelectricalshockcanresultinseriousinjuryor deathtoyouorotherpersonnel.

WARNING!

Donotmoveanyhydrauliccontrolleverunlessyouarecertain thateveryoneiscompletelyclearofanymachinemovement.Accidentalmachinemovementcancauseseriousinjuriesoreven deathtoyouorthemaintenanceperson.

WARNING!

Neverdisconnectahydraulichoseifthecircuitispressurizedorif thereisaloadonthecircuit.Ifahoseisdisconnectedwhilethe circuitispressurizedoraloadisonthecircuit,theloadwillfall causingdamagetothemachineorseriousinjuryordeathtoyou orotherworkers.

WARNING!

Youcouldbeseriouslyinjuredorevenkilledbyfallingloads.Observethesafeworkingloadlimitsofliftingorblockingdevices andkeepasafedistancefromsuspendedloads.

Overviewofsafetyinstructions _________________________________

NOTICE!

Ifthegearcaseisscheduledforoildrainandrefill,obtaintheoil samplepriortotheoilchange.

IMPORTANT!

Alwayscollectoilsamplesusingasiphonpump.Donotremove thedrainplugandcollectoilbyallowingittorunoutintothebottle.

IMPORTANT!

Alwaysusethecollectionhoseprovidedwitheachbottle.Always discardhoseimmediatelyfollowingcollectionoftheoilanddonot useitforthenextsample.Todosowillcontaminatethenext samplewithoilfromtheprevioussample.

NOTICE!

Incorrectgreaseorovergreasingoftheelectricmotormaycause seriousdamagetothemotor.FollowthegreasingprocedureoutlinedintheMaintenancesectionofChapter5.

WARNING!

Thehydraulicoilfillpumpwillbedamagedifitisrundry.

WARNING!

Useextremecautionwhenperformingtestproceduresandmaking adjustments.Unlessnotedintheprocedures,allcontrolsaretobe intheneutralposition.

IMPORTANT!

Alwaysusethepropertoolswhenadjustingvalvecartridges.

IMPORTANT!

Donotstartanymotors - CLA,cutterhead,pump,ortractionmotors - untilallpressuresareset.Startthepumpmotorasdirected.

WARNING!

Neverrelyontheloadholdingvalveasameansofsupportingthe cutterorconveyorboomwhilemakingrepairs.Severeinjuryor deathcouldresult.

WARNING!

Alwaysallowfunctiontobottomoutandstopmovingbeforeadjustinganypressure.

IMPORTANT!

ReferencetheHydraulicsectioninthischapterforgeneralinformationontheindividualcircuits.Alwaysrefertothehydraulic schematicinyourBucyrusAmerica,Inc.partsmanualforinformationthatisspecifictoyourminer.

WARNING!

Twopeoplearerequiredtoadjustpressuresettings.Oneperson willmaketheadjustmentswhilethesecondpersonmustremain atthe“Machinestop/E-STOP”atalltimesduringtheadjustment procedure.Failuretodosomayresultinseriousinjuryordeath.

Overviewofsafetyinstructions

IMPORTANT!

Beforemakinganyfurtheradjustments,verifythatthehydraulic oilisatoperatingtemperature.

IMPORTANT!

Themainreliefissethigherthantheportreliefsandwillonlyrelieveifaspikeoccursinthesystemoriftheportreliefdoesnot functionproperly.Thisprovidesprotectionofthemainpumpsection,A1.

CAUTION!

Donotadjustthemainreliefover3,000psi.Destructionofthe valvebankandthemainpumpcouldresult.

CAUTION!

Alwaysbealertforanyunintendedmachinemovement.

IMPORTANT!

ReferencetheHydraulicsectioninChapter5forindividualcircuitinformation.Alwaysrefertothehydraulicschematicinyour BucyrusAmerica,Inc.partsmanualforyourminer.

WARNING!

Keepbodypartsclearofmachinewhileinraisedpositionorseriousinjurycouldresult.

WARNING!

Youcouldbeseriouslyinjuredorkilledbyfallingloads.Observe thesafeworkingloadofallblockingdevices.

WARNING!

FollowallFederalandminelockout/tagoutregulationsandprocedures.Failuretodosocouldresultinmachinedamageorserious injuryordeathtopersonnel.

CAUTION!

Shimsmustbeinsertedcompletelyintotheidlerslidechannel.A shimthatisnotcorrectlyseatedontheidlerslidechannel’sinside surfaceprovidesunevensupportthatcancauseidlerslant.A slantedidlercancauseunevenwearandstressonthetramtrack andcancauseimproperoperationofordamagetothetramsystem.

IMPORTANT!

Checkthattheshimsarecorrectlyseatedontheidlerslidechannel’sinsidesurfacebylookingatthechannel’sinsidesurface fromtheoppositesideoftheminerthroughthespacebetween thegatheringheadandtheidlerassembly.

IMPORTANT!

Leftandrighttake-uprodsshouldberotatedequally.Thismaintainssteady,equalpressureonthetailrollerassemblyandkeeps theconveyorchainfromdriftingoffcenter.

Overviewofsafetyinstructions _________________________________

WARNING!

Donottestthealignmentoftheshearcylinderrodendbearings andthecutterboomclevisusingyourfingers.Shiftingofthe alignedpiecescouldcauseseriousinjury.

IMPORTANT!

Thepinshouldbeinsertedsothatitsretainingchannelremains outsidethebushing.

IMPORTANT!

Inadditiontotheshearcylinders,thestabilizerandgathering headcanalsobeusedtoadjustthecutterboom’spositiontoalloweasierinsertionofthecutterboompivotpins.

IMPORTANT!

Pressurefromthecutterboomontothepivotpincanmakeitsremovalverydifficult.Theshearcylinderscanbeusedtofindthe boompositionthatputstheleastpressureonthepin.

CAUTION!

Whenthepivotpinpullpointisfound,blockthecutterboomto preventitfromdroppingormovingwhenthepivotpinisremoved.

IMPORTANT!

Pressurefromthecutterboomontotheboompivotpincanmake itsremovalverydifficult.Theshearcylinderscanbeusedtofind theboompositionthatputstheleastpressureontothepin.This positioncanbedeterminedbystrikingthepin,slightlycontracting orextendingtheshearcylinder,thenstrikingthepivotagainand comparingthe“ring”;asboompressureonthepindecreases,the “ring”ofthepinwhenitisstruckbecomeslower.Whenthe“ring” ofthepinbecomesshortandlow,pinremovalismucheasier.

CAUTION!

Useextremecautionwhenadjustingtheboomwiththeshear cylindertofindthepivotpin’spullpoint.

IMPORTANT!

Onthebackofthetractorframeclevisthereisaweldedstrapthat keepstheboompivotpinfromrotating.Oneoftheflatsofthe boompivotpinmustparallelthisstraporthepincannotbecompletelyinserted.

IMPORTANT!

Ifitisextremelydifficulttoinserttheboompivotpinthroughthe alignedtractorframeclevisandboompivotbushings,extendor contracttheshearcylinderstoimprovethealignmentbetweenthe clevisandboom.

CAUTION!

Useextremecautionwhenadjustingtheclevisandboomalignmentwiththeshearcylinders.

Overviewofsafetyinstructions

WARNING!

FollowallFederalandminelockout/tagoutregulationsandprocedures.Failuretodosocouldresultinmachinedamageorserious injuryordeathtopersonnel.

CAUTION!

Theshearcylinderisveryheavy.Verifyitsweightcanbesupported.

WARNING!

Replacementoftheshearcylinderinvolvesworkingarounda raisedcutterheadassembly.Neverworkunderanyraisedassemblywithoutproperblocking.Alwaysblockbetweentheraisedassemblyandthetractorframeinadditiontobetweentheraisedassemblyandthefloor.

WARNING!

Thisprocedureinvolvesdisconnectingthehydraulichoses.Alwaysusecautionwhenworkingwithoraroundhydraulicsystems theycanbeunderextremelyhighpressures.

WARNING!

Standclearoftheblockedcutterheadassemblyduringshearcylindercontraction.

WARNING!

FollowallFederalandminelockout/tagoutregulationsandprocedures.Failuretodosocouldresultinmachinedamageorserious injuryordeathtopersonnel.

WARNING!

Thenextstepsdisconnecttheshearcylinderfromthetractor frame.Theshearcylinderisextremelyheavy.Bepreparedtosupportitsweightbeforeperformingthefollowingsteps.

WARNING!

Neverdisconnectahydraulichoseifthecircuitispressurizedorif thereisaloadonthecircuit.Ifahoseisdisconnectedwhilethe circuitispressurizedoraloadisonit,theloadwillfall,causing damagetothemachineorseriousinjuryordeathtopersonnel.

WARNING!

Standclearoftheshearcylinderandtheblockedcutterheadassemblyduringextensionoftheshearcylinder.

WARNING!

Replacementofthecutterheadcenterdruminvolvesworking aroundaraisedcutterheadassembly.Neverworkunderany raisedassemblywithoutproperblocking.Alwaysblockbetween theraisedassemblyandthetractorframeinadditiontobetween theraisedassemblyandthefloor.

WARNING!

Thisprocedureinvolvesdisconnectingandreconnectingthe miner’strailingcable.Alwaysbeawareofwhetherornottheminer isenergized.Neverperformmaintenanceonanenergizedminer.

Overviewofsafetyinstructions _________________________________

WARNING!

Standclearofthecutterheadassemblyandtheunsecuredupper halfofthecenterdrumwhileloweringit.

WARNING!

Whilethispowercableisdetachedfromthemotor,thetrailing cableshouldnotbereconnectedtoenergizetheminer.Damageto theminer,personalinjuryordeathcouldresult.

WARNING!

Federallawrequiresthatminingequipmentelectricalconnections mustbeinspectedbyacertifiedelectricianbeforetheequipment canbeoperated.

WARNING!

Thisprocedureinvolvesattachinganelectricalpowercabletothe cutterheaddrumdrivemotor.Thetrailingcablemustbedisconnectedtosafelyperformthisoperationorseriousinjuryordeath willresult.

WARNING!

Thecutterheadgearcaseisextremelyheavy.Keepbodyparts andotherobjectsfromunderneathituntilitiscompletelysecured.

WARNING!

Useextremecautionwhentrammingtheminerforwardtoposition theboomfaceagainstthegearcase.

WARNING!

Standclearoftheblockedcutterheadandgatheringheadassembliesduringthecontractionofthegatheringheadliftcylinders.

CAUTION!

Whenseparatingthegatheringheadfromthetractorframe,ensurethatthedisconnectedendsoftheconveyorchainsmoothly slideoutofthegatheringhead.

CAUTION!

Whentrammingtheminertowardthegatheringhead,becareful thattheconveyorchainandgatheringheadliftcylindersdonot becomepinchedbetweenthetractorframeandthegathering head.

CAUTION!

Usecautionwhenusingtheliftcylindersandstabilizertoadjust thealignmentoftheclevisandpivotpins.

WARNING!

Thenextstepsdisconnectthegatheringheaddrivemotorfrom theadapterthatlinksittothegatheringheadgearcase.Thegatheringheaddrivemotorisextremelyheavy.Bepreparedtosupport thisweightbeforeperformingthefollowingsteps.

Overviewofsafetyinstructions

IMPORTANT!

Thebottomportsonthehighspeedinputcasesarethefilllines. Thetopportsonthehighspeedinputcasesarethechecklines.

IMPORTANT!

Improperconveyorchaintensioncanleadtoexcessivewear,mechanicalproblems,andminerdowntime.Alwayskeeptheconveyorchainatpropertension.

IMPORTANT!

Positionthefootshaftsoitssprocketwillengagetheconveyor chainlinkswhenthechainisreconnected.

IMPORTANT!

Hogringsshouldbeinstalledsothattheirsharppointsare directedclockwise.

WARNING!

Thenextstepremovesthesecondaryplanetarygearringfromthe secondaryplanetarygearassembly.Thesecondaryplanetary gearringisextremelyheavy.Bepreparedtosupportitsweight beforeremovingitfromthesecondaryplanetaryassembly.

IMPORTANT!

Theflatedgeofthecoverlocatedadjacenttothelubricationfitting isthetopofthecover.Orientthecoversothatthelubricantlevel checkplugisonthemotorsideofthecoverandthedrainplugis onthebottom.

WARNING!

Thenextstepremovesthetramcasefromthetractorframe.The tramcase(withsprocketandreachgears)isextremelyheavy.Be preparedtosupportthetramcasebeforeremovingitfromthe tractorframe.

WARNING!

Ensurethattheelectricalcablesandcoolingwaterhosesforthe trammotorarefreefromthetramcasesbeforeattemptingtoremovethetramcasefromthetractorframe.

IMPORTANT!

Theguidewireswillbeusedtopullthetramtracklinksontothe tramcasesprocketafterthetramcaseisinstalled.

WARNING!

Beforeattemptingtoslidethetramcaseintothetractorframe, ensurethatthetrammotorelectricalandwaterconnectionsare outoftheway.Failuretodosomayresultindamagetotheelectricalandwaterconnections.

IMPORTANT!

There-installationprocedureforthetramcaseincludesreinstallationoftheprimaryandsecondaryplanetarygearsandthe trammotor,andreconnectionofthetramtrack.

Overviewofsafetyinstructions _________________________________

WARNING!

Thenextstepremovesthesprocketfromthetramcase.The sprocketisextremelyheavy.Bepreparedtosupportitsweight beforeremovingitfromthetramcase.

IMPORTANT!

Whenthebearingsleeveisinsertedintoposition,theo-ringforms asealbetweenthesleeveandthepiecethatholdsit.

WARNING!

Standclearoftheminerwhenusingthemotortopullthetram trackthroughthetramcase.

WARNING!

Doublecheckthatthelinksofthetramtrackarecorrectlyseated ontothetramdrivesprocket.Improperengaugementofthetram tracklinksontothesprocketcancauseseriousmechanicaldamage.

WARNING!

Thehydraulicpumpmotorisnowdetachedfromthetractorframe andcanberemoved.Thehydraulicpumpmotorisextremely heavy.Preparetosupportitsweightbeforeremovingitfromthe tractorframe.

WARNING!

Thescrubberfan/motorisnowdetachedfromthetractorframe andcanberemoved.Thehydraulicpumpmotorisextremely heavy.Preparetosupportitsweightbeforeremovingitfromthe tractorframe.

WARNING!

Standclearoftheblockedtractorframeduringcontractionofthe stabilizercylinder.

WARNING!

Followallfederalandminelockout/tagoutregulations.Failureto dosocouldresultinmachinedamageorseriousinjuryordeathto personnel.

WARNING!

Thenextstepsrequirecrawlingundertheblocksupportedconveyortailsection.Verifythatthistailsectionisadequatelysecuredbeforeproceeding.

IMPORTANT!

Machinepowermustbedisconnectedduringinstallationofthe currentgenerator.Cuttermotorfeedbackadjustmentisnormally setwiththecrawlertracksofftheminefloor,stabilizerandcutter headdown(machinejack-knifed).Tojack-knifethemachineyou shouldbefamiliarwiththehydrauliccircuitsontheminer,andin particular,thecutterheadcylinderandthesheardown/ maintenancevalve(anti-chatter)operationasdescribedinthehydraulicsectionofthischapter.(Chapter5)

Overviewofsafetyinstructions

WARNING!

Eachstabilizercylinderisextremelyheavy.Thenextstepswill removethecylinderfromitstractorframemounting.Beprepared tosupporttheweightfromitstractorframemounting.Bepreparedtosupporttheweightofthecylinderwhenitbecomesfree fromthemounting.

IMPORTANT!

Toobtainmaximumperformance,theduoconesealsmustbeinstalledaccuratelytoinsureuniformloadingatthematingfaces andachieveastablerunningposition.Misalignmentorcockingof sealringsduringassemblycanproducenon-uniformloadingand wobblingofthesealsintheirhousingsresultinginleakagedueto scoringand/orpumpingofdebrispastthetoricrings.Improper installationcanalsoresultinbreakageofthemetalsealrings.

NOTICE!

Impropercareandinstallationofduoconesealscanresultinimmediateleakageorreducedservicelife.

IMPORTANT!

Thetoricmustlieuniformlyinthesealwiththesealingringand paralleltotheseatface.Besurethatthetoricisnottwistedand thatitrestsuniformlyagainsttheretaininglipornotdeeperinone sideoftheseatthantheother.

IMPORTANT!

Donotgetanyoilontotherubbertorics!

IMPORTANT!

Evenasmallpieceoflintcanholdthefacesapartandcauseleakage!

IMPORTANT!

Amixtureofmarkingcompoundandspindleoilisgoodlubefor thegearsunderlightloadsfor2-3revolutionsonly.Checktooth patternsallroundtomakesurethepattern/markingsareuniform.

CAUTION!

Becarefulnottosetfiretoanygreaseorlubricantwhenheating bearings!

IMPORTANT!

Observeallapplicablefireandsafetyregulationswhenheating bearings!

Overviewofsafetyinstructions _________________________________

CAUTION!

Becausegearmaintenancetechniquesarespecialized,they shouldbeperformedonlybyqualifiedpersonnel.

CAUTION!

Donotpowerwrenchtheleadthreadofthelockringinsertuntilit isengagedbyhandturning.Thentightennormally

IMPORTANT!

Anti-seizingcompoundsmaybeusedwiththistypeoflocknut. Washersarenotnormallyrequiredhere,butifassemblydoes,includethemastheyareneededduetohighstresstorque.

WARNING!

Componentsnotmeetingspecificationscanfail,causeserious injury,anddamageequipment.

WARNING!

Donotsubstitutematerialsorcompoundsnotcomplyingwiththe OEMspecifications.Useofnon-OEMsuppliesmayvoidwarranties.

IMPORTANT!

Whenperformingmaintenanceonthemachine,rememberthat fabrication,installation,modificationsoradjustmentsmustbeaccordingtoOEMspecifications.

IMPORTANT!

Airorelectricpowerwrenchesoftheappropriatesizemaybe usedforrunningupjackbolts.Attempttotightenasconsistently aspossibleandremovethepowerwrenchfrequently;donot tightenallatonce.Useastandardtorquewrenchtoverifyfinal torquevalues.

WARNING!

Sometroubleshootingproceduresmustbecarriedoutwiththe coveroftheelectricalcontrollerremovedandsomeprocedures requirethecontrollertobeenergizedduringthetests.Itisextremelyimportantthatyoutakeallnecessaryprecautionstopreventaccidentalelectricalshockwhileworkingwithinthecontroller.AnMSHA-certifiedelectricianmustsuperviseandinspectall workperformed.

IMPORTANT!

Ifbreakerresetoptionisused,seewarningtag(Fig.13).

Overviewofsafetyinstructions

Chapter6:Technicaldata

IMPORTANT!

Thetechnicaldatalistedinthischapterisforstockmachines only.Customerspecialsmaynotbelisted.

IMPORTANT!

Duetotheapplicationoffastenersbeingsubjecttogreatstresses andheavyorextremevibration,itisimperativethatallboltsbe appliedwithanadequateamountoftorque.Forthisreasonthis listofrecommendedtorquesettingsfordifferenttypesandsizes offastenersusedhasbeencompiled.Thetighteningtorques statedinthesparepartslistshavetobeobserved,aswell,forinstallationandmaintenance.

IMPORTANT!

Useacalibratedtorquewrenchforaccuracy!

NOTICE!

UseonlylubricationfluidsandgreasesapprovedbyBucyrus America,Inc.!ThesefluidsandgreaseshavebeentestedatBucyrusAmerica,Inc.andguaranteereliableoperationofthemechanicalandhydraulicfunctionsofthemachine.

IMPORTANT!

Thelubricationfluidsandgreaseslistedinthesametablecanbe mixed.Otherproductsmayonlybeusedifthesuppliercanguaranteethattheyareequivalent.

Differentlycomposedfluidsandgreasesmustnotbemixedas thismaychangetheconsistency,i.e.themixturecanbecome thinnersothatthelubricationeffectisnotsufficient.Itmayalso bedangeroustouselubricatinggreasesandfluidshavingthe samespecificationbasebutdifferentorigins.

Incaseofdoubt,themanufacturerofthelubricationtobeused shouldbecontactedastothecompatibilityofthelubricationin question.

IMPORTANT!

BucyrusAmerica,Inc.expresslypointoutthattheapprovalofthe listedproductsrelatesonlytothepuretechnicaluseinourmechanicalandhydraulicsystems.Theresponsibilityfortheconstituentsusedinthehydraulicconcentratesliessolelywiththe respectivemanufacturer.

IMPORTANT!

Besuretousethemanufacturer’sinstructionsforuse.

NOTICE!

Whenperformingmaintenanceonthemachine,allusedoiland lubricantsshouldbestoredanddisposedofperyourlocalEPA standards.

Overviewofsafetyinstructions _________________________________

IMPORTANT!

Aslubricationtechnologyevolves,manufacturerscontinuetoreformulatetheirproductstoobtainimprovedcharacteristicsregardingwear,waterdispersion,waterabsorption,environmental impactandavarietyofotherperformancecriteria.Whenanapprovedlubricantonthislisthasbeensupersededbyanewformulation,itisrecommendedthatthenewformulationbetestedto ensurecompliancewiththeappropriateBucyrusspecification.At aminimum,astatementofconformancefromthelubricantsuppliershouldbeobtained.

Storageandtransport

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Storageandtransport

Thischaptercontainsimportantinformationonthecorrectstorageand transportoftheContinuousMiner.Storageproceduresaregeneral. Forspecificproceduresforyourenvironment,contactBucyrusAmerica,Inc.Engineering.

Observanceoftheinstructionsandtipswillincreasetheservicelifeand availabilityofthemachine.Youwillalsobeabletocarryoutthetransportworkquickerandmoresafely.Carefulattentiontothepointsin thischapterwillhelpyoutosimplifyyourday-to-daywork.

Storage

Componentscoatedwithtemporarycorrosioninhibitorareprotectedfor approximatelysixmonths.

Beforedelivery,thehydraulicfunctionsaretestedandthehydraulic pressuresarepresettoOEMspecifications.

Storageofthemachineandspareparts

Storetheequipmentindoorsorcoverwithatarpaulintoprotectagainst directexposuretosunlight.

Protecttheequipmentandallsparepartsstoredoutdoorsagainst moistureanddirt,e.g.usingtarpaulins.

Protectthehydraulicplugconnectorsandtheconnectorsofthe electricalcableswiththecapsandplugssupplied.

Duringshort-termstorage(approximately4weeks)ofequipment outdoors,butattemperaturesabovefreezing,electricalcomponents neednotberemoved.Suchcomponentsmustbeparticularlyprotectedagainstexcessivetemperatures,dirt,andmoisture.

Iftheequipmentistobestoredmorethansixmonths,thefollowing lubricationandcorrosioninhibitingproceduresmustbefollowed:

■ Ifthecylinderrodsareexposed,therodsmustbecoatedwitha corrosioninhibitingfluid.

■ Completelyfillthehydraulicoiltankwithoil.

■ Fillallgearcase(s)tothemaximumfilllevel.Thegearcase(s) mustberotatedmonthlytoensurethattheinteriorofthegearcase remainslubricated.

■ Lubricateallgreasepoints(seetheMaintenancesectionin Chapter5ofthismanual).

■ Completelydrainthewatersystemandrefillwitha50/50antifreeze/watersolution.Pumptheantifreezemixthroughthesystem untiltheantifreezemixcomesoutthewatersprays.ENSURE THATTHESYSTEMISCOMPLETELYPURGEDANDNO WATERORAIRPOCKETSEXIST.

■ Theequipmentmustbestoredinawellventilated,dryroom.Do notstoreoutdoors.

Storageandtransport

ForcedPotatoelectroniccomponentshavethefollowingstorage requirements:

■ Graphicdisplaysmustbestoredattemperaturesabove14°F (-10°C)

■ Powersuppliesmustbestoredattemperaturesabove -3°F(-20° C)

■ Othercomponentsmustbestoredattemperaturesabove -13°F (-25°C)

Thetractiondrivesshouldbestoredat -10to50°C(14to122°F).

Majorproblemswithcondensationcanoccurifadriveisstoredin acoldenvironmentandisthentakenintoadeepminewherethe temperatureismuchhigher.Eventhoughthehumiditymaybeat anacceptablelevel,condensationwilloccuronthecolddrive.Slight exposuretoacondensingenvironmentisnotharmfulprovidedthe driveiscompletelydrybeforeelectricalpowerisapplied.

Afterastorageperiodofapproximatelytwoyears,arandomsample inspectionmustbeperformedtodeterminewhetherthemeasures takenandthemethodofstoragehaspreventeddamage. Onrequest,theinspectioncanbecarriedoutbyBucyrusAmerica,Inc.

Evenwithproperstorage,sealsandhosesaresubjecttonatural ageing.Donotusethesepartsiftheyhavebeenstoredformorethan twoyears.

Instructionsonthestorageofconcentratesforhydraulicfluidscanbe found,ifrequired,inchapter6inthisoperatingmanual.

IMPORTANT!

Takecaretoinsurethatnewmaintenancesuppliesarestored separatelyfromexistingstockandthatremovaltakesplaceonthe “firstin,firstout”principle.

Long-termstorageofsparecomponents

Ifacomponentistobestoredmorethansixmonths,thehydraulic componentmustbecompletelyfilledwithacorrosioninhibitingfluid. Fillthehollowareasofhydrauliccomponents(e.g.thepistonchambers)inhorizontalposition(portsfacingupwards)untiltheystartto overflowthensealtheportswithplasticorsteelplugs.

Storetheelectricalequipment,electroniccomponents,sparepartsof rubberorplastic – suchassealsandhoses – andhydraulicfluidsonly inclosedroomsattemperaturesof60°F(15°C)to77°F(25°C).

Refertothemotormanufacturer’sstorageprocedureguideinyour BucyrusAmerica,Inc.partsmanual.

Rotatetheimpeller1-1/4turnoncepermonthtopreventdimplingofthe motorbearingsrollers.

Inordertopreventplasticdeformationofthesealelements,cylinders mustbestoredinanuprightposition.Somecylindersmustberemoved sothattheycanbestoredupright.

Transport

Loadunits:dimensionsandweights

Observethetransportsheetsforthemachineandspareparts.They containinformationon:

■ dimensions,

■ weights,

■ liftingpoints,etc.

Additionalinformationonthedimensionsandweightscanbefoundin chapter6andintheliftingweightguide(Table1)inthisoperatingsection.

WARNING!

Useonlyloadhandlingdevicescomplyingwiththetechnicaland legalregulationsforthetransportofloads.Youcouldbeseriouslyinjuredorevenkilledbyfallingloads. Useonlysuitableloadhandlingdevices.

Table1:LiftingweightsofContinuousMinerAssemblies

Wheneverpossible,allremovalsshouldbeaccomplishedusingan adjustableliftingbeam.Allsupportingmembers(chainsandcables) shouldbeparalleltoeachotherandasnearlyperpendicularaspossibletothetopoftheobjectbeinglifted.

Whenitisnecessarytoremoveacomponentonanangle,remember thatthecapacityofaneyeboltdiminishesastheanglebetweenthe supportingmembersandtheobjectincreases.Eyeboltsandbrackets shouldneverbebent.

Whenaneyeboltisprovidedtoliftacomponent,useittoliftonlythat component.

Youcouldbeseriouslyinjuredorkilledasaresultoffallingloads. Donotusetheeyebolttoliftthecomponent and itsrelatedassemblies. removalandinstallationof heavycomponents

WARNING!

Storageandtransport

Transportenvironment

Beforetransportingtheequipmentattemperaturesbelowfreezing,all hydrauliccomponentsoperatedwithemulsion(HFAEorHFAS)must becompletelydrainedandthenfilledwithacorrosioninhibitor/frostproofingfluid.

Transportofequipmentattemperaturesbetween -6°F(-21°C)and40° F(-40°C)isonlypermissiblewhencertainmeasuresweretakento meettheseconditionsatthedesignandmanufacturestages.Nevertheless,theindividualpartsanddevicesofthisequipmentmustnotbe subjectedtosuddenimpactloadsatsuchlowtemperaturesandmay onlybeloadedstaticallyorquasi-statically.

Duringtransportofthisequipmentwithfloor-mountedvehiclesatsuch lowtemperatures,measuresmustalsobetakentoensurethatthe partsanddevicesarenotsubjectedtosuddenimpactloads.Atvery lowtemperaturesandonpoorroads,thetransportvehiclespeedmust thereforebelimitedtoamaximumof15mph(25kph)fortrucktransport.

Electricalandelectroniccomponentsmustbeprotectedagainstharmful environmentalinfluencesbyasuitablepackaging.Theelectricalcables remainintheequipment.Theymustbecarefullyprotectedagainst transportdamageandsoilingoftheconnections. temperaturesbelowfreezing

Installation

Pointstoobservepriortoinstallation

Whoisallowedtocarryoutinstallation?

Installationisonlyallowedtobecarriedoutbypersonnelhaving receivedadequatetrainingtoperformthistask.

Workon:

■ thesafetycomponents(pressurereliefvalves,fireextinguishing equipmentetc.)

■ theelectricalequipment(controlunits,signalingdevices,etc.)

■ thehydraulicequipment(cylinders,directionalcontrolvalves, hosesetc.)

shouldonlybecarriedoutbyBucyrusAmerica,Inc.serviceengineers orbyspeciallytrainedpersonnel.

Whichtoolsarerequiredforinstallation?

NospecialtoolsarerequiredtoputtheContinuousMinerintoservice. Variousitemsofauxiliaryequipmentandmachinesmayberequiredat thepointofinstallation.

Theseinclude:

■ hoistswithadequateliftingcapacity

■ meansofattachmentwithadequateliftingcapacity

■ unloadingdockandcribblocks

■ jackswithadequateliftingcapacity

■ impactwrenches,includingaccessories

toolbox

installationplan

Notesoninstallation

CAUTION!

SeriousdamagecanbecausedtotheContinuousMinerasa resultofincorrectinstallation.Theunitshouldthereforeonlybe installedundertheinstructionofspecialistsfromBucyrus America,Inc.

BucyrusAmerica,Inc.ContinuousMinersareshippedtothecustomer sitepercustomerpreference.TheContinuousMiner canbeshippedto thecustomersiteasacompletemachineorincomponentsections. Thisdependsonmineconditions,transportationweightrestrictions/ requirements,orsize/weightrestrictionsatthemine.

reassemblyinstructions

IMPORTANT!

Whenassemblyisrequiredaftershipmentofthemachine,theassistanceofspecialistsfromBucyrusAmerica,Inc.isrecommended.This willinsurethatthecorrectinstallation,safetyandmaintenanceproceduresarefollowed.

1. visuallyinspectallcylinders,gearboxes,tanks,andhydraulic componentsforleaksordamage.

2. visuallyinspectallelectricmotorsandelectricalcomponentsfor signsofdamage.

3. checkthefulllengthofthetrailingcablefordamage

4. ensurethatthetrailingcableisproperlysuspendedacrossintersectionsandthatthetrailingcableclampattheContinuousMiner issecure

5. visuallyinspectallhydraulichosesandelectricalcablesfor damage

6. checkthatallcoversandguardsareinplaceandsecure

7. checkthatalltagsandinstructionlabelsareinplaceandsecure

8. checkthatoperator’scanopy(optional)issecureandinplace cleananyforeignmaterialfromtheoptionaloperator’s compartment,conveyor,andgatheringpan

9. cleananyforeignmaterialfromtheoperator’scompartment(if equipped),conveyorandgatheringpan.

10. performdailymaintenance

11. checksafetyprovisionsforoperationalconditiononfire suppressionsystem

12. startupthemachineandcheckforcorrectoperationofallstop switches.

13. startthemachineandallowthehydraulicsystemtowarmupfor five(5)toten(10)minutes

14. checkhydraulicsystempressures(refertothehydraulicschematic suppliedforyourparticularmachineforpressuresettings)

15. checkandoperateallcontrolhandlesandremoteswitchesto ensureallmachinefunctionsareoperatingproperlyandarein neutralposition

16. checkthetensionoftheconveyorchainandcrawlerchain

machinestopbutton canopy/cab(optional)

firesuppression

Safetyfeatures

NOTICE!

Theoperatormustbecomefamiliarwithallthesafetyfeaturesand theirlocationonthemachinepriortoinstallationoroperation.

Safetyfeaturesinclude:(ReferenceFig.6)

Themachineisequippedwithamachinestopbuttonlocatedonboth sidesoftheminer.Themachinestopbutton(s)areusedtobreakthe controlcircuitonlyinemergencysituations,stoppingallmotors.Strikingwithasmallamountofforcewillactuatethemachinestopbutton.

Themachinemaybeshippedfromthefactorywithaprotectivecanopy/ cab(optional).Ensurethatthecanopy/cabisinplaceandsecureatall timestoprotecttheoperatorfromfallingdebris.

Themachinemaybeequippedwithfiresuppression(remote)actuators.Ifequipped,thelocationmayvary.Thisparticularsuppression systemispneumaticallyactuatedandextinguisheswithdrychemicals. Toactuatethesystemfromtheactuators,pullthesafetypinandstrike downwardontheplunger.Immediatelyaftertheplungerisstruck,dry chemicalwillbedispensedthroughoutthemachine.Thefiresuppressionsystemmustbecompletelyrechargedwithdrychemicalsand expellantsafterithasbeenactuated.

firesprays

WARNING!

Ifeitherofthefiresuppressionactuatorsisactuated,thesystem mustbecompletelyrechargedwithdrychemicalsandexpellants.

Watercanbedirectedtothefirespraynozzles manuallyfromthe firesprayvalve bythefiresprayvalveonthelefthandside ofthe machine.

Onradiounits,anelectronicallyactuated solenoidisusedtoactuate thefirespraysystem fromtheremoteposition.

IMPORTANT!

Thefiresprayvalvemustbemanuallysettothenormalposition beforethedustsuppressionwaterspraysystemcanbe operated.

CAUTION!

Theminesupplywaterpressureatthemachineshouldnot exceed500psiandshouldsupply20gpmminimumforcooling.

Theremotefiresprayactuatorlocatedonthe mainfeedbehindthe minerisusedtoactivate thefirespraywhenthereisafireand powerhas beenturnedoff. Simplyturningthevalveallows'pilot'oil to feedintothesmallhosesecuredwithinthevalve assemblyand throughthemainfeedlineintothe miner,whereitcontactsa solenoidthatactivatesthefirespraysystem.

TheContinuousMinermaybeequippedwithanoptionaldustsuppressionpackage(scrubber).ThedustsuppressorallowstheMineroperatortousefaninducedventilationattheface.Thefansuctiondrawsin thedustandliberatedmethanefromtheintakeduct(s).Thedustladen airisthendrawnthroughthescrubberscreen,whichisconstantly floodedwithwaterspray.Thedirtywateristhenremovedfromtheair streambyade-misterwhichislocateddirectlybehindthescrubber screen.Thedirtywaterflowsdowntoasumptankwhereawaterpoweredjetpumpemptiesthesumpanddumpsthedirtywaterontothe conveyororgatheringpan.Theclean,dryairexitsthede-misterandis dischargedintothemineatmosphereattherearoftheminer,diffused downwardandtowardstheribtopreventcoalfinesfrombeingblown ontheoffsideshuttlecaroperator.

Themachineisequippedwithguardsandcoverstoreducethepossibilityofpersonnelcomingincontactwithrotatingormovingparts.All guardsandcoversmustbeinstalledandsecurelyfastenedduringoperation.

DANGER!

Donotoperatethemachinewithanyoftheguardsorcovers removed.Youorotherpersonnelcouldbeseriouslyinjuredfrom movingorrotatingparts.

Everyswitchontheoperator’scontrollercasethatengagesafunction (pumpstart,cutterstart,etc.)isprotectedfromaccidentalactivationby acover.

Themachineisequippedwithamethanemonitorthatdetectsthepresenceofmethaneinthemineatmosphere.Whentheminerisbeing poweredup,themonitorlooksformethanebeforeanyotherfunctionis energized.Ifthemethanemonitordetectsalevelofmethanewithina presettolerance,themethanemonitorrelaywillcloseandpowerwillbe suppliedtotheotherfunctionsonthemachine.(Themachinecanhave anoptionaldualsnifferheadordualreadout.)

Fig.6:SafetyfeaturesontheContinuousMiner

Manualcircuit breakerreset (optional)

Machinestop (locationtypical) Safety covers

Methane monitor display

Panicbar/ machinestop

Operator’s station

Fig.7:OverviewoftheContinuousMiner

Cutter boom

Conveyor boom

Crawler assembly

Gatheringhead assembly

Operation

Thischaptercontainsimportantinformationontheoperationand maintenanceofthemachine.Italsoincludesinstructionsonthe replacementofwearparts.

Readthischaptercarefullyandthoroughly.Inparticular,observethe safetyinstructionsinchapter2“Yoursafety”.

HowtooperatetheContinuousMiner

DANGER!

Incorrectoperationendangersyourselfandothers!Incorrect operationofthemachineisoftenthecauseofveryserious accidents!Operatetheunitonlywhenyouhavebeensufficiently trainedonthemachineandhavereadandunderstoodthis operatingmanual.Shouldanythingbeunclear,pleasecontact yourimmediatesupervisor.

WhoisallowedtooperatetheContinuousMiner?

TheContinuousMinerisonlyallowedtobeoperatedbypersonswith adequateknowledgeofthecompletemachine.

Thisalsoincludes:

■ whatsafetydevicesareinstalledonthemachine.

■ wherethesesafetydevicesarelocated.

■ howthesesafetydevicesaretobeoperated.

Whencanoperationbestarted?

Operationmustnotbestarteduntilthesafeconditionandproper functionofthecompletemachinehasbeencheckedandthedaily maintenanceoperationshavebeencarriedout.

NOTICE!

Beforebeginningcuttingoperations,carefullyunloadthetrailing cableprovidingenoughslackandplacingitwhereitallows adequateclearanceforsafemaneuverabilityoftheminer.

Controlsandindicators

Operator’sstation

WARNING!

TheContinuousMinerisradioremotecontrolled.Manualoperationisgenerallyfortroubleshootingandmaintenanceunderroof support.OperatingtheContinuousMinermanuallyfromtheOperator’scasemayresultinseriousinjuryordeath.

Theprimarycontrolsforthemachinearenormallylocatedatthe operator’sstation(Fig.8)ontherighthandsideofthemachinenear therearbumper.

Theexplosionproofoperator’sstationhousesthecontrolsandindicatorsusedinthenormaloperationofthemachine.Mountedinsidethe casearethemaincircuitbreaker,auxiliarycircuitbreaker,control transformer,methanemonitorrelay,electricalmeteringpackage,controlbreakers,headlightswitch,radio/manualswitches,manualstart/ stopswitches,andbridgerectifiers.Allcontrolbreakersarelocated withinthiscase,behindthesmallaccesscoverlocatedabovethetrailingcableentrance.Thetrailingcableentersintothisenclosureatthe bottomleftcornerfacingthecase.Themachinestopismountedonthe enclosureandoperatesthepumpstopswitchtoshutthemachine down.

Themanualcircuitbreakerresetlevers(optional)arelocatedatthe frontbottomofthecase.

Fig.8:Operator’sstation

tramcontrollevers(optional)

Theoptionaltramcontrollevers(Fig.9)controlthespeedanddirection ofeach(leftandright)crawlerdrive.Thetramcontrolleverscanbe usedtogether(totramstraightforwardorstraightbackwards),inoppositedirections(forfastturns),orindividually(forslowturns).Whenin manualmode,the“TRAMDEADMAN”switchmustbedepressedand thetramcontrolleversinthecenter(neutral)position,priortostarting thepumportrammotors.

NOTICE!

TheContinuousMinerhasskidtypesteering:itiscapableofturningwithinitsownlimits.

CAUTION!

IMPORTANT!

Oncethetram/steeringcontrolleverisreleasedbytheoperatorthe controlleverautomaticallyreturnstothecentered(neutral)position.

Totramforward,pushthetramleverslowlyforward,awayfromtheoperator.Totraminreverse,pulltheleverslowlyback,towardtheoperator.Thefurthertheleverispushedorpulled,thefasterthetramming. Whenreleased,thetramleverreturnstothecentered(neutral)position.

Totramstraightforward,pushbothleversforwardatthesametime.To tramstraightback,pullbothleversbackatthesametime.

Toturnleft,pulltheleftcrawlerleverbackandpushtherightcrawler leverforward.Toturnright,pushtheleftcrawlerleverforwardandpull therightcrawlerleverback.Thespeedoftheturnisdeterminedby whethertheleversareoperatedatthesametimeorseparately.

Fig.9:Tramcontrollevers(optional)

Pressingthemachinestop(Fig.10)willshutdownthepump,causing theminertoshutdown.Torestartthemachineafterstrikingthemachinestop,follownormalpumpstartupprocedure(seeStartprocedure inthischapter).

Fig.10:Machinestop

Electricalswitches

Theelectricalswitches(Fig.11)thatcontrolthemachineoperationare agroupofpushbuttonswitcheslocatedonthecontrolcase.

WARNING! ManualoperationoftheContinuousMinerisnotallowedfor productionoperationunlesstheminerhasanoperator’spitand canopy.Manualoperationisgenerallyfortroubleshootingand maintenanceunderroofsupport.OperatingtheContinuousMiner manuallyfromtheoperator’sstationmayresultinseriousinjury ordeath.

The“PUMPSTART”switchstartsthepumpmotor.Tostartthemotor, depresstheswitch.

The“PUMPSTOP”switchstopsthepumpmotor.Tostopthemotor, depresstheswitch.

Startingthecuttermotorisatwo-handstart:pushthe“PUMPSTART” andthe“CUTTERSTART”switchatthesametime.Theleftcutter motorwillstartfirstand,afterapresettime,therightcuttermotorwill start.

The“CUTTERSTOP”switchshutsdownbothcuttermotors.Both motorsstopwhenthe“CUTTERSTOP”switchisdepressed.

Theconveyormotorscannotbestarteduntilthepumpmotorisstarted. Depressingthe“CONVEYORFWD”switchstartstheconveyormotors. Theforwarddirectionoftheconveyorchainisalwaysawayfromthe cutterhead.

Theconveyormotorscannotbestarteduntilthepumpmotorisstarted. Depressandholdthe“CONVEYORREV”switchtostarttheconveyor motors.Whentheconveyormotorsarerunninginreverse,theconveyorchainismovinginthedirectionofthecutterhead.Theconveyor willcontinuetoruninreverseuntilthe“CONVEYORREV”switchis released.Theconveyorcannotbestartedintheforwarddirectionuntil apresetamountoftimehaselapsedfromrunningtheconveyorinreverse.

“CONVEYORSTOP”

Depressingthe“CONVEYORSTOP”switchwillstoptheconveyormotorswhentheconveyorisrunningforward(awayfromthecutterhead).

Thepumpmotormustberunningbeforethescrubbermotorwillstart. Depressandholdthe“SCRUBBER”switchtostartthescrubbermotors andtoenergizethescreensprays.Tostopthescrubbermotor,release the‘SCRUBBER”switch.

The“TRAMDEADMAN”switchmustbedepressedandheldtotram. Releasingthe“TRAMDEADMAN”switchwillstoptrammingfunctions.

The“LIGHTS”switchhasthreepositions:“MANUAL”,“OFF”,AND “RADIO”.The“OFF”positionturnsalllights,arealightsandheadlights, off.Whenthelightswitchisturnedtothe“MANUAL”position,the headlightsandthearealightswillbothturnon.whenthelightswitchis turnedtothe“RADIO”position,thearealightsareilluminatedandthe headlightscanbeturnedonandoffwiththeradioremote.

The“RADIO/MANUALSW.1”switchputsthemachineundermanualor radiocontrol.

The“RADIO/MANUALSW.2”switchconnectsmotorcontroltothe manualpushbuttonsandisolatescontrolfromthemachinecontroller. Intheradioposition,“RADIO/MANUALSW.2”isolatesthepushbuttonsandconnectsmotorcontroltothemachinecontroller.

Thecontrolbreakerswitchesturnthebreakersonandoffandarealso usedtoresetabreakerthathastripped.Allcontrolbreakersareturned onbypushingthebuttoninandareturnedoffbypullingthebuttonout. Ifabreakertrips,thebuttonmustbepulledouttoresetthebreaker, thenpushedintoturniton.Thecontrolbreakersmayvaryandcanbe identifiedbythelabelsonthefrontoftheoperator’scase.

Fig.11:Electricalcontrolswitches

“PUMP START” “CUTTER START” “CONVEYOR FWD”

“CUTTER STOP”

“PUMP STOP”

Circuit breaker resetpanel

“RADIO/ MANUALSW.1”

“RADIO/ MANUALSW.2”

“SCRUBBER”

“CONVEYOR STOP”

“LIGHTS”

“TRAM DEADMAN”

“CONVEYOR REV”

“LEFTCUTTERMOTOR” and “RIGHTCUTTERMOTOR” “LEFTCONVEYORMOTOR” and “RIGHTCONVEYORMOTOR”

Electricalmeteringpackage(optional)

Theoptionalelectricalmeteringpackage(Fig.12)consistsofagroupof metersthatmonitorcurrentdrawonthemotors,machinevoltage,and cutterandconveyorhoursofoperation.

The“LEFTCUTTERMOTOR”and“RIGHTCUTTERMOTOR” ammetersmonitorthecurrentdrawbythecuttermotors.Duringnormal operation,thetwometersshouldindicateapproximatelythesame currentdraw.Ifonemeterconsistentlyreadshigherthantheother meter,shutdownthemachine(seeShutdownprocedureinthischapter) andcontactMaintenance.

The“LEFTCONVEYORMOTOR”and“RIGHTCONVEYORMOTOR” ammetersmonitorthecurrentdrawbytheconveyormotors.During normaloperation,thetwometersshouldindicateapproximatelythe samecurrentdraw.Ifonemeterconsistentlyreadshigherthanthe othermeter,shutdownthemachine(seeShutdownprocedureinthis chapter)andcontactMaintenance.

The“MACHINEVOLTAGE”voltmeterindicatesthecontrolcircuitvoltage.Duringnormaloperation,theindicatorshouldstaybetween855 and1,045volts(950V±10%).Shouldthemeterindicatehighorlow voltage,shutdownthemachine(seeShutdownprocedureinthis chapter)andcontactMaintenance.

The“CUTTERHOURS”meterindicatesthehoursofrunningtimefor thecutterheadmotors.

The“CONVEYORHOURS”meterindicatesthehoursofrunningtime fortheconveyormotors.

Fig.12:Electricalmeteringpackage(optional)

“LEFTCUTTER MOTOR”ammeter

“LEFTCONVEYOR MOTOR”ammeter

“MACHINEVOLTAGE” voltmeter

“RIGHTCUTTER MOTOR”ammeter

“RIGHTCONVEYOR MOTOR”ammeter

“CUTTER HOURS”meter

“CONVEYOR HOURS”meter

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circuitbreaker

Thecircuitbreakeristhemaincircuitbreakerforthemachine.The circuitbreakerhastwo(2)positions:"OFF,"tode-energizethemachine'selectricalsystemsand"ON,"fornormaloperation.Thecircuit breakershouldbeinthe"OFF"positionbeforethemachineisserviced orshutdown.

manualcircuitbreakerreset (optional)

WARNING!

Themanualcircuitbreakerresetlevers(Fig.13)arelocatedbelowthe electricalswitchesattheoperator’scontrolstation.Thecircuitbreaker tripswhentheelectricalsystemisoverloadedorshorted.

WARNING!

Oncethebreakerhastripped,itwillnotstayinthe“ON”position withoutfirstbeingmovedtothe"RESET"position,andthento "ON".

Toresetthecircuitbreakermanuallyproceedasfollows:

 Movetheselectorto“RESET”positionandmovethecircuit breakertofull“OFF”position.

 Movetheselectortothe“ON”positionfornormaloperation.

Fig.13:Manualcircuitbreakerreset

“MAINBREAKER”reset (shownwithpinout)

“AUXILIARYBREAKER” reset(notshown)

machinestop/e-stop

methanemonitor

TheContinuousMinerisequippedwithamachinestopbutton(Fig.14) locatedontheleftandrightsidesofthemachine.Themachinestop/estopbuttonisusedtobreakthecontrolcircuit,stoppingallmotors. Strikingwithasmallamountofforcewillactuatethemachinestop.

WARNING!

Bepreparedforasuddenstopwhenthemachinestop/e-stopis actuatedduringnormaltrammingofthemachine.

Machinestop(2) (locationtypical)

Themachineisequippedwithamethanemonitoringsystem(Fig.15) which,whenenergized,maintainsacontinuouscheckonmethanegas concentration.ThismachinehasanLEDindicatordisplayswhichshow thepercentageofmethanegasinlargernumerals.

Consultthemanufacturer’smanualandliteratureintheBucyrusparts bookforyourmachineforthesetup,operation,andmaintenanceofthe methanemonitoringsystem.

IMPORTANT!

Itistheresponsibilityofthecontinuousminerowner/operatorto knowandfollowallregulationsregardingmethanemonitoring requirements,including,butnotlimitedto,dailyoperation,maintenanceandtesting.

Methanemonitor display

Fig.15:Methanemonitordisplay

Fig.14:Machinestop/e-stop—rightside

Whenoperatedbyaradio(Fig.16),aportablewirelessremotewitha uniquecodefeaturesendsradiocommandstoareceiverintheswitch consoleviaawhipantennasetup.Thesmallwhipantennaeintercept theradiosignalswhichthereceivertranslatesintoelectricalcommandstovariouselectricalcircuitstoperformthefunctionselected. Thesecircuitsenergizesolenoidswhichactuatepilot-valves,switches, orrelayscontrollingaspecificmechanical,hydraulic,orelectricalfunction.

Thereareeightselectablefrequencieswhichpermitseachoperatorto activateonlyhisdesignatedminer,allowingseveralremote-controlled minerstooperateinthesameareawithoutgettingtheirradiosignals crossed.Inaddition,animproperlydecodedradiosignalwillautomaticallyshutdowntheminer.

Alwaysrefertothespecificradioremotecontroloperationmanualsuppliedwithyourspecificmachinefordetailsandoptionsontheradio remotecontrol.

IMPORTANT!

Refertotheradioremotecontroloperationmanualsuppliedwith yourmachineforinformationregardingtheoperationofyourspecificremotecontrol.

Topview

Fig.16:Radioremotecontrol(typical)

Theoptional“LOWOIL”light(Fig.17)illuminateswhenthehydraulicoil levelinthemachineislow.Ifthe“LOWOIL”lightcomeson,shutdown themachine(seeShutdownprocedureinthischapter)andcheckthe hydraulicoillevel.Ifoilisneeded,addoil(seeprocedureinMaintenancesectionofthischapter).

Fig.17:“LOWOIL”light(optional)

“LOWOIL”light(optional)

“LOWOIL”

Valvebank

Themanuallyoperatedvalvebank(Fig.18)islocatedonthenearthe operator’sstationandisusedtooperatetheminerduringmaintenance andtroubleshootingfunctionswhileundersupportedroof.

NOTICE!

Onceahydrauliccontrolvalvehandleisreleasedbytheoperator, theleverwillautomaticallyreturntothecentered(“HOLD”)position.

Thefirstleverfromtheoperator’sleft,“STABILIZER”,controlsthecylinderthatraisesandlowersthestabilizershoe.Toraisethestabilizer shoeoffofthefloor,pullthelevertowardtheoperator.Tolowerthe stabilizershoetothefloor,pushtheleverawayfromtheoperator.

Thesecondleverfromtheoperator’sleft,“CONVEYOR-RAISE/ LOWER”,controlsthecylindersthatraiseandlowertheconveyor boom.Toraisetheconveyor,pullthelevertowardtheoperator.To lowertheconveyor,pushtheleverawayfromtheoperator.

Thethirdleverfromtheoperator’sleft,“CONVEYOR-LEFT/RIGHT”, controlstheconveyorswingcylinders.Toswingtheconveyorboomto theleft,pushtheleverawayfromtheoperator.Toswingtheconveyor boomtotheright,pullthelevertowardtheoperator.

Thefourthleverfromtheoperator’sleft,“GATHHD”,controlsthecylindersthatpositionthegatheringhead.Toraisethegatheringhead, pushtheleverawayfromtheoperator.Tofloatthegatheringhead, pullthelevertowardtheoperator.

Thefifthleverfromtheoperator’sleft,“CUTTINGHD”,controlsthecylindersthatraiseandlowerthecuttinghead.Toraisethecuttinghead, pullthelevertowardtheoperator.Tolowerthecuttinghead,pushthe leverawayfromtheoperator.

Fig.18:Valvebank

Gaugepanel(optional)

Theoptionalgaugepanel(Fig.19)consistsofgaugesusedtomonitor waterandhydraulicpressurethroughouttheminer.

The“MINERWATERPRESSURE”gaugemonitorsthepressureatthe maindistributionmanifoldforthewatersystemontheminer.Seethe minerwaterpressurecircuitinthehydraulicsectionofthischapterfor furtherinformation.

The“MAINPRESSURE”gaugeisusedtomeasurethepressurein mainflow - primarypressurecircuit.Seethemainflow - primarypressurecircuitinthehydraulicsectionofthischapterforfurtherinformation.

The“PILOTCIRCUITPRESSURE”gaugeisusedtomonitorthesupplypressureforallpilotfunctions.Seethepilotpressurecircuitinthe hydraulicsectionofthischapterforfurtherinformation.

The“GHFLOATPRESSURE”gaugemonitorsthepressureoftheextendportofthegatheringheadfloatcylinders.Thispressuregauge displaysdifferentreadingsdependingontheoperatingconditionofthe cylinders:

■ Withthegatheringheadworkingsectionofthemaincontrolvalve intheGatheringHeadUp(GHU)positionandthecylinderfullyextended,thegaugewilldisplaythesettingofthereliefvalve“CR” andthevalvecanbeadjustedusingthegauge.

■ Withthegatheringheadworkingsectionofthemaincontrolvalve intheGatheringHeadFloat(GHD/F)position,thegaugecanbe usedtoadjustthepressureinthegatheringheadfloatcounterbalancevalve“VR”andthevalvecanbeadjustedusingthegauge.

■ Withthegatheringheadworkingsectionofthemaincontrolvalve inthecenterposition,thegaugedisplaysthepilotpressureatthe valvemanifold.

■ Thegaugewillalsodisplayhighpressuresseenbythegathering headcylindersduringnormaloperation.

The“ACCUMULATORPRESSURE”gaugeisusedtomonitoraccumulatorpressure.Thepurposeoftheaccumulatoristostorethenecessarypilotpressuretoallowremoteoperationofthefiresuppression andbreakeron/offcontrolvalveswhenthepumpisnotoperational. Theaccumulatorpressureshouldcloselytrackthepilotcircuitpressure.Iftheaccumulatordoesnotholdpressurewhenthepumpis shutdown,callmaintenance.Seetheaccumulatorpressurecircuitin thehydraulicsectionofthischapterforfurtherinformation.

The“SHEARDOWNPRESSURE”gaugeisusedtomonitorthepressureofthecuttingheadcylindercircuitduringsheardownoperations. Seethesheardown/maintenance(anti-chatter)valveinthecutterhead cylindercircuitinthehydraulicsectionofthischapterforfurtherinformation.

Fig.19:Gaugepanel

“MINERWATER PRESSURE”

“MAIN PRESSURE”

“PILOTCIRCUIT PRESSURE”

“ACCUMULATOR PRESSURE”

“GHFLOAT PRESSURE” “SHEARDOWN PRESSURE”

waterregulatorassemblyscrubberspraygauge andjetpumpgauge

Thewaterregulatorassembly(Fig.20)islocatedinthelefthandrear ofthemachinenearthescrubber.Thewaterregulatorassemblyincludesthescrubberspraygaugeandthejetpumpgauge.Thescrubberspraygaugemonitorsthewaterpressureofthescrubbersprays. Thejetpumpgaugemonitorsthewaterpressureofthejetpump.ConsulttheschematicintheBucyrusAmerica,Inc.partsmanualsupplied withyourmachine.

Fig.20:Waterregulatorassembly

firesuppressionsprayvalvepilotoperated (optional)

Thepilotoperatedfiresuppressionsprayvalve(Fig.21)istypicallylocatedonthelefthandsideofthemachine.Thispilotoperated,2-way, 2-positionvalvecanalsobeoperatedmanually.Thespoolisdetented sothatitstaysintheopenpositionuntilitismanuallyclosedbypulling ontheknob.

Fig.21:Firesuppressionsprayvalve-pilotoperated

Firesuppression sprayvalvepilotoperated

Jetpump pressuregauge

Scrubberspray pressuregauge

firesuppressionsprayvalvemanuallyoperated

Themanualfiresuppressionsprayvalve(Fig.22)islocatedontheoppositesideofthemachineasthepilotoperatedvalve.This2-way,2positionballvalveisoperatedbyturningthehandle90degrees.

Fig.22:Firesuppressionsprayvalve-manuallyoperated

Firesuppression sprayvalvemanuallyoperated

Machinecontrolsystem

Amulti-componentsystemisusedtocontrolandmonitorthefunctions ofthemachine.Thissystemconsistsofthefollowingmaincomponents:

■ Machinecontroller

■ Powersupply

■ Input/Output(I/O)modules

■ Radioremote

■ Textdisplay

Thefollowinginformationispresentedasageneralguidetothecapabilitiesandfunctionsofthecontrolsystem.Beforeattemptingtooperate,service,ortroubleshootthecontinuousminer,trainingmustbe completed.

machinecontroller

powersupply

input/outputmodules

Themachinecontrollerunitisthemaincontrolunitofthesystem.It includestheradiodatacontrollerwhichisusedtoreceiveanddecode commandsfromtheradioremote.

Thecontrolsystemhasitsownpowersupply,withtheoptionofhaving batterybackupforthepowersupply,whichprovidespowertothemachinecontrollerandI/Omodules.

Input/outputmodulesareusedtoreaddatafromand/orsendcommandstothefollowingmachinefunctions:

■ Cuttermotors(leftandright)

■ Gatheringheadmotors(leftandright)

■ Tractionmotors(leftandright)

■ Pumpmotor

■ Hydraulicoillevel

■ Methanemonitoring

Basedontheparametersettingsandtheinputreceivedfromdifferent components,thecontrolsystemshastheabilitytoissueerrormessages,faultmessages,and/orshutdownthemachine.

radioremote

Theradioremote(Fig.23)isabatterypoweredremoteusedtocontrol thecontinuousminerduringnormaloperations.

WARNING!

Radioremotecontrolsystemsaredangerous.Thecontinuous mineroperatorcannotoperatearemotesystemuntilheisproperlytrainedintheoperationofthesystem.Remotecontrolsystemssometimeshaveautomaticfeaturesofwhichuntrainedoperatorsandworkersmaynotbeaware.

Fig.23:Radioremote(typical)

Theradioremoteshownmayvaryfromtheremotethatshippedwith yourmachine.

Textdisplay

Thereisatextdisplaylocatednearthebackrighthandsideofthemachine(Fig.24)usedtodisplaydiagnosticinformationontheminer.

Fig.24:Controlsystemdisplaylocations(typical)

Textdisplay

Thetextdisplaywillremainpoweredthroughthebatterybackupifthe controlsystemlosespower.

Normaldisplaypages

Themaindiagnosticscreen(Fig.25)isdisplayedduringnormalremote controloperationofthemachine.Thescreenpresentsrealtimediagnosticandperformanceinformation.

Fig.25:Maindiagnosticscreen,example

SystemMenu

Thecontrolsystemprovidesinformation,diagnostic,andsetupscreens thataregroupedtogetherinthesystemmenu(Fig.26).Thesystem menuisaccessedbyusingthedisplaymoduleandaremotecontrol handset.

Toaccessandnavigatethesystemmenuusingtheradioremote:

 PresstheSHIFTandMENUkeytoaccessthesystemmenu screen.

IMPORTANT!

Allfunctionsandmotorsareshutdownanddisabledwhenthe systemmenuisselected.

 PressCONVUPorCONVDOWNtomovethecursorupanddown thelist.

 PressSHIFTandMENUtoselectthehighlighteditem

 Toleavethemenuandreturntoremotemode,pressSHIFTand REMOTE.

Fig.26:Systemmenu,example

Fig.26:Systemmenu,example,continued

Otherfunctions

Thecontrolsystemallowsalargenumberofmonitoringscreenstobe selectedanddisplayedwhilethemachineisoperating.Afteraccessing theselectedscreen,pressSHIFTandMENUtoreturntothesystem menu.

Factorydefaultsettingsmayberestoredtonon-password-protected setupparameters.

Thecontrolsystemincludesthefollowingscreens:

■ Date/Timesetting

■ Moduletemperatures

■ Solenoidself-test

■ Usersetupoptions

■ Engineeringsetupoptions

■ FaultLog

Fig.27:Othercontrolsystemfunctions

Faultlog

Thefaultlog(eventmonitor)(Fig.28)allowstheusertoviewthelast32 faultsthathaveoccurredsincethelogwaslastcleared.

Tonavigatethefaultlogpage:

 PresstheCONVLEFTorCONVRIGHTkeystomovethecursor upordownthepage.

 PressSHIFTandMENUkeystogethertoreturntothesystem menu.

ItispossibletoclearthefaultlogundertheEngineeringSetupMenu, whichispasswordprotected.

IMPORTANT!

Itisnotrecommendedthatthefaultlogbeclearedunlessthemachinecontrollerhasbeenreplaced.Retainingthefaultsisvery helpfulintroubleshootingaproblemwhenamachinecontrolleris sentforservice.Faultscannotberetrievedoncetheyhavebeen cleared.Usecautionandonlyclearthelogifitisabsolutelynecessary.

Onceafaulthasbeenselected,pressandholdtheSHIFTkeytoaccessmoreinformationonthefault.

Fig28:Faultlog,example

Foracompletelistoffaults,seethetroubleshootingsectionofthis chapter.

Redzone

Remotecontrolledcontinuousminers

Theremotecontrolofminersintroducescertainpotentialsafetyhazards whichthemineroperatormustwatchforandbeawareof.Whilethe operatorisnowfreetopositionhimselfforconvenientvisibilityofmining operationsattheface,hecaneasilyexposehimselftothedangerof beingnearmobileheavyequipment.

Mostsignificantly,theoperator’sgreatestdangerisfromhisContinuous Miner,especiallywhenheismaneuveringitduringminingoperations. Themineriscapableofslewingwhenturning,especiallywhenthe crawlersaresplit.Thedischargeconveyorcanalsoswing.Ineachof thesecases,themineroperatorisindangerofbeinghit,orworseyet, runoverbyhisownmachine.Equallydangerousisthepossibilityof theoperatorbeingpinnedagainsttheribbyhisownminer.

Mineroperatordangerareas,orredzones

Sometypicalsituationsdangeroustothemineroperatorareillustrated onthefollowingpages.Thedangerarea,orredzone(Fig.29)is indicatedbyalternatingredandwhitediagonalstripes.

Fig.29:Redzone

Trammingtheminer (Fig.30)fromoneplacetoanother,especially maneuveringaroundintersections.Thisillustratesthattheoperator shouldnotplacehimselfbetweenhisminerandtherib.

Beginningthefirstsump (Fig.30)inanewcut.Theminerisagainst theleftribandthedischargeconveyorisswungtowardthecenterof theentryreadyforthehaulagecar.Theoperatormuststayclearofthe dischargeconveyorandtherearoftheminer.

Fig.30:Redzones

Trammingtheminerredzone Beginning1stsumpredzone

Sumpinginthelefthandside ofthecut(Fig.31).Astheminer penetratestheface,newunsupportedroofisbeingexposed,andthe operatornowhasanadditionalconstrainttohismovements.Hemust alsostayclearofthehaulagevehicleattherearoftheminerasit approachestheminerandwhileitisloading.

Repositioningtheminerfortherighthandcut (Fig.31).Because theminerisbackingoutandturninginclosequarters,theoperator muststaybehindtheminertobesafe.

Sumpingintherighthandcut (Fig.31).Again,theoperatormust stayawayfromthefacewherethenewly-exposedroofisunsupported, aswellasstayingclearofthehaulagevehiclewhileitapproachesand loads.

Sumpingonthelefthand sideredzone

Sumpingintherighthand cutredzone

Repositioningminerforright handcutredzone

Fig.31:Redzones

Crosscutredzones (Fig.32). Beginningandcompletingcrosscuts requiresalotofmaneuveringoftheminerandloadingthehaulage vehiclewhileatawkwardpositions.Crosscutsalsoresultinnewly exposedunsupportedroof.Respectingareddangerzoneisimportant tooperatorsafetyintheseconditions.

Whentheminerbeginningarighthandcrosscutitisnearlyagainstthe opposite(lefthand)rib,whilethedischargeconveyorisswungtoits maximum45o rightpositionforloadingthehaulagevehicle.Hence,the entirerearofthemineristreatedasaredzone.Therearetwoother dangerareas.Ontherighthandside,theminerformsapinchpointat theribwhichmustbeavoided.Also,onthelefthandsideoftheminer, astheminerprogressesintotherib,asharp-angledfenderwillbe formedwhichwillbesusceptibletosloughingandfallingoff.Hence, thatribmustbeconsideredaredzone.

Theredzonesurroundstheminerasthedischargeconveyorisfreeto swingeitherwayandmoreunsupportedroofisexposedduringthe furtherdevelopmentoftherighthandcrosscut.

Beginningarighthand crosscutredzone

Righthandcrosscut development

Fig.32:Crosscutredzones

Pillaringredzones (Fig.33) Remotecontroloffersasignificantsafety advantageinpartialorcompleteremovalofthepillarsinretreatmining becauseitplacestheoperatorfurtherawayfrompotentialcollapsing roof.

Muchoftheareaaroundtheminermustbeconsideredaredzone, mostlybecauseofextensiveunsupportedroofandtheneedfortemporarysupportsunderweakenedroof.Withremotecontrol,theoperator canpositionhimselfsafelyawayfromtheminerwhilestillretaininga goodviewoftheminingcycle.

Aredzonearoundtheminerisnolongerapplicablewhenworkingin theoppositerighthandpillar,astheoperatorisnowexcludedfromthe entireworkingareabecauseoffailingroofconsiderations,evenwiththe existenceoftemporaryroofsupports.

Whenmakinganadditionalendcutintothepillar,creatingafenderof coalbetweenthetwocuts,additionaltemporaryroofsupportsare installed.

Becauseofroofpressures,thefenderwilltendtosloughitsribsinthe processofeventuallycrushing.Hence,theoperatormuststayaway fromthisfenderaswellasavoidingtheentryandcrosscutareasas shown.

Fig.33:Pillaringredzones

Safetyprecautionsforundergroundoperation

InadditiontotheprecedinginstructionsforoperatingtheContinuous Miner,observethefollowingspecialprecautionsaftertheContinuous Mineristakenunderground.

■ Communicationisakeyelementinmaintainingsafety.Exactinstructionsandwarningsshouldbegivento,andthoroughlyunderstoodbyeachworkman.Goodcommunicationsbetweentheentire crewmustbemaintainedthroughouttheshift.

■ Checktheconditionofthetrailingcablebeforeturningpoweronat thepowersource.

■ Thismachinemustbemaintainedinapermissiblecondition,followingallstateandfederallaws.

■ MakeavisualcheckoftheContinuousMinerbeforeenergizing. Lookforloosebolts,covers,lockingdevices,damagedparts,and crackedorbrokenlenses.Anypartofthemachinewhichdoesnot functionproperlyisahazard.Reportitimmediatelytoyourimmediatesupervisorortheirdesignee.

■ Priortooperation,makesuretheworkingareaissafe.Makea visualinspectionofroofandribsandtakeallstepsnecessaryto insuresafety.

Trammingsafetyrules

■ Communicateyourintentionstotheemployeesaffectedbythe movementoftheContinuousMiner.

■ Checkthepositionofthewaterhoseandtrailingcabletobe sure thereissufficientslacktofinishtheoperation.

■ Notetheconditionoftheroadwaysandphysicalsurroundingsof theroute.

■ Positionthecutterandgatheringheadfortramming.

■ Positionthestabilizershoeandboomsfortramming.

■ Positionyourbodycompletelyinsidetheoperator'scompartment (optional),facingtheintendeddirectionoftravel.

■ PositiontheContinuousMinerinthecenteroftheroadwaytoallowmaximumsafeclearance.Consistentlymaintainclearance, whichiscriticaltothesafemovementoftheContinuousMiner.

Startingprocedure

WARNING!

Failuretoreadandunderstandalloperatinginstructionsbefore startingtheContinuousMinercouldresultinseriousinjuryor deathtotheoperatororpersonsaroundthemachineorcause damagetothemachine.

WARNING!

Readallinstructionscarefullybeforeattemptingtostartor operatemachine.

WARNING!

Understandthefunctionsofallcontrolsbeforestartingthe ContinuousMiner.Readandfollowtheinstructionsonallwarningtagsonthemachine,observeallregulationsandsafetyprecautions.

WARNING!

NeveroperateaContinuousMinerwhichhasbeendamagedoris notoperatingproperly.AnypartoftheContinuousMinerwhich doesnotfunctionproperlycanbeahazard.Reportitimmediately toyoursupervisorortheirdesignee.

WARNING!

BeforestartingtheContinuousMiner,makesurethatnooneisin theredzone(Fig.30throughFig.34).

NOTICE!

Inextremelycoldweather,allowmotorsandgearcasestoidle. Thiswillwarmthehydraulicoilsandlubricants.Stilloilsand greasescouldimmobilizethemachine.

IMPORTANT!

Apump“growl”meansnotenoughoilisreachingthepumps throughthesuctionlines.Ensurethepumpgetsprimedbefore continuingoperation.Alwayschecktheoillevel.

DANGER!

Improperpositioncouldresultininjuryordeathtotheoperator bycrushinghimagainsttheriborroofsupports.Itmayalso causehimtorunoverthetrailingcableordislodgetheroof supports.

WARNING!

Turningonthewatersprayspriortocuttingpreventstheaccumulationofdustandthegenerationofexcessiveheatwhichcould causeanignitionorexplosion.

Afterreadingthepreviousdescriptionsandlocatingeachcontrol,the operatorisreadytooperatetheContinuousMiner.Anexperienced operatorshouldmonitoranewoperator’sindoctrinationtothestarting procedure.

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WARNING!

TheContinuousMineristypicallyoperatedbyradioremote control.Manualoperationisnotallowedforproductionoperation unlesstheminerhasanoperator’spitandcanopy.Manualoperationgenerallyisfortroubleshootingandmaintenanceunderroof support.

Theoperatingprocedureslistedinthefollowingsectionsareforradio operation.

IMPORTANT!

Beforestart-up,checkthatdailymaintenancehasbeenperformed onthemachine.

WARNING!

 Turnthemaincircuitbreakertothe“ON”position.

 Select“RADIO”onthe“RADIO/MANUALSW.1”

 Turnthepowerswitchonradioremotetotheonposition.

 Press“SHIFT”andwait1/4second.

 Whilepressing“SHIFT”,press“PUMPON”.Holdbothkeysinuntil thepumpstarts.

 Releasethe“PUMPON”key.

IMPORTANT!

The“PUMPON”keymustbereleasedbefore“SHIFT”.If“SHIFT” isreleasedfirst,thepumpmotorwillshutoff.

 Releasethe“SHIFT”key.

Shutdownprocedure

TheContinuousMinermustbeproperlyshutdownbeforeleavingthe areaorbeforeperforminganymaintenanceorservice.Somemaintenanceorserviceproceduresmayrequireadditionalstepstoinsurethe safetyofthemaintenancepersonnelworkingonoraroundthemachine andwillbelistedinthemaintenancesectionofthisguide.

 Backthemineraboutonefootfromthefaceprovidingsufficient clearanceandshutoffthecutterheadmotors(seeCutteroperation inthissection).

 Tramtheminertoanareaofwellsupportedroof.Parkthemachine initsdesignatedparkingareaoutoftraffic,onflat,solidground.Ifit isnotpossibletoparkthemachineonflatground,parkthemachine atarightangletotheslope.

WARNING!

Afterturningoffthepowertothemachine,neverwalkawayand leavetheradioremoteturnedon.Failuretoturntheradioremote offcouldresultinanaccidentcausingseriousinjuryorlossof life.

 Emptytheconveyorandshutitoff(seeConveyoroperationin thischapter).

 Lowerthecutterheadtothefloor.

 Lowertheconveyorandgatheringhead.

 Pressandholdthe“PUMPOFF”key.Thepumpmotorshould shutdownimmediately.

 Releasethe“PUMPOFF”key.

 Turnoffthewatersprays.

 PositionallleversandcontrolstoNeutralorOff.

 Shutoffthemainpowersupply.

 Shutofftheminewatersupply.

Trammingtheminer

Trammingrequirescoolingwatertopreventdamage.

NOTICE!

TheContinuousMinerhasskidtypesteering:itiscapableof turningwithinitsownlimits.

WARNING!

Trammingrequirescoolingwatertothetrammotors.Failureto coolthemotorswillresultinmotordamageandprematurefailure.

 Ensurethatthestabilizershoeisawayfromtheminefloor.

 Raisecutterboomtobestpossiblepositiontoallowclearancefrom roof,ribs,andfloor.

 Raisegatheringheadawayfromtheminefloor.

 Adjustconveyorboomtobestpossiblepositiontoallowclearance fromroof,walls,andfloor.

WARNING!

Adjustconveyorboomtoallowclearancefromroof,walls,and floor.Failuretodosowillresultindamagetotheconveyorboom.

 Ensureadequateclearanceatalltimeswhiletrammingmachine. Beawardofpeople,equipment,andcables.

Remotecontrol - tramenable:

 Toenablemachinetramming,pressandreleasethe“TRAM2-3” key.

 Onceenabled,thetramleverscanbeusedtodriveleftandright trammingtracksforwardsandbackwards.Ifthetramleversare releasedforacontinuousperiodoffive(5)seconds,thetram becomesdisabled.

 Tore-enablethetramfunction,pressandreleasethe“TRAM2-3” key.

Remotecontrol - tramtrackconsole:

 Pressthe“LEFTFWD”tramkeytoturnthelefttrammingtrack forward.

 Pressthe“LEFTREV”tramkeytoturnthelefttrammingtrack backwards.

 Pressthe“RIGHTFWD”tramkeytoturntherighttrammingtrack forward.

 Pressthe“RIGHTREV”tramkeytoturntherighttrammingtrack backwards.

Remoteconsole - tramspeedcontrol:

Thesystemallowsthetrammingtobedriveninthreediscretespeeds (SPEED1,SPEED2,andSPEED3).SPEED1isthedefaulttrammingspeed.

Toadvanceaspeed:

 Pressthetramleversand“TRAM2-3”keystogethertomovefrom SPEED1toSPEED2.

 OnceinSPEED2,pressthetramleversand“TRAM2-3”together tomovefromSPEED2toSPEED3.

Thefollowingtrammingconfigurationsareenforcedbythecontrol systemforsafetyreasons:

■ SpilttracktrammingislimitedtoSPEED1whencuttermotorsare notrunning.

■ SingletracktrammingisnormallylimitedtoSPEED1whencutter motorsarenotrunning.

■ ItispossibletospeedupasingletrackfromSPEED1toSPEED2 providingthattrammingisstartedinSPEED1.

■ Trammingislimitedtosumpspeedwhilethecuttersareon.

■ Whilethecuttersarerunning,reversespeedcanbeincremented whilethereversetramkeysarebeingpressed.Notethatthisoptionisusedwhentheminerisretreatingorpillarmining.

Cutterheadoperation

Tostartthecuttermotors:

 Ensurethatthecutterheadisnotincontactwithanything.Cutter headmotorsmustneverbestartedunderaload.

WARNING!

Neverstartcutterheadmotorsunderaload.Startingmotors underloadmayresultinmotordamageorprematurefailure.

 Warn“ALLCLEAR” beforestartingthecutterhead.

WARNING!

Warn“ALLCLEAR”beforestartingthecutterhead.Failuretodo somayresultinseriousinjuryordeath.

 Ensurethatthepumpmotorisrunning.Thecuttermotorswillnot runifthepumpmotorisnotrunning.

 Press“SHIFT”andwait1/4second.

 Whileholdingin“SHIFT”,press“CUTTERON”.Continuetohold bothkeysinuntilthecuttermotorsturnon.

IMPORTANT!

Bothcuttermotorsdonotstartatthesametime.Thereisapreset timeddelaybetweentheleftcuttermotorstartingandtheright cuttermotorstarting.

 Releasethe“CUTTERON”key.

IMPORTANT!

The“CUTTERON”keymustbereleasedbefore“SHIFT”. If“SHIFT”isreleasedfirst,thecuttermotorswillshutoff.

 Releasethe“SHIFT”key.

Tostopthecuttermotors:

 Pressandholdthe“CUTTEROFF”key.Thecuttermotorsshould shutdownimmediately.

 Releasethe“CUTTEROFF”key.

Conveyoroperation

Tostarttheconveyormotorsinforward:

 Placeconveyorboomindesiredposition.

 Warn“ALLCLEAR” beforestartingtheconveyor.

WARNING!

Warn“ALLCLEAR”beforestartingtheconveyor.Failuretodoso mayresultinseriousinjuryordeath.

 Ensurethatthepumpmotorisrunning.Theconveyormotorswill notstartifthepumpmotorisnotrunning.

 Press“SHIFT”andwait1/4second.

 Whileholdingin“SHIFT”,press“CONVON”.Continuetoholduntil theconveyormotorturnsonandtheconveyorstartstorunforward.

 Releasethe“CONVON”key.

IMPORTANT!

The“CONVON”keymustbereleasedbefore“SHIFT”.If“SHIFT” isreleasedfirst,theconveyormotorswillshutoff.

 Releasethe“SHIFT”key.

Tostoptheconveyormotors - conveyorforward

 Pressandholdthe“CONVOFF”key.Theconveyormotorsshould shutdownimmediately.

Tostarttheconveyormotorsinreverse(momentaryonly)

 Placeconveyorboomindesiredposition.

 Warn“ALLCLEAR” beforestartingtheconveyor.

WARNING!

Warn“ALLCLEAR”beforestartingtheconveyor.Failuretodoso mayresultinseriousinjuryordeath.

 Ensurethatthepumpmotorisrunning.Theconveyormotorswill notstartifthepumpmotorisnotrunning.

 Press“SHIFT”andwait1/4second.

 Whileholdingin“SHIFT”,press“CONVREV”.Continuetohold untiltheconveyormotorturnsonandtheconveyorstartstorunin reverse.

 Theconveyorwillcontinuetoruninreverseuntilthe“CONVREV” orthe“SHIFT”keyisreleased.

Scrubbermotor

Tostartthescrubberfanmotor:

 Ensurethatthepumpmotorisrunning.Thescrubbermotorwill notstartifthepumpmotorisnotrunning.

 Press“SHIFT”andwait1/4second.

 Whileholdingshift,press“FANON”.Continuetoholduntilthe scrubberfanmotorturnson.

 Releasethe“FANON”key.

IMPORTANT!

The“FANON”keymustbereleasedbefore“SHIFT”.If“SHIFT”is releasedfirst,thefanmotorwillshutoff.

 Releasethe“SHIFT”key.

Tostopthescrubberfanmotor:

 Pressandholdthe“FANOFF”key.Thefanmotorwillshutdown immediately.

 Releasethe“FANOFF”key.

Controlheadlightsandarealights

Thelightswitchhasthreepositions:arealightsonly,allonandalloff. Whenthepoweristurnedontothecontinuousminer,themethane monitorrelayisclosedandthelightswitchison.Whenthelightswitch isturnedtotheallonposition,theheadlightsandthearealights(Fig. 29)willcomeon.Whenthelightswitchisturnedtothearealightsonly position,theheadlightsonly(notthearealights)canbeturnedonand offwiththeradio.

Theheadlightscanbeturnedoffandonfromtheremoteconsole atanytimethatthelightswitchisinallonpositionandtheremote consoleisonby:

ReferenceFig.16.

 Pressthe“SHIFT”and“LIGHTS”keystogethertoturnthelights on.

 Pressthe“SHIFT”and“LIGHTS”keystogethertoturnthelights off.

Firesuppressioninradioremote

Thecontrolsystemusesasolenoidoutputtodrivethefiresuppression systemonthecontinuousminer.Thefiresuppressioncanbeactivated atanytimefromtheremotecontrolconsole.Ifthemachineisfitted withthebatterybackupversionofthepowersupply,thefiresuppressioncanalsobeactivatedinbatterystandbymode.Thesystemwill remaininbatterystandbymodeforatleasttenminutesafterlossof mainpowertothemachine.

Wheninradiomode,thefiresuppressioncanbeactivatedfromthe radioasfollows:

 Pressthe“SHIFT”and“FIRE”keysatthesametimeandholdfor two(2)fullseconds.

 Aftertwoseconds,thefiresuppressionsystemwillactivate.Atthis time,the“SHIFT”and“FIRE”keyscanbereleased.

Seetheoperationmanualfortheradioremotethatshippedwithyour machineforoptions.

Conveyorraise/lowerandleft/rightinradioremote

Thepumpmotormustberunninginordertocontroltheconveyorraise, lower,andswingleft/right.

Tocontroltheconveyorfromtheradioremote:

 Pressthe“CONVEYORLEFT”keytothelefttoswingtheconveyor tailtotheleft.Thesolenoidcontrollingtheleftconveyorswingwill remainenergizeduntilthekeyisreleased.

 Pressthe“CONVEYORRIGHT”keytotherighttoswingtheconveyortailtotheleft.Thesolenoidcontrollingtherightconveyor swingwillremainenergizeduntilthekeyisreleased.

 Pressthe“CONVEYORDWN”keytolowertheconveyorboom. Thesolenoidcontrollingtheconveyorlowerfunctionwillremain energizeduntilthekeyisreleased.

 Pressthe“CONVEYORUP”keytoraisetheconveyorboom.The solenoidcontrollingtheconveyorraisefunctionwillremainenergizeduntilthekeyisreleased.

Note:Conveyorleftandrightaredescribedasviewedbytheoperator fromtherearofthemachinefacingtowardstheconveyordischarge.

Stabilizer(stab)cylinderraise/lowerinradioremote

Thepumpmotormustberunninginordertoraiseorlowerthe stabilizercylinder.

 Press“STABUP”toraisethestabilizercylinder.Thestabilizer cylindersolenoidremainsenergizeduntilthekeyisreleased.

 Press“STABDOWN”tolowerthestabilizercylinder.Thestabilizer cylinderdownsolenoidremainsonuntilthekeyisreleased.

Seetheoperationmanualfortheradioremotethatshippedwithyour machineforoptions.

Shearup/downinradioremote

Thepumpmotormustberunninginordertoraiseorlowerthecutter head.

 Press“SHEARUP”tomovethecutterheadup.Theshearup solenoidremainsenergizeduntilthekeyisreleased(unlessheight limitingisinforce).

 Press“SHEARDOWN”tomovethecutterheaddown.Theshear downsolenoidremainsenergizeduntilthekeyisreleased.

Seetheoperationmanualfortheradioremotethatshippedwithyour machineforoptions.

Gatheringheadraise/floatinradioremote

Thepumpmotormustberunninginordertoraiseorlowerthe gatheringhead.

 Press“PANUP”toliftthegatheringhead.Thepanupsolenoid remainsenergizeduntilthekeyisreleased.

 Press“PANFLOAT”to“float”theheaddown.

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