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ThismanualisintendedtoprovideGENERALproductinformationfor theModel30M4-NPContinuousMiner.Theillustrations,descriptions andprocedurescontainedinthispublicationapplyonlytoTHISmachine.BucyrusAmerica,Inc.reservestherighttorevisemodelsand designswithoutpriornotice.
ThisContinuousMinerwasmanufacturedundertheguidelines,procedures,andrequirementsoftheU.S.FederalCoalMineHealthand SafetyAct,CodeofFederalRegulations,Title30,Chapter1,Subparto, Part75forundergroundcoalminesandotherapplicablenon-U.S.regulatoryagencystandards.
Atthecompletionofthemanufacturingprocess,thisunitwasissuedthe appropriateapprovalnumbersandnameplatesindicatingitmetthe technicalrequirementsoftheseregulatoryagencies.Anychangetothe designorstructureofthisunit,withouttheconsentofBucyrusAmerica, Inc.andtheseregulatoryagencies,oranyrepairorreplacementof partscontrarytoBucyrusAmerica,Inc.’sinstructions,mayinvalidate theseapprovalsandrenderthisunitunsafetooperate.
Strictcompliancewithalllaws,regulationsandpracticesregardingthe safeoperationandmaintenanceofundergroundminingequipmentand strictadherencetotheinstructionsinthismanualisnecessaryforthe personalsafetyofthoseworkingonoraroundthisunit.
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.
4. Installation Aboutthismanual Aboutthismanual Thischapterprovidesimportantinformationmakingiteasierforyouto usethismanual.Itcontainsinformationonthestructureofthemanual andthesymbolsandcharactersused.
Beforestartingtowork Takecaretoensurethattheoperatingmanualavailabletoyouisapplicableforthetypeofequipmentormachineused.
Thisoperatingmanualisintendedfor:
BucyrusModel30M4-NPContinuousMiner
SerialNo.:N/A
andisonlypermittedtobeusedforequipmentofthistype.
Theoperatingmanualmustbeaccessibleatalltimestoallpersons workingonorwiththemachine.Itshould,ifpossible,alwaysbeavailableattheplaceofoperation.
Sendforanewoperationmanualimmediatelyifthepresentmanualis nolongercompleteorhasbecomeillegible.
Whoisthisoperatingmanualintendedfor? Thisoperatingmanualisintendedforthosepersonswhoworkwithor onthemachine.Everypersonworkingonthefaceorintheintersectionbetweenfaceandentryorintheentrymustreadthisoperating manual.
Thisincludespersonswho:
■ operatethemachine
■ areinchargeoftransport
■ performassembly/disassemblywork
■ find/fixfaults
■ performdailyroutineworkatthefaceorintheentry
■ performmaintenancework
■ performrepairwork
supervisorypersonnelwho:
■ initiateand/orsupervisetheactivitiesjustindicated.
Beforestartingtowork Whatisthepurposeofthisoperatingmanual? Thisoperatingmanualisintendedtohelpyouworkefficientlyand safelywithourproduct.Itcontainsimportantinformationonalltheactivitiesrelatedtothemachine.
Readthisoperatingmanualcompletelyandatease.Payspecialattentiontothesafetyinstructions.Trytomemorizetheappearanceandthe meaningofthesafetyandinstructionsymbols.
Ifanydetailsarenotclearlyunderstood,pleasecontactourservicedepartment.Ourserviceaddressisgiveninthechaptertitled“Foryour information”.
Readthechapter“Foryoursafety”withspecialattention.Thechapter containsimportantinformationindicatingpossiblehazards.Observe theinformationgivenandfollowtheproceduralinstructions.
Charactersandsymbolsused Thefollowingcharactersandsymbolsareusedforsafetyinstructions andimportantinformationintheoperatingmanual.
Trytomemorizethesymbolsandtheirmeanings.
DANGER! Pointsinthetextmarkedwiththissymboldrawyourattentionto immediatelyimpendingdanger.Possibleconsequencesare: veryseriousinjuryorevendeath.
WARNING! Thesepointscontaininformationondangeroussituations.Possibleconsequencesare:veryseriousinjuryorevendeath.
CAUTION! Thissymboldrawsattentiontodangeroussituations.Possible consequencesare:lighttomoderatelyseriousinjuriesandmachinedamage.
NOTICE! Pointsinthetextmarkedwiththissymboldrawattentiontoharmfulsituations.Possibleconsequencesare:damagetothemachineordamageintheimmediatevicinity.
IMPORTANT! Pointsinthetextmarkedwiththissymbolcontainusefultipsand informationintendedtofacilitateworkforyou.Theydonotwarn aboutharmfulordangeroussituations.
■ Itemsinlistsaremarkedwithbullets.
– Pointsinsub-listsaremarkedwithalongdashatthestartof theline.
Pointsintextmarkedinthiswaydescribeindividualoperations. Followtheseinstructionsstepbystep.Theywillhelpyoucarryout yourworkfasterandmoreimportantly,safer.
Yoursafety Thischapterprovidesvitalinformationforyoursafety.Payspecialattentiontothischapter.Thesafetyinstructionsandrulesofprocedure willhelpyoutoavoidhazardoussituationsandtoperformthenecessaryworkassafelyaspossible.
Thismachinehasbeenmanufacturedinaccordancewithstateofthe artandgenerallyrecognizedsafetystandardsandregulations. Youandotherscan,nevertheless,beexposedtodangeroussituations e.g.asaresultofenvironmentalinfluences,machinedamageoroperatorerrors.
Donotmakeanyalterationsormodificationswhichcouldimpairthe safeoperationandmaintainabilityofthemachine.Allmodifications andchangesmustbeapprovedbyBucyrusandallappropriateregulatoryagencies.
UseonlyoriginalsparepartsfromBucyrus.Notethattheuseofparts fromothermanufacturerswillvoidthewarranty.
Inadditiontothisoperatingmanualbesuretoalsoobservetherespectivelegalprovisionsandregulationsinyourcountry.
Observethesafetyandaccidentpreventionregulations
■ ofthemine,
■ ofthemine’sinspectors,and
■ oftheminingsupervisoryauthorities.
Readtheoperatingmanualsofthecomponentsrequiredforoperation, e.g.ofgearboxes,electricmotors,etc.,carefullyandthoroughly.Clarifyanyquestions before startingwork.
Personnel Operation Themachinemayonlybeoperatedbyqualified,trainedpersonnel.
Themachineisonlyallowedtobeoperatedbyqualifiedpersonnelwho canprovideproofofhavingbeentrainedonthisunit.
Readingoftheoperationmanual,especiallythechapteronsafety,shall constituteapartofthistraining.
Youmusthaveadequateknowledgeofthe
■ mechanics,
■ hydraulics,and
■ controlengineering andmustbeabletoprovethisknowledge.
Installationandrepair Asafundamentalrule,installationandrepairworkmayonlybecarried outbypersonnelwhohavebeenadequatelytrainedfortheseparticular requirements.
Installationandrepairworkon:
■ safetycomponents(pressurereliefvalves,extinguishers,etc.)
■ theelectrics(motors,controllers,etc.)
■ thehydraulics(controls,cylinders,etc.)
mayonlybecarriedoutbyserviceengineersfromBucyrusorbyspeciallyqualifiedpersonnelofthemine.
Operatingconditions Intendeduse TheContinuousMinerhasbeendesignedandmanufacturedforspecificuses.Intendedusesinclude:
■ extractionofcoal,phosphate,potash,salt,trona,andothermediumhardnessminerals
■ loadingthematerialslistedaboveontoahaulagesystemorshuttle car,ordumpingitontothegroundforloadingatalatertime
■ operationongradesoflessthan10degrees
Unauthorizeduse Applicationsnotexpresslylistedasintendedusesareunauthorized usesandarenotallowedtobeperformedwiththemachine.
■ thetransportofpersons
■ stonedevelopmentorextraction
BucyrusAmerica,Inc.acceptsnoliabilityforanydamageresulting fromanysuchunauthorizeduse.
Safetyinstructions Generalrules Alwaysworkwithfullconcentrationandfamiliarizeyourselfwithyour workingenvironment.
Alwayswearyourpersonalprotectiveequipment.Thisalsoincludes earprotectorsasthenoiseemittedbyotherequipmentintheareamay attimesexceed85db(A).
Informyourcolleaguesof
■ yourexactlocation,
■ theworkyouareperforming,and
■ thetimethatyouwillprobablyrequire.
Startthemachineonlywhenitisinagoodandsafeoperatingcondition andallprotectivedevices,e.g.emergencystopdevices,machinestop buttons,coverplates,etc.arecorrectlyinstalled.
Observethesymbolplatesonthemachine.
Pressanemergencystopbuttonimmediatelyintheeventoffaultor irregularitiesinoperation.Reportanyirregularitiestoyoursuperiorso thatnecessarymeasurescanbetakenimmediately.
Disconnect,lockout,andtagthepowersystem,followingallapplicable rulesandregulations,whileperformingmaintenance,inspection,orrepairwork.
Cordonoffyourworkingareawidelyforthemachine.
Neverallowpartsofyourbodytocomebetweenpartswhichcould move,suchase.g.:
■ chains,flights,andchainsprockets
■ pivotpoints
■ crawlerassembliesandconveyors
■ cutterandgatheringheadassemblies
Safetyinstructions Storageandtransport Maintaintheprescribedstorageperiodsandobservetheinstructions forstorage.
Donotstorematerialsorpartsinthetravelwayorinyourworking area.
Informthepersonsinvolvedabouttheintendedtransportrouteandthe anticipateddurationofthetransport.
Ensurethatthetransportsafetydevicesarecorrectlyfitted. Fixallmovingpartswithtransportlocks.
Neverstandunderunsupportedpartsorsuspendedloads.
Connecttheliftingequipmenttothepointsofattachmentprovidedfor thatpurpose.Observethedifferentloadlimitsoftheattachment points.Also,observetheinstructionsonthetransportsheet.
Onlyusemeansofattachmentwhichareingoodconditionandhave beendesignedfortheloadstobehandled.Forroundcomponentsuse transportstrapsonly;neverusechainsorsteelcablesforthispurpose. Donotdamagethetreatedorpolishedsurfacesofshafts,sealingsurfaces,etc.
Whenusingmobilehandlingsystemsfortransportmakesurethatthe centerofgravityisaslowaspossible.
Pre-startinspection Readthisentiremanualbeforeattemptingtooperatethismachine.
Inspectthemachineandhaveanymalfunctioning,brokenormissing partscorrectedorreplacedbeforeuse.
Verifythatallmaintenancehasbeenperformed.
Verifythatallinstructionandsafetytagsareinplaceandreadable. Theseareasimportantasanyotherequipmentonthemachine.
Installationandstart-up Oninclinedfacessecureallcomponentpartsbychains,e.g.tothe support.
Whenworkingwithoils,greasesandotherchemicalsubstances,observethesafetyregulationsapplicabletotheproduct.SafetyregulationscanbefoundonthecontainerorontheMaterialSafetyData Sheet(MSDS)fortheproduct.
Disposeofcleaningrags,etc.whichhavebeensoiledwithoil,grease orotherchemicalsubstancesinanenvironmentallysafemanner.
Whenstartingupmachine,donotoperateanycontrolslocatedinside theoperator’spitfromoutsidethepit.
Followthestartingprocedureinstructionsintheoperationsmanual.
Donotoperateanylevers,pedalsorcontrolsifanyoneisinthered zone.(SeeRedZoneinChapter5ofthismanual)
Operation Operatethemachineonlyifyouhaveaprofoundknowledgeofthe controlelementsandtheirfunctions.Itisnecessarythatyouhave beentasktrainedontherespectiveContinuousMiner.
Beforestart-up,ensurethattherearenopersonsorobstructionsin yourlineoftravelorinthearticulationareawhensteeringtheunit.
Checkthatallprotectivedevicesareinstalledonthemachineandfunctionproperly.
Useextremecautionwhentravelinginclosequartersorincongested orblind-travelareas.
Nevercarrypassengers.Passengersmaybethrownoffthemachine orcrushedbetweenthemachineandoutsideobjects.
Alwaysfollowallsafetyrulesofeachparticularminewhenoperating themachine.
Ifproblemsormalfunctionsareencounteredwhileoperatingtheunit, themachinemustbeproperlyshutdownandtheproblemcorrected immediately.
Safetyinstructions Stopping Alwaysparktheunitonsolid,levelground.Ifthisisnotpossible,park theunitatarightangletotheslopetopreventaccidentalmovementof themachine.
Useproperflags,warningsorbarrierswhenparkinginareasoftraffic.
Maintenanceandrepair Besuretoobservetheprescribedmaintenanceandinspectionintervals.
Informthesupervisorypersonnelandthefacecrewofanymaintenance andrepairoperations.Givetheminformationontheintendedoperationsandtheanticipatedduration.
trailingcableuncoupled andlockedandtaggedout
Beforeattemptinganyrepairs,a DANGER signmustbeattachedtothe appropriatecircuitatthepowerdistributionbox.Itismandatoryunder governingregulationsthatthetrailingcablebeuncoupled,taggedand locked-outfromthepowersourcetoprovidevisualevidencethatthe minerisde-energized.
Secureyourworkingareaoverawiderange,inordertoavoidendangeringotherpersons.
Disconnectthepowerfromthemachinetopreventunauthorizedand unintentionalrestarting.
Protectyourworkareaagainstfallingrocks.
Passdefectivecomponentsremovedonforservicingwithoutdelayin ordertopreventthesepartsbeingreinstalledelsewhere.
Useonlysparepartswhichsatisfythespecifiedtechnicalrequirements. ThisisonlyensuredwithoriginalBucyrusspareparts.Pleasereferto thesparepartslistsorpartscatalogfortheordernumbers.
ForraisingtheContinuousMineruseonly:
■ cribblockswithadequateload-holdingcapacity.
■ hoists,jacksorcraneswithadequateload-carryingcapacity.
handlingofhydraulicfluids
maintenance/repair
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.
Someillustrationsinthismanualshowguardsorcoverpanelsremoved forpurposesofclarity.Neveroperateunitwithoutguardsorcoverpanelsinplace.
Carryoutavisualinspectionofallthehydrauliccomponentsatregular intervals.Inparticularcheckthat:
■ thehosesarenotpinchedortrapped.
■ thehoseshavenobubblesorblisters.
■ thehoseoroutersheathsofthehosearenotabnormallyrigidor hard.
■ theoutersheathofthehosesisnotdamaged.
■ theconnectorsaresecurelyinsertedintothesockets.
■ theconnectionsareleak-tight.
Safetyinstructions permissiblehoses
installinghydraulichoses
Ensurethatnodirtentersthehydraulicsystemduringrepairwork.Dirt inthehydraulicsystemcancauseseriousdamageinthewholesystem! Flushoutthehydrauliclinesthoroughlybeforeconnecting.
Ifhydraulichosecouplersaredifficulttodisconnectorcannotbedisconnected,thehydrauliclinemaystillbepressurized.Besuretodepressurizethelinebeforedisconnectingcouplers.
Securetheconnectorsofthehydraulicelementsonlywiththeproper couplingclamps.Alwaysfastentheclampscompletelyandwithboth sides.Neverusenails,wireorsimilarmaterialsforsecuring.
Afterfinishingrepairwork,checkallconnectorsandconnectionsfor leaksbeforepressurizingthesystemagain.
Useonlyhydraulichosesapprovedfortheprevailingpressures.
Donotuseanyhydraulichoseswithdamagedconnectorsorwornorings.
Replacehydraulichosesonlywithhosesofthesameorahigherquality.
Nevertrytoholdajumpinghydraulichose.Depressurizethelinein questionimmediately.
Nevertrytorepairdamagedhydraulichoses.
Replacehydraulichosesatthefirstsuspicionofdamage.
Installthehydraulichosesproperlybehindthebracketsandclamps providedforthem.
Alwaysinstallhydraulichosessothey:
■ alwayshavealittleslack.
Fig.1:Installinghydraulichoses,slack
■ arenottwisted.
Fig.2:Installinghydraulichoses,twisting Right Wrong
■ arenotbentdirectlybehindtheconnections. (distancemin.1.5xnominaldiameter).
Fig.3:Installinghydraulichoses,bending Right Wrong
■ alwayshavealittleslack.
■ arenotkinked.
■ donothavetowithstandtensilestrains.
■ areprotectedagainstthermalradiation.
■ areaccessibleatalltimes.
Screwhydraulichosesintothesocketsonlybyhandandfingertighten. Nevertrytodrivethehydraulichosesinwithatoolasthiswilldamage theconnections.Usetheappropriateamountoftorquetoensurea properhosefit.
Safetyinstructions Wheninstallingthehydraulichoses,ensurethattheycannotbe:
■ tornout,
■ kinked,
■ crushed,
■ drivenoveror
■ twistedbymovementofthemachine.
Fig.4:Installinghydraulichoses,connectionsonmovingparts
Right
Wrong
Overviewofthesafetyinstructions Thisisasummaryofallthesafetyinstructionswhichhavetobeobservedinthefollowingchapters.Thissummaryisintendedonlytogive youanoverviewofalltheinstructions.Insomecases,thereisnologicalrelationshipbetweentheindividualinstructions.
Chapter3:Storageandtransport IMPORTANT!
Takecaretoinsurethatnewmaintenancesuppliesarestored separatelyfromexistingstockandthatremovaltakesplaceonthe “firstin,firstout”principle.
WARNING!
Useonlyloadhandlingdevicescomplyingwiththetechnicaland legalregulationsforthetransportofloads. Youcouldbeseriouslyinjuredorevenkilledbyfallingloads.
WARNING!
DonotusetheeyebolttoliftthecomponentANDitsrelatedassemblies.
Chapter4:Installation CAUTION!
SeriousdamagecanbecausedtotheContinuousMinerasaresultofincorrectinstallation.TheunitshouldthereforeonlybeinstalledundertheinstructionofspecialistsfromBucyrus.
IMPORTANT!
Thesequenceofoperationsduringinstallationmustbeadaptedto theindividualconditionsprevailingatthesite.Beforestartingthe workadetailedlistofstepstobetakenwithrespecttotransport andassemblyshouldbepreparedandacorrespondingplan established.
NOTICE!
Themachinewasinspectedpriortoshipmentfromthefactoryto ensureproperfunctioningandinstallationofallcomponents. However,toensurethatnotransitdamagehasoccurred,thefollowingpre-startupchecksshouldbeperformed:
NOTICE!
Theoperatormustbecomefamiliarwithallthesafetyfeaturesand theirlocationonthemachinepriortoinstallationoroperation.
WARNING!
Ifeitherofthefiresuppressionactuators(optional)isactuated, thesystemmustbecompletelyrechargedwithdrychemicalsand expellants.
DANGER!
Donotoperatethemachinewithanyoftheguardsorcoversremoved.Youorotherpersonnelcouldbeseriouslyinjuredfrom movingorrotatingparts.
Overviewofsafetyinstructions Chapter5:Operation DANGER!
Incorrectoperationendangersyourselfandothers!Incorrectoperationofthemachineisoftenthecauseofveryseriousaccidents!Operatetheunitonlywhenyouhavebeensufficiently trainedonthemachineandhavereadandunderstoodthisoperatingmanual.Shouldanythingbeunclear,pleasecontactyourimmediatesupervisor.
NOTICE!
Beforebeginningcuttingoperations,carefullyunloadthetrailing cableprovidingenoughslackandplacingitwhereitallowsadequateclearanceforsafemaneuverabilityoftheminer.
DANGER!
Thecontinuousminerisdesignedtobeoperatedfromwithinthe operator’spit.Donotattempttooperatethecontrolsandlevers locatedintheoperator’spitfromoutsidethepit.Severeinjuryor deathmayresult.
WARNING!
Beforeoperatinganycontrolsmakesurenooneisintheredzone (seeRedzoneinthischapter).Donotoperateanycontrolsfrom outsidetheoperator’spit.
WARNING!
Donotopen/disconnectcuttermotorswhilemotorsarerunning. Openingthedisconnectdoesnotremoveall4160Vfromtheentire machine,justthecuttermotors.
WARNING!
Readallinstructionscarefullybeforeattemptingtostartoroperatethemachine.Failuretoreadandunderstandalloperatinginstructionsbeforestartingthecontinuousminercouldresultin seriousinjuryordeathtotheoperatororpersonsaroundthemachineorcausedamagetothemachine.
WARNING!
Understandthefunctionsofallcontrolsbeforestartingthecontinuousminer.Readandfollowtheinstructionsonallwarning tagsonthemachineandobserveallregulationsandsafetyprecautions.
WARNING!
Neveroperateacontinuousminerwhichhasbeendamagedoris notoperatingproperly.Anypartofthemachinewhichdoesnot functionproperlycanbeahazard.Reportitimmediatelytoyour supervisorortheirdesignee.
WARNING!
Beforestartingthemachine,makesurethatnooneisinthered zone(Fig.22throughFig.24).
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NOTICE!
Inextremelycoldweather,allowmotorsandgearcasestoidle. Thiswillwarmthehydraulicoilsandlubricants.Coldoilsand greasescouldimmobilizethemachine.
IMPORTANT!
Apump“growl”meansnotenoughoilisreachingthepumps throughthesuctionlines.Ensurethepumpgetsprimedbefore continuingoperation.Alwayschecktheoillevel.
Aftertraining,whichincludesreadingandunderstandingtheControls andIndicatorssectionofthischapter,andbecomingfamiliarwiththe locationsandfunctionsofallmachinecontrols,theoperatorisreadyto operatethecontinuousminer.Anexperiencedoperatorshouldmonitor anewoperator’sindoctrinationtothestartingprocedure.
IMPORTANT!
Beforestart-up,checkthatdailymaintenancehasbeenperformed onthemachine.
WARNING!
Visuallycheckforotherpersonnelandverballyshoutawarning beforestartingthismachine.Makesureallpersonnelarecompletelyclearofthemachineandit’scomponentsandcheckthat theareaisclearbeforestartingthemachine.
NOTICE!
Thecontinuousminerhasskidtypesteering:itiscapableofturningwithinitsownlimits.
WARNING!
Trammingrequirescoolingwatertothetrammotors.Failureto coolthemotorswillresultinmotordamageandprematurefailure.
WARNING!
Neverstartcutterheadmotorsunderaload.Startingmotorsunderloadmayresultinmotordamageorprematurefailure.
WARNING!
WarnALLCLEARbeforestartingthecutterhead.Failuretodoso mayresultinseriousinjuryordeath.
IMPORTANT!
Bothcuttermotorsdonotstartatthesametime.Thereisapreset timeddelaybetweentheleftcuttermotorstartingandtheright cuttermotorstarting.
WARNING!
WarnALLCLEARbeforestartingtheconveyor.Failuretodoso mayresultinseriousinjuryordeath.
Overviewofsafetyinstructions _________________________________ CAUTION! Alwaysensureoperatorsafetywhileoperatingthemachine.Be alertforhazardousconditionsandtakecorrectiveactionasnecessary.Failuretobealertandcorrecthazardoussituationsmayresultinseriousinjury.
IMPORTANT!
Careshouldbetakennottostallcuttersorconveyorduringcuttingoperations.Severedamagetomotorsandgearboxescould occurifcuttersorconveyorarerepeatedlystalled.
IMPORTANT! Tramislimitedintheforwarddirectionwhilethecuttersarerunningwiththecutterheadfeedbackcircuit.Asthecutterheadbeginstocutthematerialfromtheface,thesumpspeedwillautomaticallyslowthetramdowntopreventoversumpingthemachine.
WARNING!
Thissectionisintendedtofamiliarizetheuserwiththemajormechanicalassembliesofthecontinuousminer.Allmechanical maintenanceshouldbeperformedbyaqualifiedtechnicianwith theknowledgeofthefunctionoftheassembliesinvolved.
WARNING!
Failuretomaintainthehydraulicsystemwillresultindamageto itshydrauliccomponentswhichwillresultinincreasedwearand prematurefailure.
IMPORTANT!
Schematicsmayvaryfromoneunittothenext.ConsulttheBucyrusAmerica,Inc.partsmanualforthecorrectschematicfor yourmachine.
IMPORTANT! Duringdisassemblyofcontrolvalves,giveparticularattentionto identificationofpartsforreassembly.Spoolsareselectivelyfitted tovalvebodiesandmustbereturnedtothesamebodiesfrom whichtheywereremoved.SpoolsareNOTinterchangeablebetweenvalvebodies.
WARNING!
Donotsalvagespoolsorvalvebodiesforlaterusein“new”combinations.Damagedorimpropercomponentsusedduringassemblymayresultininternalleakageorin"sticking"(hangingup)of thespoolinthevalvebody.Incorrectcomponentcombinations mayresultinimproperoperationofthevalvesection,possibly causingunexpectedmachineoperationthatcouldresultinmachinedamageorinjurytopersonnel.
WARNING!
Neverrunthemachinewithouttheproperfilterelementsinplace. Runningthemachinewithincorrectornofiltersmayresultinhydraulicsystemcontamination,machinefailure,erraticoperation, andinjury.
Overviewofsafetyinstructions WARNING!
Donotrelyontheloadholdingvalvewhenworkingunderthecutterheadortheconveyor.Alwaysblocktheconveyororthecutter headifitmustbeelevated.Seriousinjuryordeathmayresult fromnotmechanicallyblockingtheload.
WARNING!
TheloadholdingvalvesonthecutterheadandconveyorcylindersarepresetandDONOTrequireadjustment.Adjustmentof thesevalvemayresultinveryseriousinjuryorevendeath.
DANGER!
Theareaunderandaroundtheraisedcutterheadisdangerous. Securelyblocktheheadbeforeperformingmaintenanceonor belowit.Failuretoblocktheraisedcutterheadcouldresultin seriousinjuryorevendeath.
DANGER!
Donotadjust,modify,orremovetheloadholdingcartridgevalve mountedinthecutterheadcylinders.Itisasafetyfeaturetopreventaccidentalloweringofthecutterhead.
DANGER!
Thisloadholdingvalve,likethoseonthestabilizercylindersis preset. DONOTADJUSTIT.Ifitmalfunctions,replaceitimmediately.
WARNING!
Youcouldbeseriouslyinjuredorkilledbyfallingloads.Blockthe minerbeforeperformingmaintenanceandalwaysobservethe safeworkingloadlimitsofallliftingandblockingdevices.
DANGER!
Neverruntheconveyorwithouttheneedlevalveclosed.Injuryor deathmayoccur.
IMPORTANT!
Toensureagainstleakageonthebrakeshaftseal, Itisimportant thatthetankconnectionfromthebrakecoolingoutletis unimpeded. Thissealshouldnotbeexposedtopressuresabove 4bar(65psi).
WARNING!
Thissectionisintendedonlytofamiliarizetheuserwiththeelectricalcomponentsofthecontinuousminer.Electricalmaintenanceshouldonlybeperformedbyaqualifiedelectricianwith knowledgeofthefunctionsofthecomponentsinvolved.
WARNING!
Beforeremovinganycoverfromanelectricalcaseorattempting anymaintenanceortroubleshooting,themainpowermustbedisconnectedandlockedoutatthemainpowercenter.
Overviewofsafetyinstructions _________________________________ IMPORTANT!
Hangtrailingcablestopreventdamagefrommovingequipment!
WARNING!
Neverrunoveranunprotectedtrailingcable.Damagedcables shouldberepairedimmediately.
DANGER!
Neverhandleenergizedtrailingcablewithoutproperprotective equipment.Contactwithanenergizedtrailingcablewithcompromisedinsulationcouldresultindeathbyelectrocution.
WARNING!
Alwaysusecautionwhenstandingnearorcrossingtrailingcables.Thetrailingcablemaymoveasthemachinemoves.
WARNING!
Openingthecuttermotordisconnectswitchonthefrontofthe 4160casewillremovepowertothecuttermotorsonly.Thetrailingcableandthemachinewillremainenergized.Tode-energize themachine,thepilotdisconnectswitch,“PILOTDISC”,mustbe turnedto“OFF”orthe“POWERSTOP”buttonmustbeactivated.
WARNING!
Closingthecuttermotordisconnectswitchonthefrontofthe 4160casewillremovepowertothecuttermotorsonly.Thetrailingcableandthemachinewillremainenergized.Tode-energize themachine,thepilotdisconnectswitch,“PILOTDISC”,mustbe turnedto“OFF”andthe“POWERSTOP”buttonmustbeactivated.
WARNING!
Beforeperformingmaintenanceonthemachinethepowermust beturnedoff,thepilotmustbedisconnected,andthetrailingcablemustbeunplugged.Followallregulationsforlockout/tagout procedures.Accidentalmachinemovementorelectricalshock canresultinseriousinjuryordeathtoyouorotherpersonnel.
WARNING!
Donotmoveanyhydrauliccontrolleverunlessyouarecertain thateveryoneiscompletelyclearofanymachinemovement.Accidentalmachinemovementcancauseseriousinjuriesoreven deathtoyouorthemaintenanceperson.
WARNING!
Neverdisconnectahydraulichoseifthecircuitispressurizedorif thereisaloadonthecircuit.Ifahoseisdisconnectedwhilethe circuitispressurizedoraloadisonthecircuit,theloadwillfall causingdamagetothemachineorseriousinjuryordeathtoyou orotherworkers.
WARNING!
Youcouldbeseriouslyinjuredorevenkilledbyfallingloads.Observethesafeworkingloadlimitsofliftingorblockingdevices andkeepasafedistancefromsuspendedloads.
WARNING!
Observethesafeworkingloadlimitsofallblockingdevices.You couldbeseriouslyinjuredorkilledbyfallingloads.
WARNING!
Useextremecautionwheninspectingforleakswiththemachine running.Unexpectedmachinemovement,orcontactwithmoving parts,couldresultininjury.
NOTICE!
Ifthegearcaseisscheduledforoildrainandrefill,obtaintheoil samplepriortotheoilchange.
IMPORTANT!
Alwayscollectoilsamplesusingasiphonpump.Donotremove thedrainplugandcollectoilbyallowingittorunoutintothebottle.
IMPORTANT!
Alwaysusethecollectionhoseprovidedwitheachbottle.Always discardhoseimmediatelyfollowingcollectionoftheoilanddonot useitforthenextsample.Todosowillcontaminatethenext samplewithoilfromtheprevioussample.
IMPORTANT!
Formotorbearingsthatrequirehightemperaturelithiumcomplex grease(Spec.100-15),Bucyrusprovidesaspecial“button”style lubricationfitting(Fig.116)topreventtheaccidentaluseofmultipurposelithiumcomplexgreaseattheselocations.
NOTICE!
Incorrectgreaseorovergreasingoftheelectricmotormaycause seriousdamagetothemotor.Followthegreasingprocedureoutlinedabove.
IMPORTANT!
Alwaysusethepropertoolswhenadjustingvalvecartridges.
IMPORTANT!
Donotstartanymotors - CLA,cutterhead,pump,ortractionmotors - untilallpressuresareset.Startthepumpmotorasdirected.
WARNING!
Neverrelyontheloadholdingvalveasameansofsupportingthe cutterorconveyorboomwhilemakingrepairs.Severeinjuryor deathcouldresult.
Overviewofsafetyinstructions _________________________________ IMPORTANT!
ReferencetheHydraulicsectioninthischapterforindividualcircuitinformation.Alwaysrefertothehydraulicschematicinyour BucyrusAmerica,Inc.partsmanualforyourminer.
WARNING!
Twopeoplearerequiredtoadjustpressuresettings.Oneperson willmaketheadjustmentswhilethesecondpersonmustremain atthemachinestopatalltimesduringtheadjustmentprocedure. Failuretodosomayresultinseriousinjuryordeath.
WARNING!
Alwaysallowcylinderfunctionstobottomout(stopmoving)beforeadjustinganypressure.Pressureadjustmentswillonlybe accuratewhenthecylinderisinthiscondition.
IMPORTANT!
Themaininletreliefissethigherthantheportreliefsandwillonly relieveifaspikeoccursinthesystemoriftheportreliefdoesnot functionproperly.Thisprovidesprotectionofthemainpumpsection,A2.
CAUTION!
Donotadjustthemaininletreliefover207bar(3,000psi).Destructionofthevalvebankandthemainpumpcouldresult.
CAUTION!
Alwaysbealertforanyunintendedmachinemovement.
WARNING!
Keepbodypartsclearofmachinewhileinraisedpositionorseriousinjurycouldresult.
WARNING!
Alwaysallowfunctiontobottomoutandstopmovingbeforeadjustinganypressure.
WARNING!
Youcouldbeseriouslyinjuredorkilledbyfallingloads.Observe thesafeworkingloadofallblockingdevices.
WARNING!
FollowallFederalandminelockout/tagoutregulationsandprocedures.Failuretodosocouldresultinmachinedamageorserious injuryordeathtopersonnel
CAUTION!
Shimsmustbeinsertedcompletelyintotheidlerslidechannel.A shimthatisnotcorrectlyseatedontheidlerslidechannel’sinside surfaceprovidesunevensupportthatcancauseidlerslant.A slantedidlercancauseunevenwearandstressonthetramtrack andcancauseimproperoperationofordamagetothetramsystem.
IMPORTANT! Checkthattheshimsarecorrectlyseatedontheidlerslidechannel’sinsidesurfacebylookingatthechannel’sinsidesurface fromtheoppositesideoftheminerthroughthespacebetween thegatheringheadandtheidlerassembly.
CAUTION! Disassemblyandassemblyprocedureslistedinthissectionare specializedand,assuch,shouldonlybeperformedbyqualified personnel.
WARNING!
Failuretofollowallapplicableregulationsregardinglockout/ tagoutproceduresmayresultinmachinedamageorseriousinjuryordeathofpersonnel.
WARNING!
Neverdisconnectahydraulichoseifthecircuitispressurizedorif thereisaloadonthecircuit.Ifahoseisdisconnectedwhilethe circuitispressurizedorunderload,theloadwillfall.Machine damageorseriousinjuryordeathtopersonnelmayresult.
WARNING!
Donotuseyourfingerstocheckthealignmentoftherodbearing intheclevis.Shiftingofthepartscouldresultinseriousinjury.
IMPORTANT!
Inadditiontotheshearcylinders,thestabilizerandgathering headcanbeusedtoadjustthecutterboom’spositiontoallow easierinstallationofthecutterboompivotpins.
IMPORTANT!
Beforedetachingthesethree(3)lugs,tagthewirestomakereconnectioneasier.
WARNING!
Powershouldnotbereconnectedtotheminerwhilethemotor powercableisdisconnected.Damagetotheminerorpersonal injuryordeathcouldresult.
WARNING!
Lawrequiresthatminingequipmentelectricalcomponentsmust beinspectedbyacertifiedelectricianbeforetheequipmentcan beoperated.
WARNING!
Thisprocedureinvolvesattachinganelectricalpowercabletoa motor.Thetrailingcablemustbedisconnectedandlockedand taggedouttosafelyperformthisoperation.FollowallMine,State, andFederallockout/tagoutprocedures.Failuretodosomayresultinseriousinjuryordeath.
Overviewofsafetyinstructions _________________________________ IMPORTANT!
Acertifiedelectricianmustinspectallworkandcheckforpermissibility.
IMPORTANT!
Duringtheremovalofthecapscrewsthatsecurethegearcaseto theframe,itmaybenecessarytoadjusttheblockingunderthe gearcase.Ensurethatthegearcaseissecurelyblockedatall timesandthatitdoesnotshiftasitisunbolted.
WARNING!
Standclearoftheminerandthegearcasewhiletrammingthe miner.Youcouldbeseriouslyinjuredorkilledbyfallingloads.
WARNING!
Donotattempttostartthecutterheadmotors.Youcouldbeseriouslyinjuredorkilled.
CAUTION!
Usecarewhentrammingtheminerawayfromthegearcase. Whileeachcuttermotorissupportedbyabracketattherearof themotor,excessivebumpingcouldcausethemotortofall.
IMPORTANT!
Makesurethatthelowersectionoftheconveyorchainisfreeof thefootshaftsothatwhenthemineristrammedawayfromthe gatheringhead,thechainwillpullfreeofthereturndeck.
NOTICE!
Whenthegatheringheadwasremoved,thelowerlengthofthe conveyorchainwaspulledfreeofthegatheringhead.Thisendof theconveyorchainmustbebroughtforwardwhenthemineris trammedtothegatheringhead.
DANGER!
Allpersonnelmuststayclearoftheminerwhileitistrammingand beingalignedwiththegatheringheadassembly.Standingunder thecutterheadorinthepathoftheminerwhileitistrammingmay resultinsevereinjuryordeath.
CAUTION!
Toavoidinjurywhilerelievingtensionoffoftheconveyorchain, wearproperpersonalprotectiveequipment,toinclude,ataminimum,safetyglassesandgloves.
IMPORTANT!
Positionthefootshaftsothatit’ssprocketwillengagetheconveyorchainlinkswhenthechainisreconnected.
WARNING!
Donotreconnectthetrailingcabletotheminerwhilethepower cableisdisconnectedfromthemotor.Seriousinjuryordeathmay occur.
WARNING!
Theendofthechain,justforwardoftheseparationpoint,should beblocked.Personnelshouldstayclearofthechainduringseparationtoavoidinjurywhenthechainisdisconnected.
IMPORTANT! Besurethatthegrousersareinthecorrectdirectionbeforeinstallingthechainintothemachine.Checkthepartsbookforyour machinetoverifythecorrectdirection.
WARNING!
Besureallconveyorcomponentsarecorrectlyinstalledandthat theconveyorchainisproperlyengagedbythefootshaftbefore startingtheminer.
WARNING!
Someproceduresmustbecarriedoutwiththecoveroftheelectricalcontrollerremovedandsomeproceduresrequirethecontroller tobeenergizedduringthetests.Itisextremelyimportantthatyou takeallnecessaryprecautionstopreventaccidentalelectrical shockwhileworkingwithinthecontroller.Ancertifiedelectrician mustsuperviseandinspectallworkperformed.
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.
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.
Protectthehydraulicplugconnectorsandtheconnectorsoftheelectricalcableswiththecapsandplugssupplied.
Duringshort-termstorage(approximately4weeks)ofequipmentoutdoors,butattemperaturesabovefreezing,electricalcomponentsneed notberemoved.Suchcomponentsmustbeparticularlyprotected againstexcessivetemperatures,dirt,andmoisture.
Iftheequipmentistobestoredmorethansixmonths,thefollowing lubricationandcorrosioninhibitingproceduresmustbefollowed:
■ Ifthecylinderrodsareexposed,therodsmustbecoatedwitha corrosioninhibitingfluid.
■ Completelyfillthehydraulicoiltankwithoil.
■ Fillallgearcasestothemaximumfilllevel.Thegearcasesmust berotatedmonthlytoensurethattheinteriorofthegearcaseremainslubricated.
■ Lubricateallgreasepoints(seetheMaintenancesectioninChapter5ofthismanual).
■ Theequipmentmustbestoredinawellventilated,dryroom.Do notstoreoutdoors.
Storageandtransport Electroniccomponentsmustbestoredattemperaturesbetween -10°C and55°C(14°Fand131°F).
Thetractiondrivesshouldbestoredat -10to50°C(14to122°F).
Majorproblemswithcondensationcanoccurifadriveisstoredina coldenvironmentandisthentakenintoadeepminewherethetemperatureismuchhigher.Eventhoughthehumiditymaybeatanacceptablelevel,condensationwilloccuronthecolddrive.Slightexposuretoacondensingenvironmentisnotharmfulprovidedthedriveis completelydrybeforeelectricalpowerisapplied.
Afterastorageperiodofapproximatelytwoyears,arandomsample inspectionmustbeperformedtodeterminewhetherthemeasures takenandthemethodofstoragehaspreventeddamage.Onrequest, theinspectioncanbecarriedoutbyBucyrusAmerica,Inc.
Evenwithproperstorage,sealsandhosesaresubjecttonaturalageing.Donotusethesepartsiftheyhavebeenstoredformorethantwo years.
Instructionsonthestorageofconcentratesforhydraulicfluidscanbe found,ifrequired,inchapter6inthisoperatingmanual.
IMPORTANT! Takecaretoinsurethatnewmaintenancesuppliesarestored separatelyfromexistingstockandthatremovaltakesplaceonthe “firstin,firstout”principle.
Long-termstorageofsparecomponents Ifacomponentistobestoredmorethansixmonths,thehydrauliccomponentmustbecompletelyfilledwithacorrosioninhibitingfluid.Fillthe hollowareasofhydrauliccomponents(e.g.thepistonchambers)in horizontalposition(portsfacingupwards)untiltheystarttooverflow thensealtheportswithplasticorsteelplugs.
Storetheelectricalequipment,electroniccomponents,sparepartsof rubberorplastic – suchassealsandhoses – andhydraulicfluidsonly inclosedroomsattemperaturesof15°Cto25°C(60°Fto77°F).
Refertothemotormanufacturer’sstorageprocedureguideinyourBucyrusAmerica,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.Fig.5illustratesthepositionofliftingpointsofthevariousassembliesofthemachine.Fordetailedliftinginstructions,seecomponent hoistinginformation.
WARNING!
Useonlyloadhandlingdevicescomplyingwiththetechnicaland legalregulationsforthetransportofloads.Youcouldbeseriouslyinjuredorevenkilledbyfallingloads.Useonlysuitable loadhandlingdevices.
Table1:Liftingweightsofcontinuousminerassemblies Wheneverpossible,allremovalsshouldbeaccomplishedusinganadjustableliftingbeamwheneverpossible.Allsupportingmembers (chainsandcables)shouldbeparalleltoeachotherandasnearlyperpendicularaspossibletothetopoftheobjectbeinglifted.
Whenitisnecessarytoremoveacomponentonanangle,remember thatthecapacityofaneyeboltdiminishesastheanglebetweenthe supportingmembersandtheobjectincreases.Eyeboltsandbrackets shouldneverbebent.
Whenaneyeboltisprovidedtoliftacomponent,useittoliftonlythat component.
WARNING!
Youcouldbeseriouslyinjuredorkilledasaresultoffallingloads. Donotusetheeyebolttoliftthecomponent and itsrelatedassemblies.
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Storageandtransport Beforetransport Beforetransportingtheequipmentattemperaturesbelowfreezing,all hydrauliccomponentsoperatedwithemulsion(HFAEorHFAS)must becompletelydrainedandthenfilledwithacorrosioninhibitor/frostproofingfluid.
Transportofequipmentattemperaturesbetween -21°Cand -40°C(-6° Fand -40°F)isonlypermissiblewhencertainmeasuresweretakento meettheseconditionsatthedesignandmanufacturestages.Nevertheless,theindividualpartsanddevicesofthisequipmentmustnotbe subjectedtosuddenimpactloadsatsuchlowtemperaturesandmay onlybeloadedstaticallyorquasi-statically.
Duringtransportofthisequipmentwithfloor-mountedvehiclesatsuch lowtemperatures,measuresmustalsobetakentoensurethatthe partsanddevicesarenotsubjectedtosuddenimpactloads.Atvery lowtemperaturesandonpoorroads,thetransportvehiclespeedmust thereforebelimitedtoamaximumof25kph(15mph)fortrucktransport.
Electricalandelectroniccomponentsmustbeprotectedagainstharmful environmentalinfluencesbyasuitablepackaging.
Theelectricalcablesremainintheequipment.Theymustbecarefully protectedagainsttransportdamageandsoilingoftheconnections.
Installation Installation Pointstoobservepriortoinstallation
Whoisallowedtocarryoutinstallation?
Installationisonlyallowedtobecarriedoutbypersonnelhavingreceivedadequatetrainingtoperformthistask.
Workon:
■ thesafetycomponents(pressurereliefvalves,fireextinguishing equipmentetc.)
■ theelectricalequipment(controlunits,signalingdevices,etc.)
■ thehydraulicequipment(cylinders,directionalcontrolvalves, hosesetc.)
shouldonlybecarriedoutbyBucyrusAmerica,Inc.serviceengineers orbyspeciallytrainedpersonnel.
Whichtoolsarerequiredforinstallation? GeneraltoolsarerequiredtoputtheContinuousMinerintoservice.
Variousitemsofauxiliaryequipmentandmachinesmayberequiredat thepointofinstallation.
Theseinclude:
■ hoistswithadequateliftingcapacity
■ meansofattachmentwithadequateliftingcapacity
■ unloadingdockandcribblocks
■ jackswithadequateliftingcapacity
■ impactwrenches,includingaccessories
toolbox
installationplan
Notesoninstallation CAUTION! SeriousdamagecanbecausedtotheContinuousMinerasaresultofincorrectinstallation.TheunitshouldthereforeonlybeinstalledundertheinstructionofspecialistsfromBucyrusAmerica, Inc.
BucyrusAmerica,Inc.ContinuousMinersareshippedtothecustomer sitepercustomerpreference.TheContinuousMinercanbeshippedto thecustomersiteasacompletemachineorincomponentsections. Thisdependsonmineconditions,transportationweightrestrictions/ requirements,orsize/weightrestrictionsatthemine.
reassemblyinstructions
IMPORTANT! Thesequenceofoperationsduringinstallationmustbeadaptedto theindividualconditionsprevailingatthesite.Beforestartingthe workadetailedlistofstepstobetakenwithrespecttotransport andassemblyshouldbepreparedandacorrespondingplanestablished.
Whenassemblyisrequiredaftershipmentofthemachine,theassistanceofspecialistsfromBucyrusAmerica,Inc.isrecommended.This willinsurethatthecorrectinstallation,safetyandmaintenanceproceduresarefollowed.
Pre-installationchecklist NOTICE! Themachinewasinspectedpriortoshipmentfromthefactoryto ensureproperfunctioningandinstallationofallcomponents. However,toensurethatnotransitdamagehasoccurred,thefollowingpre-startupchecksshouldbeperformed:
■ visuallyinspectallcylinders,gearboxes,tanks,andhydraulic componentsforleaksordamage.
■ visuallyinspectallelectricmotorsandelectricalcomponentsfor signsofdamage.
■ checkthefulllengthofthetrailingcable(ifapplicable)fordamage
■ ensurethatthetrailingcableisproperlysuspendedacrossintersectionsandthatthetrailingcableclampattheContinuousMiner issecure
■ cleananyforeignmaterialfromtheconveyorandgatheringpan
■ checkthatallcoversandguardsareinplaceandsecure
■ checkthatalltagsandinstructionlabelsareinplaceandsecure
■ checksafetyprovisionsforoperationalconditiononfiresuppressionsystem
■ visuallyinspectallhydraulichosesandelectricalcablesfordamage
■ startupthemachineandcheckforcorrectoperationofallstop andemergencystopbuttons(bothonthemachineandonthe transmitter)
■ afterstartingthemachine,allowthehydraulicsystemtowarmup forfive(5)toten(10)minutesandthencheckhydraulicsystem pressures(refertothehydraulicschematicsuppliedforyourparticularmachineforpressuresettings)
■ checkandoperateallcontrolhandlesandswitchestoensureall machinefunctionsareoperatingproperlyandareinneutralposition
■ checkthetensionoftheconveyorchainandcrawlerchain
Safetyfeatures NOTICE!
Theoperatormustbecomefamiliarwithallthesafetyfeaturesand theirlocationonthemachinepriortoinstallationoroperation.
Safetyfeaturesinclude:(ReferenceFig.6)
Themachineisequippedwithfourmachinestopbuttons,twooneach sideofthemachine.Themachinestopbuttonsareusedtoshutdown allfunctionscapableofproducingmovementonthemachine.Striking withasmallamountofforcewillactuatethemachinestop.
Themachinemaybeequippedwithfiresuppression(remote)actuators.Ifequipped,thelocationoftheactuatorsmayvary.Thesuppressionsystem(ifequipped)ispneumaticallyactuatedandextinguishes withdrychemicals.Toactuatethesystemfromtheactuators,pullthe safetypinandstrikedownwardontheplunger.Immediatelyafterthe plungerisstruck,drychemicalwillbedispensedthroughoutthemachine.Thefiresuppressionsystemmustbecompletelyrechargedwith drychemicalsandexpellantsafterithasbeenactuated.
WARNING! Ifafiresuppressionactuatorsisactuated,thesystemmustbe completelyrechargedwithdrychemicalsandexpellants.
Watercanbedirectedtothefirespraynozzles(optional)manuallyfrom afiresprayvalveorviasolenoidfromtheremotetransmitter.If equipped,seeChapter5foroperatinginstructionsandlocationsofthe valves.
IMPORTANT! Thefiresprayvalvemustbemanuallysettothenormalposition beforethedustsuppressionwaterspraysystemcanbeoperated.
CAUTION! Theminesupplywaterpressureatthemachineshouldnotexceed 500psi(34bar)andshouldsupply20gpm(76Lpm)
Themachineisequippedwithguardsandcoverstoreducethepossibilityofpersonnelcomingincontactwithrotatingormovingparts.All guardsandcoversmustbeinstalledandsecurelyfastenedduringoperation.
DANGER! Donotoperatethemachinewithanyoftheguardsorcoversremoved.Youorotherpersonnelcouldbeseriouslyinjuredfrom movingorrotatingparts.
Therearetwocutterboomsafetysupports(Fig.6),oneoneachsideof thecutterboom.Thesupportsareusedtoblockupthecutterboom duringmaintenanceoperations.
Fig.6:SafetyfeaturesontheContinuousMiner
Machinestop
Machinestop
Machinestop
Machinestop
Fig.6(continued):SafetyfeaturesontheContinuousMiner
Cutterheadsafety support - installed
Cutterheadsafety support - typical bothsides
Fig.7:OverviewoftheContinuousMiner
Conveyorassembly
Operator’sstation
Stabilizershoe
Gatheringpan assembly
Cutterhead assembly
Tramassembly
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Operation Thischaptercontainsimportantinformationontheoperationandmaintenanceofthemachine.Italsoincludesinstructionsonthereplacementofwearparts.
Readthischaptercarefullyandthoroughly.Inparticular,observethe safetyinstructionsinchapter2“Yoursafety”.
Howtooperatethecontinuousminer DANGER! Incorrectoperationendangersyourselfandothers!Incorrectoperationofthemachineisoftenthecauseofveryseriousaccidents!Operatetheunitonlywhenyouhavebeensufficiently trainedonthemachineandhavereadandunderstoodthisoperatingmanual.Shouldanythingbeunclear,pleasecontactyourimmediatesupervisor.
Whoisallowedtooperatethecontinuousminer?
TheContinuousMinerisonlyallowedtobeoperatedbypersonswith adequateknowledgeofthecompletemachine.
Thisalsoincludes:
■ whatsafetydevicesareinstalledonthemachine.
■ wherethesesafetydevicesarelocated.
■ howthesesafetydevicesaretobeoperated.
Whencanoperationbestarted? Operationmustnotbestarteduntilthesafeconditionandproperfunctionofthecompletemachinehasbeencheckedandthedailymaintenanceoperationshavebeencarriedout.
NOTICE! Beforebeginningcuttingoperations,carefullyunloadthetrailing cableprovidingenoughslackandplacingitwhereitallowsadequateclearanceforsafemaneuverabilityoftheminer.
Fig.8:Operator’sstation
Controlsandindicators Operator’sstation
DANGER!
TheContinuousMinerisradioremotecontrolledduringproductionoperations.Manualoperationviacontrolsattheoperator’s stationisnotpermittedforproductionoperation.Manualoperationisfortroubleshootingandmaintenanceundersupportedroof only.TrammingviatheEmergencytrampendantisonlypermitted insituationswhentheradioremotesystemisinoperable.operatingtheContinuousMinerwithmanualorpendantcontrolsunder unsupportedroofmayresultinsevereinjuryordeath.
Theoperator’sstation(Fig.8)islocatedontherighthandsideofthe machine,neartherearbumper.
breakers
“START/ STOP” Horn Switches
“MACHINE STOP” Viewpanel Viewpanel Circuitbreaker resethandles (power)
Firespray valve
“MACHINESTOP” The“MACHINESTOP”button(Fig.9)isalargeredpushbuttonlocatedonthetopleftoftheoperator’scase.Thisisoneoffour(4)machinestopbuttonslocatedontheminer.Pushing“MACHINESTOP” willshutdownthepumpmotor,causingtheminertoshutdown.Follow thenormalstarupprocedure(SeeStartupprocedureinthischapter) torestartthemachineafterpushing“MACHINESTOP”.
The“MINERMODE”selectorswitch(Fig.9)islocatedtotherightof the“MACHINESTOP”button.Thisswitchhastwo(2)positions:
■ “REMOTE” - Thispositionallowstheminertobeoperatedbyradio remote.Duringnormalminingoperations,theswitchshouldbein thisposition.
■ “OFF/E-TRAM” - Thispositionallowstheminertobetrammed fromthependantcontrols.“E-TRAM”isusedintheeventthatthe minercannotbeoperatedin“REMOTE”mode.
The“350VOLT”switchisusedtocheckgroundinthe350voltcircuit. Theswitchhasthree(3)positions:
■ “NORMALMODE” - Theswitchshouldbeinthispositionduring normaloperationofthemachine.
■ “GNDCHK” - Whentheswitchisturnedtothisposition,the350V circuitwillbegrounded,causingthemachinetoshutdown.
■ “RESET” - The350Vcircuitmustberesetafterithasbeen grounded.Toresetthecircuit,turntheswitchtothe“RESET”position.
The“120VOLT”switchisusedtocheckgroundinthe120voltcircuit. Theswitchhasthree(3)positions:
■ “NORMALMODE” - Theswitchshouldbeinthispositionduring normaloperationofthemachine.
■ “GNDCHK” - Whentheswitchisturnedtothisposition,the350V circuitwillbegrounded,causingthemachinetoshutdown.
■ “RESET” - The120Vcircuitmustberesetafterithasbeen grounded.Toresetthecircuit,turntheswitchtothe“RESET”position.
The“12VOLT”switchisusedtocheckgroundinthe12voltcircuit. Theswitchhasthree(3)positions:
■ “NORMALMODE” - Theswitchshouldbeinthispositionduring normaloperationofthemachine.
■ “GNDCHK” - Whentheswitchisturnedtothisposition,the350V circuitwillbegrounded,causingthemachinetoshutdown.
■ “RESET” - The12Vcircuitmustberesetafterithasbeen grounded.Toresetthecircuit,turntheswitchtothe“RESET”position.
“MINERMODE”
“MACHINELIGHTING”
firesprayvalve
The“MACHINELIGHTING”switchisusedtocontroltheareaandhead lightsonthemachine.Theswitchhasfour(4)positions:
■ “OFF” - Whentheswitchisinthe“OFF”position,alllightsonthe machineareoff.
■ “AREALIGHTS” - Turningtheswitchtothe“AREALIGHTS”positionwillturnonthearealightsonly.
■ “HEADLIGHTS” - Turningtheswitchtothe“HEADLIGHTS”positionwillturnontheheadlightsonly.
■ “ON” - Turningtheswitchtothe“ON”positionturnsonboththe areaandheadlights.
Thefiresprayvalve(Fig.9)locatedtotheleftofthecontrolcasecan beoperatedmanuallyorbyremote.Tomanuallyoperatethevalve, pullouttoturnonandpushintoturnoff.
Fig.9:“MACHINESTOP”,switches,andfiresprayvalve “MACHINE STOP” “MINER MODE” “350VOLT” “120VOLT” “12VOLT” “MACHINE LIGHTING”
Firespray valve
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