Cat Bucyrus 25M0 Continuous Miner Operation Manual A6474X332 - PDF DOWNLOAD (1)

Operation Manual Bucyrus - Continuous Miner Model - 25C Doc. No.: A6474X308

Bucyrus America, Inc. ________________________________________ 4041 Wurno Road Pulaski, VA 24301

Telephone: 540-980-4530 Fax: 540-994-3763

Internet: www.bucyrus.com

__________________________________________________________

This manual is intended to provide GENERAL product information for the Model 25C Continuous Miner. The illustrations, descriptions and procedures contained in this publication apply only to THIS machine.

Bucyrus America, Inc. reserves the right to revise models and designs without prior notice.

This Continuous Miner was manufactured under the guidelines, procedures and requirements of the U. S. Federal Coal Mine Health and Safety Act, Code of Federal Regulations, Title 30, Chapter 1, Subpart 0, Part 75 for underground coal mines, and other applicable non-U.S. regulatory agency standards.

At the completion of the manufacturing process, this unit was issued the appropriate approval numbers and nameplates indicating it met the technical requirements of these regulatory agencies. Any change to the design or structure of this unit, without the consent of Bucyrus America, Inc. and these regulatory agencies, or any repair or replacement of parts contrary to Bucyrus America, Inc.’s instructions, may invalidate these approvals and render this unit unsafe to operate.

Strict compliance with all Federal and State Mining laws, regulations and practices regarding the safe operation and maintenance of underground mining equipment and strict adherence to the instructions in this manual is necessary for the personal safety of those working on or around this unit.

While this manual attempts to anticipate the most important operations and maintenance needs for this unit, unforeseen circumstances may arise that have not been addressed in this manual. If any concerns or questions arise, please contact your Bucyrus America. Inc. Service Representative immediately.

This work contains information protected under trade secret and other intellectual property laws, and is protected under the U. S. Copyright Act of 1976, as amended. This work is provided under license and the license is non-transferable. Distribution and access is limited only to authorized personnel. Disclosure, reproduction, distribution or unauthorized use may be a violation of federal and state laws and may subject the unauthorized user to criminal liability.

© BUCYRUS AMERICA, INC.

ALL RIGHTS RESERVED

________________________________________________ Table of contents

Table of contents 1. About this manual About this manual .................................................................. 1.3 Before starting to work ......................................................... 1.3 Who is this operating manual intended for? ........................ 1.3 What is the purpose of this operating manual? ................... 1.4 Characters and symbols ...................................................... 1.5

2. Your safety Your safety .............................................................................. 2.3 Personnel............................................................................. 2.4 Operation ........................................................................ 2.4 Installation and repair...................................................... 2.4 Operating conditions ............................................................ 2.5 Intended use ................................................................... 2.5 Unauthorized use............................................................ 2.5 Safety instructions................................................................ 2.7 General rules: ................................................................. 2.7 Storage and transport ..................................................... 2.8 Pre-start inspection ......................................................... 2.8 Installation and start-up................................................... 2.9 Operation ........................................................................ 2.9 Stopping .........................................................................2.10 Maintenance and repair .................................................2.10 Permissible hoses..........................................................2.12

3. Storage and transport Storage and transport ............................................................ 3.3 Storage ................................................................................ 3.3 Storage of the machine and spare parts......................... 3.3 Long-term storage of spare components........................ 3.4 Transport.............................................................................. 3.5 Weights ........................................................................... 3.5 Before transport .............................................................. 3.6

4. Installation Installation ............................................................................... 4.3 Points to observe prior to installation................................... 4.3 Who is allowed to carry out installation?......................... 4.3 Which tools are required for installation?........................ 4.3 Notes on installation........................................................ 4.4 Pre-installation check list ................................................ 4.5 Safety features ................................................................ 4.6

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Table of contents _________________________________________________ 5. Operation Operation ................................................................................. 5.3 How to operate the Continuous Miner ................................. 5.3 Who is allowed to operate the Continuous Miner ........... 5.3 When can operation be started?..................................... 5.3 Controls and indicators ........................................................ 5.4 Red zone.............................................................................5.30 Safety precautions for underground operation ...................5.35 Tramming safety rules ........................................................5.38 Radio remote operation ......................................................5.36 Starting procedure ..............................................................5.37 Shutdown procedure...........................................................5.39 Tramming the miner............................................................5.40 Cutter head operation .........................................................5.42 Conveyor operation.............................................................5.43 Scrubber motor operation ...................................................5.44 Area and headlight operation..............................................5.45 Fire suppression in radio remote operation ........................5.46 Conveyor boom control.......................................................5.46 Stabilizer cylinder raise/lower in radio remote operation ....5.47 Shear up/down in radio remote operation...........................5.47 Gathering head raise/float in radio remote operation .........5.47 Breaker on/off in radio remote operation ............................5.48 E-stop bypass .....................................................................5.49 Typical cutting sequence ....................................................5.50 Mining operations................................................................5.52 Mechanical assemblies.......................................................5.57 Hydraulic system.................................................................5.65 Water system ......................................................................5.97 Electrical system ............................................................... 5.107 Instructions on the maintenance....................................... 5.127 Important notes ............................................................ 5.127 Before maintenance..................................................... 5.127 Torque values .............................................................. 5.129 Lubricants, fluids and capacities .................................. 5.129 Specific lubrication and maintenance instructions ............ 5.133 Every shift .................................................................... 5.133 Every third shift (daily) ................................................. 5.137 Weekly ......................................................................... 5.144 Monthly......................................................................... 5.148 Every three months ...................................................... 5.154 Every six months.......................................................... 5.159 Instructions on the adjustment procedures....................... 5.163 Setting hydraulic pressures.......................................... 5.163 Load holding valve ....................................................... 5.164 Pilot pump circuit relief valve ....................................... 5.165 Tram track .................................................................... 5.167 Tail shim....................................................................... 5.172 Chain tension ............................................................... 5.175 Sump tramming (cutter motor feedback) ..................... 5.176

_________________________________________________________________ Bucyrus – Model 25C Continuous Miner

________________________________________________ Table of contents Replacement of wear parts............................................... 5.183 CAN solenoid ............................................................... 5.183 AC drive encoder ......................................................... 5.188 Traction drive ............................................................... 5.194 Cutter head (boom) assembly ..................................... 5.199 Boom pivot pin ............................................................. 5.203 Shear cylinder .............................................................. 5.205 Center cutter drum ....................................................... 5.210 End cutter drum ........................................................... 5.216 Drum drive motor ......................................................... 5.219 Drum drive torque limiting clutch ................................. 5.223 Drum drive gear case................................................... 5.227 Gathering head assembly ............................................ 5.231 Gathering head drive motor ......................................... 5.236 Gathering head gear case ........................................... 5.242 Gathering head foot shaft ............................................ 5.248 Gathering head lift cylinder .......................................... 5.251 CLA .............................................................................. 5.254 CLA tip replacement .................................................... 5.257 Tram motor................................................................... 5.258 Tram primary planetary gear........................................ 5.264 Tram secondary planetary gear ................................... 5.267 Tram case .................................................................... 5.271 Tram reach gear set..................................................... 5.276 Tram sprocket .............................................................. 5.284 Tram track front idler.................................................... 5.291 Front idler take-up cylinder .......................................... 5.295 Hydraulic pump ............................................................ 5.297 Hydraulic pump motor.................................................. 5.300 Scrubber fan/motor ...................................................... 5.304 Stabilizer cylinder......................................................... 5.306 Swivel pin assembly..................................................... 5.309 Tail roller ...................................................................... 5.312 Chain replacement....................................................... 5.314 Duo-cone seals ............................................................ 5.315 Bearings ....................................................................... 5.321 Bevel gears .................................................................. 5.327 Gears and gear failures ............................................... 5.328 Lock wire fasteners ...................................................... 5.330 Special fasteners ......................................................... 5.330 Self-locking screws ...................................................... 5.330 Locknuts....................................................................... 5.331 Troubleshooting procedures ............................................. 5.333 Typical hydraulic problems .......................................... 5.334 Contaminants in hydraulic systems ............................. 5.335 Specific hydraulic circuits............................................. 5.336 Multi-function failure............................................. 5.336 Oil tank fill ............................................................ 5.337 Cutter head raise ................................................. 5.337 Cutter head lower ................................................ 5.337 Gathering head raise ........................................... 5.338 Gathering head float ............................................ 5.338 Conveyor raise..................................................... 5.338 Conveyor lower .................................................... 5.339

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Table of contents _________________________________________________ Conveyor swing............................................................ 5.339 Stabilizer raise.............................................................. 5.339 Stabilizer lower............................................................. 5.339 General safety procedures for shutdown.......................... 5.340 Excessive noise ................................................................ 5.341 Excessive heat.................................................................. 5.342 Incorrect flow..................................................................... 5.343 Incorrect pressure ............................................................. 5.344 Faulty operation ................................................................ 5.345 Restarting checklist........................................................... 5.346 Water system .................................................................... 5.347 Bearings............................................................................ 5.349 Electrical system ............................................................... 5.350 AC traction system............................................................ 5.353 Inverter fault and warning codes.................................. 5.353 Rectifier fault and warning codes................................. 5.357 AC traction system interfacing connectors and cabling................................................................... 5.359 Control system pin outs .................................................... 5.361 Solenoid fault and warning codes..................................... 5.367 RTD corresponding temperature values........................... 5.370

6. Technical data Technical data ......................................................................... 6.3 Tightening torques ............................................................... 6.5 Permissible data .................................................................. 6.7 Lubrication fluids and greases ........................................ 6.7

7. For your information For your information .............................................................. 7.3 Our service........................................................................... 7.3 Service address .............................................................. 7.3

_________________________________________________________________ Bucyrus – Model 25C Continuous Miner

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About this manual

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___________________________________________ Before starting to work

About this manual This chapter provides important information making it easier for you to use this manual. You will also be given information on the structure of the manual and the symbols and characters used.

Before starting to work applicable operating manual machine type

Take care to ensure that the operating manual available to you is applicable for the type of equipment or machine used.

This operating manual is intended for: Bucyrus Model 25C Continuous Miner Serial No.: N/A and is only permitted to be used for equipment of this type.

new operation manual

The operating manual must be accessible at all times to all persons working on or with the machine. It should, if possible, always be available at the place of operation.

Send for a new operation manual immediately if the present manual is no longer complete or has become illegible.

Who is this operating manual intended for?

This operating manual is intended for those persons who work with or on the machine. Every person working on the face or in the intersection between face and entry or in the entry must read this operating manual.

This includes persons who: ■

are in charge of transport

■

perform assembly / disassembly work

■

operate the machine

■

eliminate faults

■

perform daily routine work on the face or in the entry

■

perform maintenance work

■

perform repair work

supervisory personnel who: ■

initiate and/or supervise the activities just indicated.

______________________________________________________________ A6474X308 Rev. 0 1.3

Before starting to work ____________________________________________ What is the purpose of this operating manual? cost-effectiveness

This operating manual is intended to help you work efficiently and safely with our product. It contains important information on all the activities related to the machine.

Read this operating manual completely and at ease. Pay special attention to the safety instructions. Try to memorize the appearance and the meaning of the safety and instruction symbols.

service

If any details are not clearly understood, please contact our service department. Our service address is given in the chapter titled “For your information”.

safety

Read the chapter “For your safety” with special attention. The chapter contains important information indicating possible hazards. Observe the information given and follow the procedural instructions.

_________________________________________________________________ 1.4 Bucyrus – Model 25C Continuous Miner

___________________________________________ Before starting to work Characters and symbols used The following characters and symbols are used for safety instructions and important information in the operating manual.

Try to memorize the symbols and their meanings.

DANGER! Points in the text marked with this symbol draw your attention to immediately impending danger. Possible consequences are: very serious injury or even death.

WARNING! These points contain information on dangerous situations. Possible consequences are: very serious injury or even death.

CAUTION! This symbol draws attention to dangerous situations. Possible consequences are: light to moderately serious injuries and machine damage.

NOTICE! Points in the text marked with this symbol draw attention to harmful situations. Possible consequences are: damage to the machine or damage in the immediate vicinity.

IMPORTANT! Points in the text marked with this symbol contain useful tips and information intended to facilitate work for you. They do not warn about harmful or dangerous situations.

______________________________________________________________ A6474X308 Rev. 0 1.5

Before starting to work ____________________________________________

_________________________________________________________________ 1.6 Bucyrus – Model 25C Continuous Miner

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Your safety

________________________________________________________________

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______________________________________________________ Personnel

Your safety This chapter provides vital information for your safety. Pay special attention to this chapter. The safety instructions and rules of procedure will help you to avoid hazardous situations and to perform the necessary work as safely as possible. state of the art

The machine has been manufactured in accordance with the state of the art and generally recognized safety standards and regulations.

You and others can, nevertheless, be exposed to dangerous situations e.g. as a result of environmental influences, machine damage or operator errors.

Do not make any alterations or modifications which could impair the safety of the machine. All modifications and changes must be approved by Bucyrus America, Inc. and any appropriate regulatory agency.

Use only original spare parts from Bucyrus America, Inc. Note that the use of parts from other manufacturers will void the warranty.

In addition to this operating manual be sure to also observe the respective legal provisions and regulations in your country.

Observe the safety and accident prevention regulations

further operating manuals

■

of the mine,

■

of the mine inspector, and

■

of the mining supervisory authorities.

Read the operating manuals of the components required for operation, e.g. of gearboxes, electric motors, radio remotes, etc., carefully and thoroughly. Clarify any questions before starting work.

______________________________________________________________ A6474X308 Rev. 0 2.3

Personnel _______________________________________________________ Personnel Operation training

The machine may only be operated by qualified, trained personnel.

The machine is only allowed to be operated by qualified personnel who can provide proof of having been trained on this unit.

Reading of the operation manual, especially the chapter on safety, shall constitute a part of this training.

You must have adequate knowledge of the ■

mechanics,

■

hydraulics, and

■

control engineering

and must be able to prove this knowledge.

Installation and repair As a fundamental rule, installation and repair work may only be carried out by personnel who have been adequately trained for these particular requirements.

Installation and repair work on: ■

safety components (pressure relief valves, extinguishers, etc.)

■

the electrics (motors, controllers, etc.)

■

the hydraulics (controls, cylinders, etc.)

may only be carried out by service engineers from Bucyrus America, Inc. or by specially qualified personnel of the mine.

_________________________________________________________________ 2.4 Bucyrus – Model 25C Continuous Miner

_____________________________________________ Operating conditions Operating conditions Intended use This Continuous Miner has been designed and manufactured for the extraction of coal, phosphate, potash, salt, trona and other medium hardness minerals.

Intended uses include: ■

extraction of coal, phosphate, potash, salt, trona and other medium hardness minerals

■

loading the materials listed above onto a haulage system or shuttle car, or dumping it onto the ground for loading at a later time

■

operation on grades of less than 10 degrees

Unauthorized use Applications not expressly listed as intended uses are unauthorized uses and are not allowed to be performed with the machine.

■

the transport of persons

■

stone development or extraction

Bucyrus America, Inc. accepts no liability for any damage resulting from any such unauthorized use.

______________________________________________________________ A6474X308 Rev. 0 2.5

Operating conditions _____________________________________________

_________________________________________________________________ 2.6 Bucyrus – Model 25C Continuous Miner

_______________________________________________ Safety instructions Safety instructions General rules general

Always work with full concentration.

Familiarize yourself with your working environment.

noise emissions

Always wear your personal protective equipment. This also includes ear protectors as the noise emitted by other equipment in the area may at times exceed 85 db(A).

Inform your colleagues of

safety equipment

■

your exact location,

■

the work you are performing, and

■

the time that you will probably require.

Start the machine only when it is in a good and safe operating condition and all protective devices, e.g. EMERGENCY STOP devices, cover plates, etc. are correctly installed.

Observe the acoustic and optical start-up warnings of the machine.

symbol plates emergency stop

lock-out and tag-out

cordon off working area moving parts

Observe the symbol plates on the machine.

Press the EMERGENCY STOP button immediately in the event of fault or irregularities in operation. Report any peculiarity to your superior so that necessary measures can be taken immediately.

Lock-out, tag-out and disconnect the power system while performing: ■

maintenance work

■

inspection work

■

repair work

Cordon off your working area widely for the machine.

Never allow parts of your body to come between parts which could move, such as: ■

chains, flights, and chain sprockets

■

pivot points

■

cutter head and loading head

■

crawler assemblies and conveyors

■

cutter and gathering head assemblies

______________________________________________________________ A6474X308 Rev. 0 2.7

Safety instructions _______________________________________________ Storage and transport Maintain the prescribed storage periods and observe the instructions for storage.

Do not store materials or parts in the travel way or in your working area.

Inform the persons involved about the intended transport route and the anticipated duration of the transport. transport safety device

Ensure that the transport safety devices are correctly fitted.

Fix all moving parts with transport locks.

Never stand under unsupported parts or suspended loads.

means of attachment

Connect the lifting equipment only to the points of attachment provided for that purpose. Observe the different load limits of the attachment points. Also observe the instructions on the transport sheet.

Only use means of attachment which are in good condition and have been designed for the loads to be handled.

For round components use transport straps, only. Never use chains or steel cables for this purpose.

Do not damage the treated or polished surfaces of shafts, sealing surfaces, etc.

mobile handling equipment

When using mobile handling systems for transport make sure that the center of gravity is as low as possible.

Pre-start inspection operation

Read this entire manual before attempting to operate this machine.

inspection

Inspect the machine and have any malfunctioning, broken or missing parts corrected or replaced before use.

maintenance instruction and safety tags

Verify that all maintenance has been performed.

Verify that all instruction and safety tags are in place and readable.

These are as important as any other equipment on the machine.

_________________________________________________________________ 2.8 Bucyrus – Model 25C Continuous Miner

_______________________________________________ Safety instructions Installation and start-up inclined face

environmental acceptability

On inclined faces secure all component parts by chains, e.g. to the support.

When working with oils, greases and other chemical substances, observe the safety regulations applicable to the product.

Dispose of cleaning rags, etc. which have been soiled with oil, grease or other chemical substances in an environmentally safe manner.

controls

When starting up machine, do not operate any controls located inside the operator’s compartment (optional) from outside the compartment.

starting procedures

Follow the starting procedure instructions in the operations manual.

red zone

Do not operate any levers, pedals or controls if anyone is in the red zone. (See Red Zone in Chapter 5 of this manual)

Operation training

Operate the machine only if you have a profound knowledge of the control elements and their functions. It is necessary that you have been task trained on the respective Continuous Miner.

before start-up

Before start-up, ensure that there are no persons or obstructions in your line of travel or in the articulation area when steering the unit.

protective devices

Check that all protective devices are installed on the machine and function properly.

traveling

Use extreme caution when traveling in close quarters or in congested or blind-travel areas.

passengers

Never carry passengers. Passengers may be thrown off the machine or crushed between the machine and outside objects.

safety rules

Always follow all safety rules of each particular mine when operating the machine.

problems and malfunctions

If problems or malfunctions are encountered while operating the unit, it must be properly shutdown and the problem corrected immediately.

______________________________________________________________ A6474X308 Rev. 0 2.9

Safety instructions _______________________________________________ Stopping parking

Always park the unit on solid, level ground. If this is not possible, park the unit at a right angle to the slope to prevent accidental movement of the machine.

Use proper flags, warnings or barriers when parking in areas of traffic.

radio

There is a unique code switch setup which permits each operator to activate only his designated miner, allowing several remote-controlled miners to operate in the same area without getting their radio signals crossed. In addition, an improperly decoded radio signal will automatically shut-off the miner. Follow the general safety notices and safety recommendations listed in the remote control system troubleshooting guide.

Maintenance and repair Be sure to observe the prescribed maintenance and inspection intervals.

Inform the supervisory personnel and the face crew of any maintenance and repair operations. Give them information on the intended operations and the anticipated duration. trailing cable uncoupled and locked-out

securing

Before attempting any repairs, a DANGER sign must be attached to the appropriate circuit at the power distribution box. It is mandatory under the United States Federal Law, that the trailing cable be uncoupled and locked-out and tagged-out from the power source to provide visual evidence that the miner is de-energized.

Secure your working area over a wide range, in order to avoid endangering other persons.

Disconnect the power from the machine to prevent unauthorized and unintentional restarting.

Protect your work area against falling rocks.

replacing components

Disconnect the power from machine to prevent from restarting before replacing any defective components.

Pass defective components removed on for servicing without delay in order to prevent these parts being reinstalled elsewhere.

original parts

Use only spare parts which satisfy the specified technical requirements.

This is only ensured with original Bucyrus America, Inc. spare parts.

Please refer to the spare parts lists for the order numbers.

methane monitoring

Before attempting any repairs or maintenance, methane air monitoring must be completed before and during the repair and maintenance.

_________________________________________________________________ 2.10 Bucyrus – Model 25C Continuous Miner

_______________________________________________ Safety instructions lifting

handling of hydraulic fluids

For raising the Continuous Miner use only: ■

crib blocks with adequate load-holding capacity.

■

hoists, jacks or cranes with adequate load-carrying capacity.

Avoid direct contact between the skin and hydraulic fluids. Hydraulic fluid can penetrate the skin and cause serious infection.

Never use hydraulic fluid for rinsing or cleaning. Hydraulic fluid represents a very serious danger to health.

maintenance, repair

Only persons who have and can demonstrate a special knowledge of hydraulics are allowed to work on the hydraulic system.

Avoid, whenever possible, servicing, cleaning or examining the machine in congested areas.

Avoid, whenever possible, servicing or providing maintenance to the unit unless the appropriate safety devices are placed where recommended to prevent accidental movement of the unit.

Do not alter the electrical or hydraulic settings from that indicated in this manual or as set at the factory.

Always replace damaged or lost decals and metal instruction plates.

Disconnect the power when working with the electrical system, or when welding on the unit to prevent electrical shock.

Always follow all safety procedures of each particular mine when performing maintenance.

It is important that any procedure not specifically recommended in this guide be thoroughly evaluated from the standpoint of safety before it is implemented.

______________________________________________________________ A6474X308 Rev. 0 2.11

Safety instructions _______________________________________________ Some illustrations in this manual show guards or cover panels removed for purposes of clarity. Never operate unit without guards or cover panels in place.

Carry out a visual inspection of all the hydraulic components at regular intervals. In particular check that: ■

the hoses are not pinched or trapped.

■

the hoses have no bubbles or blisters.

■

the hose or outer sheathes of the hose are not abnormally rigid or hard.

■

the outer sheath of the hoses is not damaged.

■

the connectors are securely inserted into the sockets.

■

the connections are leak-tight.

Ensure that no dirt enters the hydraulic system during repair work. Dirt in the hydraulic system can cause serious damage in the whole system!

Flush out the hydraulic lines thoroughly before connecting. permissible hoses

If hydraulic hose couplers are difficult to disconnect or cannot be disconnected, the hydraulic line may still be pressurized. Be sure to depressurize the line before disconnecting couplers.

Secure the connectors of the hydraulic elements only with the proper coupling clamps. Always fasten the clamps completely and with both sides. Never use nails, wire or similar materials for securing.

After finishing repair work, check all connectors and connections for leaks before pressurizing the system again.

Use only hydraulic hoses approved for the prevailing pressures.

Do not use any hydraulic hoses with damaged connectors or worn orings.

Replace hydraulic hoses only with hoses of the same or a higher quality.

Never try to hold a jumping hydraulic hose. Depressurize the line in question immediately.

Never try to repair damaged hydraulic hoses.

Replace hydraulic hoses at the first suspicion of damage.

_________________________________________________________________ 2.12 Bucyrus – Model 25C Continuous Miner

_______________________________________________ Safety instructions installing hydraulic hoses

Install the hydraulic hoses properly behind the brackets and clamps provided for them.

Always install hydraulic hoses so they: ■

always have a little slack.

Fig. 1: Installing hydraulic hoses, slack Right

■

Wrong

are not twisted.

Fig. 2: Installing hydraulic hoses, twisting Right

■

Wrong

are not bent directly behind the connections. (distance min. 1.5 x nominal diameter).

Fig. 3: Installing hydraulic hoses, bending Right

Wrong

______________________________________________________________ A6474X308 Rev. 0 2.13

Safety instructions _______________________________________________ ■

always have a little slack.

■

are not kinked.

■

do not have to withstand tensile strains.

■

are protected against thermal radiation.

■

are accessible at all times.

Screw hydraulic hoses into the sockets only by hand and finger tighten.

Never try to drive the hydraulic hoses in with a tool as this will damage the connections. Use the appropriate amount of torque to ensure a proper hose fit.

When installing the hydraulic hoses, ensure that they cannot be: ■

torn out,

■

kinked,

■

crushed,

■

driven over or

■

twisted by movement of the machine.

Fig. 4: Installing hydraulic hoses, connections on moving parts Right

Wrong

_________________________________________________________________ 2.14 Bucyrus – Model 25C Continuous Miner

_______________________________________________________________

Storage and transport

________________________________________________________________

________________________________________________________________

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____________________________________________ Storage and transport

Storage and transport This chapter contains important information on the correct storage and transport of the Continuous Miner. Storage procedures are general.

For specific procedures for your environment, contact Bucyrus America, Inc. Engineering.

Observance of the instructions and tips will increase the service life and availability of the machine. You will also be able to carry out the transport work quicker and more safely. Careful attention to the points in this chapter will help you to simplify your day-to-day work.

Storage corrosion protection

Components coated with temporary corrosion inhibitor are protected for approximately six months.

Before delivery, the hydraulic functions are tested and the hydraulic pressures are preset to OEM specifications.

Storage of the machine and spare parts no direct exposure to sunlight dirt and moisture

Store the equipment indoors or cover with a tarpaulin to protect against direct exposure to sunlight.

Protect the equipment and all spare parts stored outdoors against moisture and dirt, e.g. using tarpaulins.

Protect the hydraulic plug connectors and the connectors of the electrical cables with the caps and plugs supplied.

short-term storage

During short-term storage (approximately 4 weeks) of equipment outdoors, but at temperatures above freezing, electrical components need not be removed. Such components must be particularly protected against excessive temperatures, dirt, and moisture.

long-term storage

If the equipment is to be stored more than six months, the following lubrication and corrosion inhibiting procedures must be followed: ■

If the cylinder rods are exposed, the rods must be coated with a corrosion inhibiting fluid.

■ Completely fill the hydraulic oil tank with oil.

■ Fill all gear case(s) to the maximum fill level. The gear case(s) must be rotated monthly to ensure that the interior of the gear case remains lubricated.

■ Lubricate all grease points (see the Maintenance section in Chapter 5 of this manual).

■ Completely drain the water system and refill with a 50/50 antifreeze/water solution. Pump the antifreeze mix through the system until the antifreeze mix comes out the water sprays. ENSURE THAT THE SYSTEM IS COMPLETELY PURGED AND NO WATER OR AIR POCKETS EXIST. ■ The equipment must be stored in a well ventilated, dry room. Do not store outdoors. ______________________________________________________________ A6474X308

Rev. 0

3.3

Storage and transport _____________________________________________ machine electrical components traction drives

Electronic components must be stored at temperatures between -10° C and 55° C (14° F and 122° F) The traction drives should be stored at -10 to 50 °C (14 to 122 °F).

Major problems with condensation can occur if a drive is stored in a cold environment and is then taken into a deep mine where the temperature is much higher. Even though the humidity may be at an acceptable level, condensation will occur on the cold drive. Slight exposure to a condensing environment is not harmful provided the drive is completely dry before electrical power is applied.

random sample inspection

After a storage period of approximately two years, a random sample inspection must be performed to determine whether the measures taken and the method of storage has prevented damage.

On request, the inspection can be carried out by Bucyrus America, Inc.

natural aging

Even with proper storage, seals and hoses are subject to natural ageing. Do not use these parts if they have been stored for more than two years.

HFA fluids

Instructions on the storage of concentrates for hydraulic fluids can be found, if required, in chapter 6 in this operating manual.

IMPORTANT! Take care to insure that new maintenance supplies are stored separately from existing stock and that removal takes place on the “first in, first out” principle.

Long-term storage of spare components hydraulic components

miscellaneous components

motors

If a component is to be stored more than six months, the hydraulic component must be completely filled with a corrosion inhibiting fluid.

Fill the hollow areas of hydraulic components (e.g. the piston chambers) in horizontal position (ports facing upwards) until they start to overflow then seal the ports with plastic or steel plugs.

Store the electrical equipment, electronic components, spare parts of rubber or plastic – such as seals and hoses – and hydraulic fluids only in closed rooms at temperatures of 60° F (15° C) to 77° F (25°C).

Refer to the motor manufacturer’s storage procedure guide in your Bucyrus America, Inc. parts manual.

fan assembly

Rotate the impeller 1-1/4 turn once per month to prevent dimpling of the motor bearings rollers.

plastic deformation

In order to prevent plastic deformation of the seal elements, cylinders must be stored in an upright position. Some cylinders must be removed so that they can be stored upright.

_________________________________________________________________ 3.4 Bucyrus – Model 25C Continuous Miner

____________________________________________ Storage and transport Transport Load units: dimensions and weights Observe the transport sheets for the machine and spare parts. They contain information on: ■

dimensions,

■

weights,

■

lifting points, etc.

Additional information on the dimensions and weights can be found in chapter 6 and in the lifting weight guide (Table 1) in this operating section.

WARNING! Use only load handling devices complying with the technical and legal regulations for the transport of loads. You could be seriously injured or even killed by falling loads.

Table 1: Lifting weights of Continuous Miner Assemblies

removal and installation of heavy components

Description

Approximate Weight

Complete Machine

140,000 lbs. (63,503 kg)

Tractor Frame Assembly

65,000 lbs. (29,484 kg)

Gathering Head Assembly

23,000 lbs. (10,433 kg)

Conveyor Assembly

17,000 lbs. (7,711 kg)

Cutter Head Support Frame with Drum Drives and Drums

35,000 lbs. (15,846 kg)

Whenever possible, all removals should be accomplished using an adjustable lifting beam. All supporting members (chains and cables) should be parallel to each other and as nearly perpendicular as possible to the top of the object being lifted.

When it is necessary to remove a component on an angle, remember that the capacity of an eyebolt diminishes as the angle between the supporting members and the object increases. Eyebolts and brackets should never be bent.

When an eyebolt is provided to lift a component, use it to lift only that component.

WARNING! You could be seriously injured or killed as a result of falling loads.

Do not use the eyebolt to lift the component and its related assemblies.

______________________________________________________________ A6474X308 Rev. 0 3.5

Storage and transport _____________________________________________ Before transport temperatures below freezing

Before transporting the equipment at temperatures below freezing, all hydraulic components operated with emulsion (HFAE or HFAS) must be completely drained and then filled with a corrosion inhibitor/frostproofing fluid (e.g. CV 50).

Transport of equipment at temperatures between -6° F (-21° C) and 40° F (-40° C) is only permissible when certain measures were taken to meet these conditions at the design and manufacture stages. Nevertheless, the individual parts and devices of this equipment must not be subjected to sudden impact loads at such low temperatures and may only be loaded statically or quasi-statically.

During transport of this equipment with floor-mounted vehicles at such low temperatures, measures must also be taken to ensure that the parts and devices are not subjected to sudden impact loads. At very low temperatures and on poor roads, the transport vehicle speed must therefore be limited to a maximum of 15 mph (25 kph) for truck transport.

electronic components

Electrical and electronic components must be protected against harmful environmental influences by a suitable packaging.

The electrical cables remain in the equipment. They must be carefully protected against transport damage and soiling of the connections.

Do not open electrical components without direction from Bucyrus Engineering.

_________________________________________________________________ 3.6 Bucyrus – Model 25C Continuous Miner

_______________________________________________________________

Installation

________________________________________________________________

________________________________________________________________

_________________________________________________________________

_____________________________________________________ Installation

Installation Points to observe prior to installation Who is allowed to carry out installation?

Installation is only allowed to be carried out by personnel having received adequate training to perform this task.

Work on: ■

the safety components (pressure relief valves, fire extinguishing equipment etc.)

■

the electrical equipment (control units, signaling devices, etc.)

■

the hydraulic equipment (cylinders, directional control valves, hoses etc.)

should only be carried out by Bucyrus America, Inc. service engineers or by specially trained personnel.

Which tools are required for installation? tool box

General tools are required to put the Continuous Miner into service.

Various items of auxiliary equipment and machines may be required at the point of installation.

These include: ■

hoists with adequate lifting capacity

■

means of attachment with adequate lifting capacity

■

unloading dock and crib blocks

■

jacks with adequate lifting capacity

■

sockets, Allen wrenches, wrenches, including accessories (Imperial and metric)

______________________________________________________________ A6474X308 Rev. 0 4.3

Installation ______________________________________________________ Notes on installation CAUTION! Serious damage can be caused to the Continuous Miner as a result of incorrect installation. The unit should therefore only be installed under the instruction of specialists from Bucyrus America, Inc. installation plan

Bucyrus America, Inc. Continuous Miners are shipped to the customer site per customer preference. The Continuous Miner can be shipped to the customer site as a complete machine or in component sections.

This depends on mine conditions, transportation weight restrictions/ requirements, or size/weight restrictions at the mine.

IMPORTANT! The sequence of operations during installation must be adapted to the individual conditions prevailing at the site. Before starting the work a detailed list of steps to be taken with respect to transport and assembly should be prepared and a corresponding plan established.

reassembly instructions

When assembly is required after shipment of the machine, the assistance of specialists from Bucyrus America, Inc. is recommended. This will insure that the correct installation, safety, and maintenance procedures are followed.

_________________________________________________________________ 4.4 Bucyrus – Model 25C Continuous Miner

_____________________________________________________ Installation Pre-installation check list NOTICE! The machine was inspected prior to shipment from the factory to ensure proper functioning and installation of all components.

However, to ensure that no transit damage has occurred, the following pre-startup checks should be performed: ■

visually inspect all cylinders, gear boxes, tanks, and hydraulic components for leaks or damage.

■

visually inspect all electric motors and electrical components for signs of damage.

■

check the full length of the trailing cable for damage

■

ensure that the trailing cable is properly suspended across inter sections and that the trailing cable clamp at the Continuous Miner is secure

■

clean all foreign material from the conveyor and gathering pan

■

check that all covers and guards are in place and secure

■

check that all tags and instruction labels are in place and secure

■

check safety provisions for operational condition on fire suppression system

■

perform daily maintenance

■

visually inspect all hydraulic hoses and electrical cables for damage

■

start up the machine and check for correct operation of all stop and emergency stop switches on both the machine and the radio remote

■

after starting the machine, allow the hydraulic system to warm up for five (5) to ten (10) minutes and then check the hydraulic system pressures (refer to the hydraulic schematic supplied for your particular machine for pressure settings)

■

check and operate all control handles and remote switches to ensure all machine functions are operating properly and are in neutral position

■

check the tension of the conveyor chain and crawler chain

______________________________________________________________ A6474X308 Rev. 0 4.5

Installation ______________________________________________________ Safety features NOTICE! The operator must become familiar with all the safety features and their location on the machine prior to installation or operation.

Safety features include: (Reference Fig. 5) emergency stop (E-stop) button

The machine is equipped with an emergency stop (e-stop) typically located on the offside . The e-stop (s) are used to break the control circuit only in emergency situations, stopping all motors. Striking with a small amount of force will actuate the e-stop. The panic bar is an e-stop located at the operator’s station that will shutdown the pump when struck.

panic bar

There is a panic bar located on the control panel on the right side of the machine. Striking the panic bar will shutdown the pump motor, thereby shutting down the machine.

radio remote emergency stop

The machine is equipped with a radio remote for the radio system that has an e-stop push button. See the specific radio manual for your machine in the parts book for options and features.

fire suppression (optional)

The machine may be equipped with fire suppression (remote) actuators. If equipped, the location may vary. This particular suppression system is pneumatically actuated and extinguishes with dry chemicals.

To actuate the system from the actuators, pull the safety pin and strike downward on the plunger. Immediately after the plunger is struck, dry chemical will be dispensed throughout the machine. The fire suppression system must be completely recharged with dry chemicals and expellants after it has been actuated.

WARNING! If either of the fire suppression actuators is actuated, the system must be completely recharged with dry chemicals and expellants.

fire sprays (optional)

Water can be directed to the fire spray nozzles manually from the fire spray valve above the switch box in the operator's compartment or by the fire spray valve on the left hand side of the machine. On radio units, an electronically actuated solenoid is used to actuate the fire spray system from the remote position.

IMPORTANT! The fire spray valve must be manually set to the normal position before the dust suppression water spray system can be operated.

CAUTION! The mine supply water pressure at the machine should not exceed 500 psi and should supply 20 gpm minimum for cooling.

The remote fire spray actuator located on the main feed behind the miner is used to activate the fire spray when there is a fire and power has been turned off. Simply turning the valve allows 'pilot' oil to feed into the small hose secured within the valve assembly and through the main feed line into the miner, where it contacts a solenoid that activates the fire spray system. _________________________________________________________________

4.6

Bucyrus – Model 25C Continuous Miner

_____________________________________________________ Installation guards and covers

The machine is equipped with guards and covers to reduce the possibility of personnel coming in contact with rotating or moving parts. All guards and covers must be installed and securely fastened during operation.

DANGER! Do not operate the machine with any of the guards or covers removed. You or other personnel could be seriously injured from moving or rotating parts.

start switch safety covers

Every switch on the operator’s controller case that engages a function (pump start, cutter start, etc.) is protected from accidental activation by a cover.

methane monitor

The machine is equipped with a methane monitor that detects the presence of methane in the mine atmosphere. When the miner is being powered up, the monitor looks for methane before any other function is energized. If the methane monitor detects a level of methane within a preset tolerance, the methane monitor relay will close and power will be supplied to the other functions on the machine.

______________________________________________________________ A6474X308 Rev. 0 4.7

Installation ______________________________________________________ Fig. 5: Safety features

Start switch safety covers

Emergency stop (location typical)

Emergency stop (location typical)

_________________________________________________________________ 4.8 Bucyrus – Model 25C Continuous Miner

_____________________________________________________ Installation Fig. 5 (continued): Safety features Emergency “STOP” button, radio remote

______________________________________________________________ A6474X308 Rev. 0 4.9

Installation ______________________________________________________ Fig. 6: Overview of the Continuous Miner

Cutter head assembly Conveyor boom

Operator’s station Crawler assembly Scrubber intake (typical both sides)

Gathering head assembly

_________________________________________________________________ 4.10 Bucyrus – Model 25C Continuous Miner

_______________________________________________________________

Operation

________________________________________________________________

________________________________________________________________

_________________________________________________________________

_______________________________________________________Operation

Operation This chapter contains important information on the operation and maintenance of the machine. It also includes instructions on the replacement of wear parts.

Read this chapter carefully and thoroughly. In particular, observe the safety instructions in chapter 2 “Your safety”.

How to operate the Continuous Miner DANGER! Incorrect operation endangers yourself and others! Incorrect operation of the machine is often the cause of very serious accidents! Operate the unit only when you have been sufficiently trained on the machine and have read and understood this operating manual. Should anything be unclear, please contact your immediate supervisor.

Who is allowed to operate the Continuous Miner?

The Continuous Miner is only allowed to be operated by persons with adequate knowledge of the complete machine.

This also includes: ■

what safety devices are installed on the machine.

■

where these safety devices are located.

■

how these safety devices are to be operated.

When can operation be started?

Operation must not be started until the safe condition and proper function of the complete machine has been checked and the daily maintenance operations have been carried out.

NOTICE! Before beginning cutting operations, carefully unload the trailing cable and placing it where it allows adequate clearance for safe maneuverability of the miner.

______________________________________________________________ A6474X308 Rev. 0 5.3

Operation _______________________________________________________ Controls and indicators The 25C continuous miner is operated through the use of a radio remote. There is an emergency tram pendant available in the event that radio operation is not possible.

Operator’s case The explosion proof operator’s case (Fig. 7) is located on the right hand side of the machine, near the rear bumper. The trailing cable enters into this enclosure at the top left corner of the case.

The right side emergency stop (panic bar), pump start, control breaker reset buttons, manual/remote selector switch, light switch, hour meters, and a graphics display are located on the case. Two (2) manual circuit breaker reset levers are located at the front bottom of the case: one is for breaker “CB1” and the other is for breaker “CB2”.

Fig. 7: Operator’s case Panic bar (not shown)

Control breakers

Manual/remote switch

“CB1” breaker reset

Light switch

Hour meters

Graphics display

“CB2” breaker reset

_________________________________________________________________ 5.4 Bucyrus – Model 25C Continuous Miner

_______________________________________________________Operation panic bar (e-stop)

The panic bar/e-stop (Fig. 8) is used to shutdown the machine in an emergency situation. Striking the panic bar with a small amount of force will shutdown the pump motor, thereby shutting down all functions. To restart the machine after striking the panic bar, follow normal pump start up procedures (see Start procedure in this chapter).

“LIGHTS”

The “LIGHTS” switch (Fig. 8) has three positions: “MANUAL”, “OFF”, AND “RADIO”. The “OFF” position turns all lights, area lights and headlights off. When the light switch is turned to the “MANUAL” position, the headlights and the area lights will both turn on. When the light switch is turned to the “RADIO” position, the area lights are illuminated and the headlights can be turned on and off with the radio remote.

“TRAM MANUAL/TRAM RADIO”

The “TRAM MANUAL/TRAM RADIO” switch (Fig. 8) is used to control whether the radio remote or the tram pendant is active. When the switch is in the “TRAM MANUAL” position, the emergency tram pendant is active. When the switch is in the “TRAM RADIO” position, the radio remote is active.

control breakers

The control breaker switches (Fig. 8) turn the breakers on and off and are also used to reset a breaker that has tripped. All control breakers are turned on by pushing the button in and are turned off by pulling the button out. If a breaker trips, the button must be pulled out to reset the breaker, then pushed in to turn it on.

Fig. 8: Switches, breakers, and panic bar Control breakers Panic bar/e-stop

“PUMP STOP”

“PUMP STOP”

“TRAM MANUAL/ TRAM RADIO” switch

“LIGHTS” switch

______________________________________________________________ A6474X308 Rev. 0 5.5

Operation _______________________________________________________ “PUMP HOURS”

The “PUMP HOURS” meter (Fig. 9) indicates the hours of running time for the pump motor.

“CUTTER HOURS”

The “CUTTER HOURS” meter (Fig. 9) indicates the hours of running time for the cutter head motors.

“CONVEYOR HOURS”

The “CONVEYOR HOURS” meter (Fig. 9) indicates the hours of running time for the conveyor motors.

Fig. 9: Hour meters

“PUMP HOURS” meter

“CUTTER HOURS” meter

“CONVEYOR HOURS” meter

_________________________________________________________________ 5.6 Bucyrus – Model 25C Continuous Miner

_______________________________________________________Operation Resetting circuit breakers There are three circuit breakers on this machine: the main circuit breaker, the auxiliary (cutter) circuit breaker, and the tram circuit breaker. If any one circuit breaker trips, they must all be reset.

There are three different ways the circuit breakers on the machine can be reset: with the radio remote, with the manual hydraulic reset, or with the levers on the front of the operator’s case.

To reset the circuit breakers using the radio remote, please see the operating procedures in this chapter. manual hydraulic circuit breaker reset

The circuit breakers can be reset with the manual hydraulic circuit breaker reset lever as long as the accumulator is charged .

To reset the circuit breakers with the hydraulic manual reset (Fig. 10):  Move the hydraulic lever to “OFF” to reset all three circuit breakers.  Move the hydraulic lever to “ON” to turn all three circuit breakers on.

If there is not enough pressure in the accumulator to reset the breakers hydraulically, they must be reset with the levers on the front of the operator’s case.

Fig. 10: Hydraulic manual breaker reset lever location

Hydraulic manual reset lever location

______________________________________________________________ A6474X308 Rev. 0 5.7

Operation _______________________________________________________ manual circuit breaker reset with levers

To reset the circuit breakers with the levers (Fig. 11):  Move both the main and auxiliary circuit breaker levers to the “OFF” position.  Move both the main and auxiliary circuit breaker levers to the “ON” position.

IMPORTANT! The tram circuit breaker is not reset at this point. To reset the tram circuit breaker, you must complete the following steps.  Turn the pump motor on and allow the system to run until the accumulator is pressurized. Accumulator pressure, as read on the multistation gauge, should be 400 psi.  Turn the circuit breakers off with either the radio remote or the manual hydraulic circuit breaker reset lever.  Turn the circuit breakers on with either the radio remote or the manual hydraulic circuit breaker reset lever.

Fig. 11: Circuit breaker reset levers

Circuit breaker “CB1” reset lever

Circuit breaker “CB2” reset lever

_________________________________________________________________ 5.8 Bucyrus – Model 25C Continuous Miner

_______________________________________________________Operation Gauge There is a multi-station gauge located on the right hand side of the machine, above the tram case (Fig. 12). The gauge will measure six (6) different pressures in the hydraulic system. There are zero points between measurements where the pressure is relieved back to tank.

To obtain pressure readings:  Turn the dial so that the arrow points to the zero directly before the pressure you want to read. The gauge should read zero.  Turn the dial so that the arrow points at desired position on the gauge (see position designations below).

IMPORTANT! The gauge must be allowed to zero out between readings in order to obtain an accurate reading.

The gauge designations are as follows: Position 1: Main pressure (P1 as labeled on the pressure manifold) used to measure the pressure in the main flow - primary pressure circuit. See the Main flow - primary pressure circuit in the Hydraulic section of this chapter for further information.

Position 2: Pilot pressure (P2 as labeled on the pressure manifold) used to monitor the supply pressure for all pilot functions.

See the Pilot pressure circuit description in the Hydraulic section of this chapter for further information.

Position 3: Shear pressure (load sensing pressure) (SH as labeled on the pressure manifold) - used to monitor the pressure of the cutting head cylinder circuit during shear down operations. See the Cutter head cylinder circuit description in the Hydraulic section of this chapter for further information.

Position 4: Regulated pilot pressure (RPG as labeled on the water pressure manifold) - used to monitor the regulated pressure for all pilot functions activated from the water pressure manifold. See the Regulated pilot pressure circuit in the Hydraulic section of this chapter for further information.

Position 5: Gathering head float valve (gathering head assist) pressure - used to monitor the pressure in the gathering head circuit during gathering head float operations. See the Gathering head raise/hold/float-lower circuit in the Hydraulic section of this chapter for further information.

Position 6: Conveyor chain take-up pressure - used to monitor the pressure of the automatic conveyor chain tensioner. See the conveyor take-up circuit in the Hydraulic section of this chapter for further information.

______________________________________________________________ A6474X308 Rev. 0 5.9

Operation _______________________________________________________ Fig. 12: Multi-station gauge

Load sense (shear) pressure

Pilot pump pressure

Main pump pressure

Regulated pilot pressure

Gathering head assist valve pressure

Conveyor chain take-up pressure

_________________________________________________________________ 5.10 Bucyrus – Model 25C Continuous Miner

_______________________________________________________Operation machine stop

The miner is equipped with a machine stop buttons located on the off side (left side) of the machine (Fig. 13). The machine stop is used to break the control circuit in emergency situations, stopping all motors.

Striking with a small amount of force will actuate the machine stop.

Fig. 13: Emergency stop

Machine stop (location typical)

methane monitoring system

The methane monitoring system consists of three parts - the readout module (Fig. 14), the power supply, and the sensor ("sniffer"). When the methane monitoring system is energized, the sensor constantly monitors the air for the presence of methane.

For detailed operating and maintenance instructions, see the methane monitor operator’s manual in the Bucyrus parts book that shipped with your machine.

IMPORTANT! It is the responsibility of the continuous miner owner/operator to know and follow all Mine, State, and Federal regulations regarding methane monitoring requirements, including but not limited to daily operation, maintenance, and testing.

Fig. 14: Methane monitor readout module (location typical)

Methane monitor readout module

______________________________________________________________ A6474X308 Rev. 0 5.11

Operation _______________________________________________________ Control system A multi-component system is used to control and monitor the functions of the machine. This system consists of the following main components: ■

Control unit

■

Power supply

■

Input/Output (I/O) modules

■

Remote control

■

Graphics display

The following information is presented as a general guide to the capabilities and functions of the control system. Before attempting to operate, service, or troubleshoot the continuous miner, training must be completed. control unit

The control unit is the main control unit of the system and is decode commands from the radio remote.

power supply

The control system has its own power supply, with the option of having battery backup for the power supply, which provides power to the machine control unit and I/O modules.

Input/Output modules

Input/Output modules are used to read data from and/or send commands to the following machine functions: ■

Cutter motors (left and right)

■

Gathering head motors (left and right)

■

Traction motors (left and right)

■

Scrubber motor

■

Pump motor

■

Hydraulic oil level

■

Methane monitoring

Based on the parameter settings and the input received from different components, the control systems has the ability to issue error messages, fault messages, and/or shutdown the machine.

_________________________________________________________________ 5.12 Bucyrus – Model 25C Continuous Miner

_______________________________________________________Operation radio control

The radio control (Fig. 15) is a battery powered remote used to control the continuous miner during normal operations.

WARNING! Radio remote control systems are dangerous. The continuous miner operator cannot operate a remote system until he is properly trained in the operation of the system. Remote control systems sometimes have automatic features of which untrained operators and workers may not be aware.

Fig. 15: Radio control (typical)

The remote control shown may vary from the remote control that shipped with your machine.

IMPORTANT! Refer to the radio remote control operation manual supplied with your machine for information regarding the operation of your specific remote control.

______________________________________________________________ A6474X308 Rev. 0 5.13

Operation _______________________________________________________ There are two displays located on the machine: a graphics display located at the operator’s case and a text display located on the back bumper (Fig. 16). Both screens are used to display diagnostic information on the miner.

Fig. 16: Control system display locations (typical)

Text display

displays

Graphics display

The graphics display, located on the operator’s case, is used to monitor machine operating parameters, for diagnosing error and fault codes, and for input of operating parameters.

The text display, located on the rear bumper of the machine, has the same functions as the graphics display. If the control system loses power, the text display will remain powered through the battery back up.

NOTE: Information priority is given to the graphics display unless the graphics display becomes unhealthy. The two monitors will not necessarily display the same information at the same time.

There are different screens that can be displayed: production monitoring, function monitoring, diagnostic, motor hours, and fault pages. A system halt message can appear as a pop-up dialog box in the middle of any screen. A message will appear when a critical conditions has occurred that prevents continued operation of the machine in a safe manner. The message box cannot be cleared and it is necessary to recycle power to the control system to restore machine operation.

Normal display pages The main diagnostic screen (Fig. 17) is displayed during normal remote control operation of the machine. The screen presents real time diagnostic and performance information.

_________________________________________________________________ 5.14 Bucyrus – Model 25C Continuous Miner

_______________________________________________________Operation Fig. 17: Main page, example

Graphics display

Text display

______________________________________________________________ A6474X308 Rev. 0 5.15

Operation _______________________________________________________ System Menu The control system provides information, diagnostic, and setup screens that are grouped together in the system menu (Fig. 18). The system menu is accessed by using either display module and a remote control handset.

To access and navigate the system menu using the radio remote:  Press the SHIFT and MENU key to access the system menu screen.

IMPORTANT! All functions and motors are shut down and disabled when the system menu is selected.  Press CONV UP or CONV DOWN to move the cursor up and down the list.  Press SHIFT and MENU to select the highlighted item  To leave the menu and return to remote mode, press SHIFT and REMOTE. Fig. 18: System menu, example

Graphics display

_________________________________________________________________ 5.16 Bucyrus – Model 25C Continuous Miner

_______________________________________________________Operation Fig. 18: System menu, example, continued

Text display

______________________________________________________________ A6474X308 Rev. 0 5.17

Operation _______________________________________________________ Diagnostic Mode Diagnostic mode allows a large number of monitoring screens to be selected and displayed while the machine is operating. Each screen provides helpful troubleshooting information such as machine information, software revision, and machine configuration. It also provides the status of the motors, digital and analog inputs, etc. Diagnostic mode is for informational purposes only. No configuration changes can be made within this mode.

To navigate through the screens: Enter menu: “SHIFT” + “MENU” Exit menu: “SHIFT” + “REMOTE” Move back one page: “SHIFT” + “CONV LEFT” Move forward one page: “SHIFT” + “CONV RIGHT” Graphics diagnostics includes the following pages: ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■

Main monitor Production monitor Pump monitor Cutter monitor Conveyor monitor Scrubber monitor I/O monitor - digital outputs I/O monitor - digital inputs I/O monitor - analog outputs Solenoid Slice 7 - breaker set/reset Solenoid Slice 6 - scrubber spray Solenoid Slice 5 - dust/fire spray Solenoid Slice 4 - stabilizer Solenoid Slice 3 - gathering pan Solenoid Slice 2 - conveyor lift Solenoid Slice 1 - conveyor swing Solenoid Slice 0 - cutter lift Radio network summary Inverter right monitor Inverter left monitor Rectifier monitor Smart contactor Drive summary Slice summary Thermistor summary Super Simpson network CAN network summary

See Fig. 19 for example screen shots of various diagnostic pages.

_________________________________________________________________ 5.18 Bucyrus – Model 25C Continuous Miner

_______________________________________________________Operation Fig. 19: Graphics display diagnostic pages, examples

______________________________________________________________ A6474X308 Rev. 0 5.19

Operation _______________________________________________________ Fig. 19: Graphics display diagnostic pages, examples, continued

_________________________________________________________________ 5.20 Bucyrus – Model 25C Continuous Miner

_______________________________________________________Operation Text display diagnostics includes the following pages: ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■

Remote mode Machine information Pump motor status Pump overloads 1 Pump overloads 2 Cutter status Left cutter overloads 1 Left cutter overloads 2 Right cutter overloads 1 Right cutter overloads 2 Conveyor status Left conveyor overloads 1 Left conveyor overloads 2 Right conveyor overloads 1 Right conveyor overloads 2 Scrubber status Fan overloads 1 Fan overloads 2 Left/right VFD summary LVFD diagnostics 1 LVFD diagnostics 2 LVFD diagnostics 3 RVFD diagnostics 1 RVFD diagnostics 2 RVFD diagnostics 3 Rectifier summary 1 Rectifier summary 2 Rectifier summary 3 24VDC inputs - X2 120VAC inputs -X1 120VAC inputs - X3 Motor Mate inputs Solenoid output summary Solenoid board diagnostics Relay board diagnostics Backup power supply diagnostics Thermistor diagnostics

To navigate the text display screens: Enter menu - “SHIFT” + “MENU” Exit menu - “SHIFT” + “REMOTE” Move back one page - “SHIFT” + “CONV LEFT” Move forward one page - “SHIFT” + “CONV RIGHT” Move cursor down - “SHIFT” + “CONV UP” Move cursor up - “SHIFT” + “CONV DOWN” Fig. 20 shows examples of various text display diagnostic pages.

______________________________________________________________ A6474X308 Rev. 0 5.21

Operation _______________________________________________________ Fig. 20: Text display diagnostic pages, examples

_________________________________________________________________ 5.22 Bucyrus – Model 25C Continuous Miner

_______________________________________________________Operation Fig. 20: Text display diagnostic pages, examples, continued

______________________________________________________________ A6474X308 Rev. 0 5.23

Operation _______________________________________________________ Event Log The event log (Fig. 21) provides a list of recent faults. Individual faults (Fig. 21) can be selected from this screen to see more information regarding the fault.

To navigate through the screens: Move browsing cursor up: “CONV UP” Move down one page: “SHIFT” + “CONV DOWN” Move up one page: “SHIFT” + “CONV UP” Move browsing cursor down: “CONV DOWN” Select a fault for more information: “SHIFT” + “MENU” Go back up one level: “SHIFT” + “REMOTE” Fig. 21: Event log and individual fault screens

_________________________________________________________________ 5.24 Bucyrus – Model 25C Continuous Miner

_______________________________________________________Operation Fault log The fault log (Fig. 22) allows the user to view the last 100 faults that have occurred since the log was last cleared.

To navigate the fault log page:  Press the CONV UP or CONV DOWN key to move the cursor up or down the page.  Press SHIFT and CONV UP or CONV DOWN move up or down one page.

It is possible to clear the fault log under the Engineering Setup Menu, which is password protected.

IMPORTANT! It is not recommended that the fault log be cleared unless the machine control unit has been replaced. Retaining the faults is very helpful in troubleshooting a problem when a machine control unit is sent for service. Faults cannot be retrieved once they have been cleared. Use caution and only clear the log if it is absolutely necessary.

Fig. 22: Fault log, example

Graphics display

______________________________________________________________ A6474X308 Rev. 0 5.25

Operation _______________________________________________________ Fig. 22: Fault log, example, continued

Text display Once a fault has been selected, the SHIFT and MENU keys can be used to access more information on the fault (Fig. 23).

Fig. 23: Fault detailed information, example

_________________________________________________________________ 5.26 Bucyrus – Model 25C Continuous Miner

_______________________________________________________Operation Hour meters Selecting hour meters (Fig. 24) from the Main Menu will display runtime for the following motors: pump, fan, left cutter, right cutter, and conveyor. Time is displayed in hours:minutes:seconds format. This runtime only reflects accumulated time since the machine control unit has been installed or since the counter was last reset. The hour meters can be cleared under the Engineering Setup Menu, which is password protected.

IMPORTANT! The hours meters should only be cleared when a motor is replaced or when the machine control unit is installed. To keep an accurate log of a motor’s total hours, the information should be recorded anytime data is cleared.

Fig. 24: Hour meters, example

Text display

Graphics display Setup Menus

There are three password protected setup menus available: Tradesman, Engineering, and OEM. Information regarding the adjustable parameters accessed on each screen is given in the machine specific training.

______________________________________________________________ A6474X308 Rev. 0 5.27

Operation _______________________________________________________ tram pendant

In the event that the radio remote cannot be used to operate the miner, a tram pendant (Fig. 25) is available to allow recovery of the miner from the face to an area under supported roof for troubleshooting and maintenance. Tramming is the only function available with the pendant.

In order to use the pendant, it must be connected to the machine via an electrical cable (pigtail). In addition, there is an umbilical cable of sufficient length for operation of the miner during recovery.

IMPORTANT! The pendant controller and it’s umbilical cord should be stored in a protected location on the working section, away from the miner, to prevent damage.

After plugging in the umbilical chord, rotate the switch on the front of the controller case from “TRAM RADIO” to “TRAM MANUAL”.

Fig. 25: Tram pendant

_________________________________________________________________ 5.28 Bucyrus – Model 25C Continuous Miner

_______________________________________________________Operation fire suppression sprays (optional)

The optional fire suppression spray valve (Fig. 26) is a ball valve typically located on the left hand side of the machine. This valve is activated manually by pulling to turn on and by pushing to turn off. The valve must be manually reset in order to reset the fire suppression circuit.

Fig. 26: Fire suppression spray (typical) Fire suppression spray valve

fire suppression spray valve

The fire suppression spray valve (Fig. 27) is a valve typically located on the left hand side of the machine. This valve is activated manually by using the handle to turn on and off.

Fig. 27: Fire suppression spray Fire suppression spray valve

______________________________________________________________ A6474X308 Rev. 0 5.29

Operation _______________________________________________________ Red zone Remote controlled continuous miners The remote control of miners introduces certain potential safety hazards which the miner operator must watch for and be aware of. While the operator is now free to position himself for convenient visibility of mining operations at the face, he can easily expose himself to the danger of being near mobile heavy equipment.

Most significantly, the operator’s greatest danger is from his Continuous Miner, especially when he is maneuvering it during mining operations.

The miner is capable of slewing when turning, especially when the crawlers are split. The discharge conveyor can also swing. In each of these cases, the miner operator is in danger of being hit, or worse yet, run over by his own machine. Equally dangerous is the possibility of the operator being pinned against the rib by his own miner.

Miner operator danger areas, or Red zones Some typical situations dangerous to the miner operator are illustrated on the following pages. The danger area, or red zone (Fig. 28) is indicated by alternating red and white diagonal stripes.

Fig. 28: Red zone

_________________________________________________________________ 5.30 Bucyrus – Model 25C Continuous Miner

_______________________________________________________Operation Tramming the miner (Fig. 29) from one place to another, especially maneuvering around intersections. This illustrates that the operator should not place himself between his miner and the rib.

Beginning the first sump (Fig. 29) in a new cut. The miner is against the left rib and the discharge conveyor is swung toward the center of the entry ready for the haulage car. The operator must stay clear of the discharge conveyor and the rear of the miner.

Fig. 29: Red zones

Tramming the miner red zone

Beginning 1st sump red zone

Sumping in the left hand side of the cut (Fig. 30). As the miner penetrates the face, new unsupported roof is being exposed, and the operator now has an additional constraint to his movements. He must also stay clear of the haulage vehicle at the rear of the miner as it approaches the miner and while it is loading.

Repositioning the miner for the right hand cut (Fig. 30). Because the miner is backing out and turning in close quarters, the operator must stay behind the miner to be safe.

Sumping in the right hand cut (Fig. 30). Again, the operator must stay away from the face where the newly-exposed roof is unsupported, as well as staying clear of the haulage vehicle while it approaches and loads.

______________________________________________________________ A6474X308 Rev. 0 5.31

Operation _______________________________________________________

Fig. 30: Red zones

Sumping on the left hand side red zone

Repositioning miner for right hand cut red zone

Sumping in the right hand cut red zone

_________________________________________________________________ 5.32 Bucyrus – Model 25C Continuous Miner

_______________________________________________________Operation Crosscut red zones (Fig. 31). Beginning and completing crosscuts requires a lot of maneuvering of the miner and loading the haulage vehicle while at awkward positions. Crosscuts also result in newly exposed unsupported roof. Respecting a red danger zone is important to operator safety in these conditions.

When the miner begs a right hand crosscut it is nearly against the opposite (left hand) rib, while the discharge conveyor is swung to its maximum 45o right position for loading the haulage vehicle. Hence, the entire rear of the miner is treated as a red zone. There are two other danger areas. On the right hand side, the miner forms a pinch point at the rib which must be avoided. Also, on the left hand side of the miner, as the miner progresses into the rib, a sharp-angled fender will be formed which will be susceptible to sloughing and falling off. Hence, that rib must be considered a red zone.

The red zone surrounds the miner as the discharge conveyor is free to swing either way and more unsupported roof is exposed during the further development of the right hand crosscut.

Fig. 31: Crosscut red zones

Beginning a right hand crosscut red zone

Right hand crosscut development

______________________________________________________________ A6474X308 Rev. 0 5.33

Operation _______________________________________________________ Pillaring red zones (Fig. 32) Remote control offers a significant safety advantage in partial or complete removal of the pillars in retreat mining because it places the operator further away from potential collapsing roof.

Much of the area around the miner must be considered a red zone, mostly because of extensive unsupported roof and the need for temporary supports under weakened roof. With remote control, the operator can position himself safely away from the miner while still retaining a good view of the mining cycle.

A red zone around the miner is no longer applicable when working in the opposite right hand pillar, as the operator is now excluded from the entire working area because of failing roof considerations, even with the existence of temporary roof supports.

When making an additional end cut into the pillar, creating a fender of coal between the two cuts, additional temporary roof supports are installed.

Because of roof pressures, the fender will tend to slough its ribs in the process of eventually crushing. Hence, the operator must stay away from this fender as well as avoiding the entry and crosscut areas as shown.

Fig. 32: Pillaring red zones

Pillaring in a left hand cut red zone

Pillaring in a end cut red zone

Pillaring in a right hand cut red zone

_________________________________________________________________ 5.34 Bucyrus – Model 25C Continuous Miner

_______________________________________________________Operation Safety precautions for underground operation In addition to the preceding instructions for operating the Continuous Miner, observe the following special precautions after the Continuous Miner is taken underground.

■

Communication is a key element in maintaining safety. Exact instructions and warnings should be given to, and thoroughly understood by each workman. Good communications between the entire crew must be maintained throughout the shift.

■

Check the condition of the trailing cable before turning power on at the power source.

■

This machine must be maintained in a permissible condition, following all state and federal laws.

■

Make a visual check of the Continuous Miner before energizing.

Look for loose bolts, covers, locking devices, damaged parts, and cracked or broken lenses. Any part of the machine which does not function properly is a hazard. Report it immediately to your immediate supervisor or their designee.

■

Prior to operation, make sure the working area is safe. Make a visual inspection of roof and ribs and take all steps necessary to insure safety.

Tramming safety rules ■

Communicate your intentions to the employees affected by the movement of the Continuous Miner.

■

Check the position of the water hose and trailing cable to be sure there is sufficient slack to finish the operation.

■

Note the condition of the roadways and physical surroundings of the route.

■

Position the cutter and gathering head for tramming.

■

Position the stabilizer shoe and booms for tramming.

■

Position your body completely inside the operator's compartment (optional), facing the intended direction of travel.

■

Position the Continuous Miner in the center of the road way to allow maximum safe clearance. Consistently maintain clearance, which is critical to the safe movement of the Continuous Miner.

______________________________________________________________ A6474X308 Rev. 0 5.35

Operation _______________________________________________________ Radio remote operation Radio remote - Power On To turn the radio remote on:   Press and hold the “ON” key forward for 1 second.  The console display should read “HOLD”.  Release the key and the display should read “ON”.

Radio remote - Power Off To turn the radio remote off:  Move the “ON/OFF” key to the “OFF” position.  The console display will show the “OFF” message for a moment and will then turn itself off.

Radio remote - Emergency Stop The Continuous Miner can be quickly shutdown at any time by using the red emergency “”STOP” button on the radio remote.

To quickly shutdown the miner in an emergency:  Press the “STOP” key down.  The console will send the stop command to shutdown all motors and functions on the miner and will then turn itself off.  To turn the console back on, the “STOP” key must be pulled out to return it to its original position.

_________________________________________________________________ 5.36 Bucyrus – Model 25C Continuous Miner

_______________________________________________________Operation Starting procedure WARNING! Failure to read and understand all operating instructions before starting the Continuous Miner could result in serious injury or death to the operator or persons around the machine or cause damage to the machine.

WARNING! Read all instructions carefully before attempting to start or operate machine.

WARNING! Understand the functions of all controls before starting the Continuous Miner. Read and follow the instructions on all warning tags on the machine, observe all regulations and safety precautions .

WARNING! Never operate a Continuous Miner which has been damaged or is not operating properly. Any part of the Continuous Miner which does not function properly can be a hazard. Report it immediately to your supervisor or their designee.

WARNING! Before starting the Continuous Miner, make sure that no one is in the red zone (see Red zone in this chapter).

NOTICE! In extremely cold weather, allow motors and gear cases to idle.

This will warm the hydraulic oils and lubricants. Still oils and greases could immobilize the machine.

IMPORTANT! A pump “growl” means not enough oil is reaching the pumps through the suction lines. Ensure the pump gets primed before continuing operation. Always check the oil level.

DANGER! Improper position could result in injury or death to the operator by crushing him against the rib or roof supports. It may also cause him to run over the trailing cable or dislodge the roof supports.

WARNING! Turning on the water sprays prior to cutting prevents the accumulation of dust and the generation of excessive heat which could cause an ignition or explosion.

______________________________________________________________ A6474X308 Rev. 0 5.37

Operation _______________________________________________________ After reading the previous descriptions and locating each control, the operator is ready to operate the Continuous Miner. An experienced operator should monitor a new operator’s indoctrination to the starting procedure.

The Continuous Miner is typically operated by radio remote control.

Manual operation is not allowed for production operation unless the miner has an operator’s pit and canopy. Manual operation generally is for troubleshooting and maintenance under roof support.

WARNING! The Continuous Miner is typically operated by radio remote control. Manual operation is not allowed for production operation unless the miner has an operator’s pit and canopy. Manual operation generally is for troubleshooting and maintenance under roof support.

The operating procedures listed in the following sections are for radio operation.

IMPORTANT! Before start-up, check that daily maintenance has been performed on the machine.

WARNING! Visually check for other personnel and verbally shout a warning before starting this machine. Make sure all personnel are completely clear of the machine and it’s components and check that any loose material, tools, oil cans or other objects are clear from the area before starting the machine.  Turn the main circuit breaker to the “ON” position.  Select “RADIO” on the “RADIO/MANUAL SW. 1” and “RADIO/ MANUAL SW. 2” on the operator’s case on the miner.  Turn the radio remote on:  Press and hold the “ON” key for 1 second. The console display should read “HOLD”.  Release the key and the display should read “ON”.  Press “SHIFT” and wait 1/4 second.  While pressing “SHIFT”, press “PUMP ON”. Hold both keys in until the pump starts.  Release the “PUMP ON” key.

IMPORTANT! The “PUMP ON” key must be released before “SHIFT”. If “SHIFT” is released first, the pump motor will shut off.  Release the “SHIFT” key and the pump should continue to run.

_________________________________________________________________ 5.38 Bucyrus – Model 25C Continuous Miner

_______________________________________________________Operation Shutdown procedure The Continuous Miner must be properly shutdown before leaving the area or before performing any maintenance or service. Some maintenance or service procedures may require additional steps to insure the safety of the maintenance personnel working on or around the machine and will be listed in the maintenance section of this guide.  Back the miner about one foot from the face providing sufficient clearance and shut off the cutter head motors (see Cutter operation in this section).  Tram the miner to an area of well supported roof. Park the machine in its designated parking area out of traffic, on flat, solid ground. If it is not possible to park the machine on flat ground, park the machine at a right angle to the slope.

WARNING! After turning off the power to the machine, never walk away and leave the radio remote turned on. Failure to turn the radio remote off could result in an accident causing serious injury or loss of life.  Empty the conveyor and shut it off (see Conveyor operation in this chapter).  Lower the cutter head to the floor.  Lower the conveyor and gathering head.  Press and hold the “PUMP OFF” key. The pump motor should shutdown immediately.  Release the “PUMP OFF” key.  Turn off the water sprays.  Shut off the main power supply.

______________________________________________________________ A6474X308 Rev. 0 5.39

Operation _______________________________________________________ Tramming the miner Tramming requires cooling water to prevent damage.

NOTICE! The Continuous Miner has skid type steering: it is capable of turning within its own limits.

WARNING! Tramming requires cooling water to the tram motors. Failure to cool the motors will result in motor damage and premature failure.   Ensure that the stabilizer shoe is away from the mine floor.  Raise cutter boom to best possible position to allow clearance from roof, ribs, and floor.  Raise gathering head away from the mine floor.  Adjust conveyor boom to best possible position to allow clearance from roof, walls, and floor.

WARNING! Adjust conveyor boom to allow clearance from roof, walls, and floor. Failure to do so will result in damage to the conveyor boom.  Ensure adequate clearance at all times while tramming machine.

Be award of people, equipment, and cables. tram enable

To enable tramming:  Press and release the “TRAM 2-3” key.  Once enabled, the tram levers can be used to drive left and right tramming tracks forwards and backwards. If the tram levers are released for a continuous period of five (5) seconds, the tram becomes disabled.  To re-enable the tram function, press and release the “TRAM 2-3” key.

tramming controls

To tram:  Press the “LEFT FWD” tram key to turn the left tramming track forward.  Press the “LEFT REV” tram key to turn the left tramming track backwards.  Press the “RIGHT FWD” tram key to turn the right tramming track forward.  Press the “RIGHT REV” tram key to turn the right tramming track backwards.

_________________________________________________________________ 5.40 Bucyrus – Model 25C Continuous Miner

_______________________________________________________Operation tram speed control

The system allows the tramming to be driven in three discrete speeds (SPEED 1, SPEED 2, and SPEED 3).

To advance a speed:  Press the tram levers and “TRAM 2-3” keys together to move from SPEED 1 to SPEED 2.  Once in SPEED 2, press the tram levers and “TRAM 2-3” together to move from SPEED 2 to SPEED 3.

The tramming configurations shown in Table 2 are enforced by the control system:

Table 2: Tram speed limitations Cutters not Running Tramming Operation

Speed Limitation

Both remote control levers forward or reverse

Tram speed selected (1,2, or 3)

One lever forward, one reverse (split track tramming)

Both motors limited to 1st speed

One lever engaged (forward or reverse), on lever home (single track tramming)

Speed of engaged motor limited to 1st or 2nd speed

Cutter Running and Cutter Amps < cutter in Face Parameter Tramming Operation

Speed Limitation

Both remote control levers forward

FWD CLEANUP speed regardless of speed selected

Both remote control levers reverse

Tram speed selected (1,2, or 3)

One lever forward, one lever reverse (split track tramming)

Speed of motor going forward limited to FWD CLEANUP speed regardless of speed selected Speed of motor going reverse limited to REV SLEW speed regardless of speed selected

One lever forward, one lever home (single track tramming)

FWD CLEANUP speed regardless of speed selected

One lever reverse, one lever home (single track tramming)

REV SLEW speed regardless of speed selected

Cutters Running and Cutter Amps > Cutter in Face Parameter Tramming Operation

Speed Limitation

Both remote control levers forward

Speed limited by control system

Both remote control levers reverse

Tram speed selected (1,2, or 3)

One lever forward, one lever reverse (split track tramming)

Speed of motor going forward limited by control system Speed of motor going reverse limited to REV SLEW speed regardless of speed selected

One lever forward, one lever home (single track tramming)

Speed is limited by control system

One lever reverse, one lever home (single track tramming)

REV SLEW speed regardless of speed selected

______________________________________________________________ A6474X308 Rev. 0 5.41

Operation _______________________________________________________ Cutter head operation cutter motor on

To start the cutter motors  Ensure that the cutter head is not in contact with anything. Cutter head motors must never be started under a load.

WARNING! Never start cutter head motors under a load. Starting motors under load may result in motor damage or premature failure.  Warn ALL CLEAR before starting the cutter head.

WARNING! Warn ALL CLEAR before starting the cutter head. Failure to do so may result in serious injury or death.  Ensure that the pump motor is running. The cutter motors will not run if the pump motor is not running.   Press “SHIFT” and wait 1/4 second.  While holding in “SHIFT”, press “CUTTER ON”. Continue to hold both keys in until the cutter motors turn on.

IMPORTANT! Both cutter motors do not start at the same time. There is a preset timed delay between the left cutter motor starting and the right cutter motor starting.   Release the “CUTTER ON” key.

IMPORTANT! The “CUTTER ON” key must be released before “SHIFT”. If “SHIFT” is released first, the cutter motors will shut off.  Release the “SHIFT” key.

cutter motor off

To stop the cutter motors   Press and hold the “CUTTER OFF” key. The cutter motors should shutdown immediately.  Release the “CUTTER OFF” key.

_________________________________________________________________ 5.42 Bucyrus – Model 25C Continuous Miner

_______________________________________________________Operation

 Conveyor operation conveyor motor on - forward

To start the conveyor motors in forward  Place conveyor boom in desired position.  Warn ALL CLEAR before starting the conveyor.

WARNING! Warn ALL CLEAR before starting the conveyor. Failure to do so may result in serious injury or death.  Ensure that the pump motor is running. The conveyor motors will not start if the pump motor is not running.   Press “SHIFT” and wait 1/4 second.  While holding in “SHIFT”, press “CONV ON”. Continue to hold until the conveyor motor turns on and the conveyor starts to run forward.  Release the “CONV ON” key.

IMPORTANT! The “CONV ON” key must be released before “SHIFT”. If “SHIFT” is released first, the conveyor motors will shut off.  Release the “SHIFT” key.

conveyor motors off - forward

To stop the conveyor motors - conveyor forward  Press and hold the “CONV OFF” key. The conveyor motors should shutdown immediately.

conveyor motors - reverse

To start the conveyor motors in reverse (momentary only)  Place conveyor boom in desired position.  Warn “ALL CLEAR” before starting the conveyor.

WARNING! Warn “ALL CLEAR” before starting the conveyor. Failure to do so may result in serious injury or death.  Ensure that the pump motor is running. The conveyor motors will not start if the pump motor is not running.   Press “SHIFT” and wait 1/4 second.  While holding in “SHIFT”, press “CONV REV”. Continue to hold until the conveyor motor turns on and the conveyor starts to run in reverse.  The conveyor will continue to run in reverse until the “CONV REV” or the “SHIFT” key is released.

______________________________________________________________ A6474X308 Rev. 0 5.43

Operation _______________________________________________________

 Scrubber motor scrubber fan motor on

To start the scrubber fan motor  Ensure that the pump motor is running. The scrubber motor will not start if the pump motor is not running.  Press “SHIFT” and wait 1/4 second.  While holding shift, press “FAN ON”. Continue to hold until the scrubber fan motor turns on.  Release the “FAN ON” key.

IMPORTANT! The “FAN ON” key must be released before “SHIFT”. If “SHIFT” is released first, the fan motor will shut off.  Release the “SHIFT” key.

scrubber fan motor off

To stop the scrubber fan motor  Press and hold the “FAN OFF” key. The fan motor will shutdown immediately.  Release the “FAN OFF” key.

_________________________________________________________________ 5.44 Bucyrus – Model 25C Continuous Miner

_______________________________________________________Operation Control headlights The light switch has three positions: manual, off & radio. When the power is turned on to the continuous miner, the methane monitor relay is closed and the light switch is off. When the light switch is turned to the manual position, the headlights and the area lights will come on.

When the light switch is turned to the radio position, the headlights only (not the area lights) can be turned on and off with the radio.

The headlights can be turned off and on from the remote console at any time that the light switch is in remote position and the remote console is on by:  Press the “SHIFT” and “LIGHTS” keys together to turn the lights on.  Press the “SHIFT” and “LIGHTS” keys together to turn the lights off.

See the operation manual for the radio remote that shipped with your machine for options.

______________________________________________________________ A6474X308 Rev. 0 5.45

Operation _______________________________________________________ Fire suppression The control system uses a solenoid output to drive the fire suppression system on the continuous miner. The fire suppression can be activated at any time from the remote control console. If the machine is fitted with the battery backup version of the power supply, the fire suppression can also be activated in battery standby mode. The system will remain in battery standby mode for at least ten minutes after loss of main power to the machine.

When in radio mode, the fire suppression can be activated from the radio as follows:  Press the “SHIFT” and “FIRE” keys at the same time and hold for two (2) full seconds.  After two seconds, the fire suppression system will activate. At this time, the “SHIFT” and “FIRE” keys can be released.

See the operation manual for the radio remote that shipped with your machine for options.

Conveyor boom control The pump motor must be running in order to operate the conveyor raise, lower, and swing functions.

To position the conveyor:  Press the “CONVEYOR LEFT” key to the left to swing the conveyor tail to the left. The solenoid controlling the left conveyor swing will remain energized until the key is released.  Press the “CONVEYOR RIGHT” key to the right to swing the conveyor tail to the left. The solenoid controlling the right conveyor swing will remain energized until the key is released.  Press the “CONVEYOR DWN” key to lower the conveyor boom.

The solenoid controlling the conveyor lower function will remain energized until the key is released.  Press the “CONVEYOR UP” key to raise the conveyor boom. The solenoid controlling the conveyor raise function will remain energized until the key is released.

See the operation manual for the radio remote that shipped with your machine for options.

Note: Conveyor left and right are described as viewed by the operator from the rear of the machine facing towards the conveyor discharge.

_________________________________________________________________ 5.46 Bucyrus – Model 25C Continuous Miner

_______________________________________________________Operation Stabilizer (stab) cylinder raise/lower The pump motor must be running in order to raise or lower the stabilizer cylinder.  Press “STAB UP” to raise the stabilizer cylinder. The stabilizer cylinder solenoid remains energized until the key is released.  Press “STAB DOWN” to lower the stabilizer cylinder. The stabilizer cylinder down solenoid remains on until the key is released.

See the operation manual for the radio remote that shipped with your machine for options.

Shear up/down The pump motor must be running in order to raise or lower the cutter head.  Press “SHEAR UP” to move the cutter head up. The shear up solenoid remains energized until the key is released (unless height limiting is in force).  Press “SHEAR DOWN” to move the cutter head down. The shear down solenoid remains energized until the key is released.

See the operation manual for the radio remote that shipped with your machine for options.

Gathering head (pan) raise/float The pump motor must be running in order to raise or lower the gathering head (pan).  Press “PAN UP” to lift the gathering head. The pan up solenoid remains energized until the key is released.  Press “PAN FLOAT” to “float” the head down.

See the operation manual for the radio remote that shipped with your machine for options.

______________________________________________________________ A6474X308 Rev. 0 5.47

Operation _______________________________________________________ Breaker “ON”/”OFF” The control system allows “CB1”, “CB2”, and the tram circuit breaker on the miner to be turned on and off using the radio remote control console. This normally requires that a battery backup version of the power supply be installed on the machine. breaker off

To turn the breakers off:  Press and hold the “SHIFT” and “C.B. OFF” keys together for two (2) seconds. After two (2) seconds, the breaker off solenoid will energize, turning off the machine circuit breaker.

breaker on

To turn the breakers on: It is essential that a battery backup version of the control system power supply be installed for this function to be available. Typically, a hydraulic valve provides the mechanical force for the breaker mechanism. To allow this valve to be operated after loss of power, a hydraulic accumulator is charged by the pump motor during normal “powered” operation of the machine. If the hydraulic accumulator is discharged, then it will not be possible for the breaker to be turned on from the radio remote.  Press and hold the “SHIFT” and “C.B. ON” keys together until the breaker has engaged; this may take one (1) to two (2) seconds.

After two (2) seconds, the breaker on solenoid will energize, turning on the machine circuit breaker.

See the operation manual for the radio remote that shipped with your machine for options.

IMPORTANT! The backup accumulator must maintain a minimum pressure of 500 psi for 12 minutes after the pump has been de-energized.

_________________________________________________________________ 5.48 Bucyrus – Model 25C Continuous Miner

_______________________________________________________Operation E-stop Bypass The continuous miner is equipped with a mushroom style emergency stop button on the left side of the machine. This button is normally used to shutdown the machine in an emergency. In difficult mining conditions, it is possible for the left side of the machine to become jammed against the wall (rib) of the mine. In these cases, the emergency stop button can become held in the on position by the wall, preventing the pump motor from be started.

To allow the machine to be started, and moved away from the wall, there is an emergency stop bypass feature in the control system that can be activated from the radio remote. When activated, the bypass function give the operator a 30 second window where the emergency stop button is bypassed and the pump motor can be started. During this window, the operator is able to tram the machine away from the wall and allowing the emergency stop button on the machine to be reset.

To activate the E-stop bypass:  Press and hold the “SHIFT” and “BYPASS” keys together for a continuous 5 seconds.

When the keys are held, the diagnostic display on the miner will show a countdown timer. The timer counts the 5 second period that the keys must be held in order for the bypass function to become enabled.

Once the 5 second delay has passed, the system will enter the E-stop bypass mode. The “SHIFT” and “BYPASS” keys can then be released.

The screen will then show that the bypass is active and will feature another countdown timer, which will countdown the 30 second bypass interval.

Once the 30 second window has expired, the bypass will be disabled.

Bypass mode can be reactivated following the above procedure.

______________________________________________________________ A6474X308 Rev. 0 5.49

Operation _______________________________________________________ Typical cutting sequence CAUTION! Always ensure operator safety while operating the machine.

CAUTION! Always be alert to hazardous conditions and take corrective action as necessary.

IMPORTANT! Care should be taken not to stall cutters on conveyor during cutting operations. Severe damage to motors and gear boxes could occur if cutters or conveyor are repeatedly stalled.  Place gathering head in the float position.  Position conveyor so it doesn't hit the roof, walls, other equipment or any other obstacle. Never operate the conveyor in its fully limited position, right left, up, or down. If in the fully limited position and contacting any obstacle, damage could occur.  Start the gathering head and conveyor. Do not start machine in face or with excessive material in the gathering head.  Engage tram and adjust for speed and direction.  Start cutter head prior to contacting area to cut.  Raise cutter head to desired mining height.  Lower the rear stabilizer to the floor to provide stability if necessary.

Do not lower the shoe enough to raise the rear of the machine. If the shoe is lowered too far the machine will not sump into the face properly.  Engage tram in the forward position.

IMPORTANT! Tram is limited in the forward direction while the cutters are running with the cutter head feedback circuit. As the cutter head begins to cut the material from the face, the sump speed will automatically slow the tram down to prevent over sumping the machine.  Continue to sump until the machine stops tramming. The depth of the sump will depend on the type of material being cut, the diameter of the cutter drum, and bit lacing.  Release tram levers.  Shear down (lower cutter head). The shear down rate is controlled by a shear down relief valve to limit the hydraulic pressure being applied to the cylinders. This is an adjustable feature and can be easily changed as mining conditions change.

_________________________________________________________________ 5.50 Bucyrus – Model 25C Continuous Miner

_______________________________________________________Operation  To maintain smooth level floor conditions, it may be necessary to tram the machine backward approximately 36 inches, thus trimming ridges and smoothing the floor. This may or may not be necessary each cut sequence depending on mine conditions.   Repeat this procedure to desired depth of cut.  Turning crosscuts is accomplished by making a series of partial cuts (sumps) until the machine can be turned to the desired angle.

Relocating the miner  Ensure rear stabilizer is raised from the floor.  Position cutter boom so as to prevent it from hitting roof, ribs, or floor.  Raise gathering head.  Lower conveyor boom down and position so it will not hit roof, ribs, floor or any other equipment or obstacles.  Ensure that trailing cable out of the path of travel.  Ensure there is enough clearance when relocating to avoid damage to machine and ensure operator safety.  Be alert to any people, obstacles, or other machines.  Know the position of fellow workers.  Engage tram in desired direction.

______________________________________________________________ A6474X308 Rev. 0 5.51

Operation _______________________________________________________ Mining operations It is presumed that the operator of this machine is experienced in continuous mining techniques. This section of the manual will present some basic rudiments of Continuous Miner mining operations but should not be considered in any way as a complete how-to of mining techniques. It is recognized that each mine will have their own methods and techniques which work best for their conditions.

One of the keys to good productivity with a Continuous Miner is to know the correct depth of sump which, when the cutting cycle is completed with shear-down, gives enough coal to adequately fill one haulage vehicle.

It is important to do as much advance cutting as possible, while awaiting the haulage vehicle, to load up the gathering head pan. When the vehicle arrives, the gathering head can then work at maximum efficiency to load out the accumulated coal while the remainder of the cutting cycle is being completed.

The following discussion outlines the various steps of an efficient Continuous Miner mining cycle.

Preparation of the face for the next cut The first view in Fig. 33 shows Continuous Miner approaching a freshly cut face. The operator has the cutter head lowered to prepare for making a 2’ to 3’ deep sump cut at the bottom of the face. This is done to make clearance for the gathering head blade when the miner is sumping at the top of the face. In this manner, the miner can make a deeper sump into the top of the face.

Fig. 33: Preparation of the face for the next cut

Approaching a freshly cut face

_________________________________________________________________ 5.52 Bucyrus – Model 25C Continuous Miner

_______________________________________________________Operation The next view in Fig. 34 depicts the miner having made a 30 in. sump cut at the bottom of the face. The operator will now back the miner out of the cut and raise the cutter head to the mine roof.

Fig. 34 Sump cut at the bottom of the face

30” sump cut at the bottom of the face

In the final view in Fig. 35, the operator has backed out of the bottom cut and raised the cutter head to the roof, positioning the miner for making a top sump.

Fig. 35: Positioning for top sump

Positioning for top sump

______________________________________________________________ A6474X308 Rev. 0 5.53

Operation _______________________________________________________ The next face cut (reference Fig. 36) Having cut bottom clearance for the gathering head blade, the operator can now make a deep sump at the top such as a full drum diameter as shown in the first view of Fig. 36. He can commence his down-cut until his gathering head pan is full. Optimally, all this is being done while awaiting the next haulage car so that maximum loading rate can be achieved when the car arrives.

While loading the haulage car, the operator completes the down-cut to the mine bottom as shown in the second view of Fig. 36.

Depending on the depth of the top sump, a small cusp of coal will be left behind the drum on the mine bottom. This cusp is removed by backing the miner out of the face a small distance while the cutter head is running.

The miner is now in a similar position as that shown in the first view of Fig. 36 and the operator can proceed with the next cutting cycle.

Using the stabilizer shoe The stabilizer shoe is located under the rear deck of the main frame and beneath the conveyor. It is hinged at its front edge and is lowered by a hydraulic cylinder.

The stabilizer shoe serves two purposes: ■

To elevate the rear of the miner for maintenance work.

■

To provide a higher down-cut force at the coal face while shearing down during mining operations.

The advantage of increasing down-cut force at the face while shearing down is important particularly when cutting hard coal seams. Figure 36 illustrates the advantage of the stabilizer shoe in the down-cut application.

Fig. 36: The next face cut

Miner sumps in at top and begins downcut

Miner completes downcut with small cusp remaining

_________________________________________________________________ 5.54 Bucyrus – Model 25C Continuous Miner

_______________________________________________________Operation The miner is shown in the middle of its shearing down cycle in Fig. 37.

Without the stabilizer shoe deployed, the machine will tend to rock back on the rear of the crawlers. The distance from the miner’s center-ofgravity to the rear of the crawlers is noted as “Lever Arm w/o Stab Shoe”.

Conversely, with the stabilizer shoe deployed, the miner will now tend to rock back on the shoe, providing a longer lever arm. In the case of this miner, the lever arm with the stabilizer shoe down is more than twice the lever arm without the stabilizer shoe, thus doubling the down force available for shearing down. This increase in down-cut force will improve the speed and efficiency of the shear down portion of the cutting cycle.

The miner is configured with an optional automatic stab function which will lower the stab during the shear down cycle and raise it again automatically.

Fig. 37: Effect of using stabilizer shoe on downcut force

Downcut Force Machine Weight

Lever Arm W/O Stab Shoe Lever Arm With Stab Shoe

Shearing up and down Most Continuous Miners have their center-of-gravity located forward of the center of the crawler footprint. This weight distribution makes the miner inherently more effective in shearing down rather than up because shearing down takes advantage of the miner’s weight to maximize down-cut force.

Shearing only downward requires the cutter head to be raised without cutting during each mining cycle, and a non-productive dead time is introduced in the mining cycle.

An alternative particularly useful in softer, easier cutting coal seams is to shear both up and down while advancing, thus maximizing the time spent actually cutting coal in the total cycle. This sequence is illustrated in Fig. 38.

______________________________________________________________ A6474X308 Rev. 0 5.55

Operation _______________________________________________________ The first view in Fig. 39 shows the miner having sumped in at the top of the coal face. If the operator intends to shear down and up, the depth of sump should be no more than half a drum diameter; otherwise, a cusp will be left at the bottom or top after shearing which will require trimming.

The second view shows the miner in the middle of the downcut.

Having completed the downcut, the third view shows the miner sumped in about half a drum diameter at the mine bottom.

Finally, the last view shows the miner in the middle of the upcut. The technique of successively shearing up and down is particularly productive when the miner is working in conjunction with a continuous haulage system.

Fig. 39: Shearing up and down

Miner shearing down

Miner sumping in at mine bottom

Miner shearing up

_________________________________________________________________ 5.56 Bucyrus – Model 25C Continuous Miner

___________________________________________ Mechanical assemblies Mechanical assemblies The following pages contain a brief description of the major mechanical assemblies that are on the Continuous Miner.

WARNING! This section is intended to familiarize the user with the major mechanical assemblies of the Continuous Miner. All mechanical maintenance should be performed by a qualified technician with the knowledge of the function of the assemblies involved.

Main frame (chassis) The tractor frame (Fig. 40) is a rectangular structure of high-strength steel weldments that supports major operating assemblies such as the cutter head frame, gathering head frame, conveyor and traction units. It houses supporting assemblies, the crawler and take-up mechanisms and planetary gear cases. It anchors the pivots for the conveyor, the gathering head, and the cutter head frame. The clevises for the hydraulic cylinders actuating these assemblies are also on the main/tractor frame. The frame also provides a platform for electrical and hydraulic control modules as well as all water controls and plumbing. Integral within the frame is the hydraulic reservoir (oil tank).

Fig. 40: Main frame/tractor frame

Conveyor raise cylinder clevis Right rear deck electrical control case

Stabilizer shoe cylinder clevis

Conveyor pivot cylinder clevis

Cutter head pivot

Left rear deck scrubber components Hydraulic oil tank access Cutter head cylinder clevis

Gathering head cylinder clevis

______________________________________________________________ A6474X308 Rev. 0 5.57

Mechanical assemblies____________________________________________ Cutter head assembly The cutter head assembly (Fig. 41) is attached to the main frame at right and left hand independent pivot point around which the assembly is articulated for vertical ranging cutting. The independent pivots allow removal of the cutting head assembly without disturbing the gathering head or conveyor components.

The cutter head assembly consists of the following: ■

The cutter head support frame. The frame is a heavy duty box structure which includes the right and left pivot points for attaching to the main chassis, upper mounting clevises for the two cutter head raise cylinders, and a bolting flange to which the cutter head drive assembly mounts.

■

The cutter head gear case assembly, which consists of a water cooled electric drive motor for each of the right and left hand sides, a right and left gear case which includes gearing, a main drive shaft, and mounting points for the right, left, and center drums, and a mounting surface for attachment onto the cutter head support frame.

The cutter head assembly is raised and lowered by two heavy duty hydraulic cylinders mounted to the main chassis at their rod ends and to the main longitudinal structural member of the cutter head support frame at their cylinder ends. These cylinders enable the cutter head assembly to travel over a predesigned range (see the general arrangement drawing for your machine for dimensions).

The right and left side power trains tie together at the center drum, allowing the combined power of both electric motors to be available to the cutter drums.

_________________________________________________________________ 5.58 Bucyrus – Model 25C Continuous Miner

___________________________________________ Mechanical assemblies Fig. 41: Cutter head assembly Cutter head center drum

Cutter head end drum

Cutter head gear case

Cutter head motor

Cutter head pivot

Cutter head cylinder

______________________________________________________________ A6474X308 Rev. 0 5.59

Mechanical assemblies____________________________________________ Gathering head assembly The gathering head assembly (Fig. 42) is attached to the main frame at right and left hand pivot points. The assembly is articulated around these pivot points to adjust the gathering head for uneven floor conditions when tramming the miner. The independent pivots allow removal of the gathering head assembly without disturbing the cutter head or conveyor.

The gathering head assembly consists of upper mounting clevises for two externally mounted gathering head raise cylinders, two electric motors (each with an input gear case and a gathering head pot) which drive rotating centrifugal loading arms (CLAs).

The gathering head assembly is raised and lowered by two hydraulic cylinders which are mounted to the main frame at one head and to the gathering head assembly at the other. The cylinders allow vertical ranging of the forward edge of the gathering head pan.

The right and left hand gear cases are connected to a common foot shaft with dual sprockets, which provides proper timing of the CLAs and drive power to the sprocket that drives the conveyor chain. The conveyor chain drive is reversible to aid in clearing debris which might restrict conveyor chain movement. The CLA input case is driven by a shear shaft which is designed to prevent damage to gearing as a result of jamming.

Fig 42: Gathering head and centrifugal loading arms (CLA’s)

Motor (behind cover)

Gear case (under cover)

Foot shaft

CLA

_________________________________________________________________ 5.60 Bucyrus – Model 25C Continuous Miner

___________________________________________ Mechanical assemblies Conveyor assembly The conveyor assembly (Fig. 43) is attached to the main frame at right and left hand pivot points. The conveyor is articulated vertically around these pivots to assist in optimum loading into a haulage vehicle. Independent pivots allow the removal of the conveyor assembly without disturbing the cutter head or gathering head components.

The conveyor assembly includes the following: ■

An intermediate conveyor structure that includes the right and left hand pivot points for attachment to the main frame, mounting clevises underneath the conveyor for the two conveyor raise cylinders, and a horizontal pivot arrangement at the rear for mounting the rear conveyor subassembly.

■

A rear conveyor assembly that includes a mating horizontal pivot arrangement that allows sideways swinging movement up to 45° on either side of the machine center line, a tail roller shaft for the conveyor chain, and two hydraulic cylinders to maintain correct chain tension.

The conveyor chain is driven by two parallel sprockets. Increased contact area between the chain and sprocket decreases wear, increasing the life of both the chain and the sprocket.

Fig. 43: Conveyor assembly Intermediate conveyor section

Chassis pivot point

Conveyor horizontal pivot

Conveyor swing cylinder

Rear conveyor section

Conveyor chain tensioning cylinder

Tail roller shaft

______________________________________________________________ A6474X308 Rev. 0 5.61

Mechanical assemblies____________________________________________ Traction drive system The traction system (Fig. 44) provides the mobility for mining operations and for tramming from place to place. It includes independent right and left drive systems, each consisting of an electric motor mounted to a drive gear case that powers drive sprockets to provide motion to the respective right or left crawler chain, a right and left forward mounted crawler chain idler roller which is used to adjust crawler chain tension, and a variable frequency drive system.

The traction drive control system provides the operator with the capability to run the crawler tracks independently: right or left tracks can be run in forward, reverse, or split to allow for maximum maneuverability.

Fig. 44: Traction system

Gear case

Electric motor

Crawler track

Idler roller

_________________________________________________________________ 5.62 Bucyrus – Model 25C Continuous Miner

___________________________________________ Mechanical assemblies stabilizer shoe

A stabilizer shoe (Fig. 45), located beneath and at the rear of the tractor frame, may be lowered to anchor the back end of the machine and provides a greater downward thrust of the cutter head for hard-cutting while preventing backward creep of the miner. The stabilizer shoe is raised and lowered hydraulically by a double acting cylinder that moves the shoe bracket up or down.

Fig. 45: Stabilizer shoe

Stabilizer shoe upper pivot point

Stabilizer shoe cylinder pivot point

Stabilizer shoe

Stabilizer shoe raise/lower cylinder

______________________________________________________________ A6474X308 Rev. 0 5.63

Mechanical assemblies____________________________________________

_________________________________________________________________ 5.64 Bucyrus – Model 25C Continuous Miner

_______________________________________________________ Hydraulic Hydraulic system overview WARNING! This section is intended to familiarize the user with the hydraulic system of the Continuous Miner. All mechanical maintenance should be performed by a qualified technician with the knowledge of the function of the assemblies involved.

Hydraulic power for all hydraulically actuated functions originates with the pump assembly. This includes power for cylinders, hydraulic motors, control valves, and pilot valves.

Fig. 46 gives an overview of the location of hydraulic cylinders on the machine.

This section gives a general description of the hydraulic components used on the miner, along with typical schematics for hydraulic functions. The schematics in this section are general; always refer to the hydraulic schematic in your Bucyrus America, Inc. parts manual supplied with your machine.

Operation considerations In order for a hydraulic system to function correctly, it must be properly maintained. Maintenance of the hydraulic system includes: ■

maintaining atmospheric pressure in the tank by keeping the breather clean and free of obstructions

■

maintaining a sufficient oil level in the tank

■

maintaining tight, leak-proof pump suction lines to prohibit air being pumped through the system

■

changing filters and fluids at prescribed intervals

WARNING! Failure to maintain the hydraulic system will result in damage to its hydraulic components, which will result in increased wear and premature failure.

For complete maintenance procedures, see the Maintenance section in this chapter.

_____________________________________________________________ A6474X308 Rev. 0 5.65

Hydraulic _______________________________________________________ Fig. 46: Hydraulic cylinder locations

Cutter head raise cylinder

Gathering head raise cylinder

Conveyor raise cylinder

Cutter head raise cylinder

Gathering head raise cylinder

Gathering head cylinder

Cutter head raise cylinder

Conveyor raise cylinder Conveyor raise cylinder

Stabilizer shoe cylinder

Stabilizer shoe cylinder Stabilizer shoe cylinder

Conveyor swing cylinder

Conveyor chain take-up cylinder

Conveyor swing cylinder Conveyor chain take-up cylinder Conveyor chain take-up cylinder

_________________________________________________________________ 5.66 Bucyrus – Model 25C Continuous Miner

_______________________________________________________ Hydraulic Hydraulic system schematics Abbreviations, Terms and Symbols Troubleshooting is easier when you can readily read and understand the diagrams and blueprints of a hydraulic network. To do this, you need to know hydraulic abbreviations, terms and symbols.

Graphic symbols denote the type of function a component performs but do not necessarily sh ow i ts s hap e or c ons tr ucti on . T hes e schematic symbols are used to trace the system flow from the reservoir to the actual work being performed and then back again to the reservoir. The symbols used are shown individually with a functional description where needed. The study of these symbols helps in understanding the system and thereby aids in troubleshooting the system.

In a hydraulic schematic, components are represented on a schematic diagram by symbols. Using the hydraulic symbols to trace a circuit will help to define the relationships of the components and circuits. The component symbols are linked together by lines, which represent the hydraulic hoses and pipes on the miner.

A schematic diagram is an illustration which shows the hydraulic relationship of the various components in the circuits. A schematic diagram does not show the physical location of the components.

IMPORTANT! Schematics may vary from one unit to the next. Consult the Bucyrus parts manual for the correct schematic for your machine.

_____________________________________________________________ A6474X308 Rev. 0 5.67

Hydraulic _______________________________________________________

Reading a hydraulic schematic All valves are shown in the neutral position on the hydraulic schematics.

To follow oil flow through a system, visually imagine the valve spool shifting as shown in Fig. 47.

Fig. 47: Oil flow through a spool

_________________________________________________________________ 5.68 Bucyrus – Model 25C Continuous Miner

_______________________________________________________ Hydraulic Main control valve The main control valve consists of a series of directional control valves assembled in a row. This row of valves is commonly referred to as a valve bank. The main control valve directs fluid flow to perform a specific function of work that transforms hydraulic energy into mechanical energy. Control is initiated electrically (through the solenoid pilot valve).

The main control valve (Fig. 48) is typically located on the right side of the machine.

Each working section on a control valve has a uniquely designed internal spool. Typically, there are (5) five working sections. Spools may be spring-loaded to return the spool to a preset position (usually neutral) when not held in the required position. When more than one function is activated, those functions will slow down in comparison to operating a single function.

IMPORTANT! During disassembly of control valves, give particular attention to identification of parts for reassembly. Spools are selectively fitted to valve bodies and must be returned to the same bodies from which they were removed. Spools are NOT interchangeable between valve bodies.

WARNING! Do not salvage spools in valve bodies for later use in “new” combinations. Damaged or improper components used during assembly may result in internal leakage or "sticking" ("hanging up") of the spool in the valve body. Incorrect component combinations may result in improper operation of the valve section, possibly causing unexpected machine operation that could result in machine damage or injury to personnel.

If the valve sections are separated for any reason, make sure that all reassembled parts are in their proper location and that all mating surfaces are free of burrs and foreign items (paint, dirt, etc.). Assembly stud nuts or screws should be tightened to specified torques. The presence of foreign items between sections or incorrect torque of assembly hardware can result in improper operation of the valve due to warping or distortion of the sections. This can cause machine malfunction.

Periodic inspection of spool operation, oil condition, and pressure connections saves time-consuming breakdowns and unnecessary parts replacement.

■

All hydraulic connections must be tight. Loose connections not only allow leakage, but also permit air to be drawn into the system, resulting in noisy and erratic operation.

_____________________________________________________________ A6474X308 Rev. 0 5.69

Hydraulic _______________________________________________________ ■

Spools not detented should return to neutral automatically when the control is released. The standard centering spring force is about 1214 pounds at the handle. If more force is necessary, the spool may be binding, or else control linkage may be faulty.

Fig. 48: Main control valve

_________________________________________________________________ 5.70 Bucyrus – Model 25C Continuous Miner

_______________________________________________________ Hydraulic accumulator

A bladder accumulator (Fig. 49) is essentially a fluid pressure storage chamber in which the potential energy of a fluid under pressure can be stored against a compressible force of a gas to do useful work. This stored fluid is readily available to perform a given task when called upon by the requirements of the system in which it is used.

breather

A breather (Fig. 49) permits air to move in and out of the oil tank reservoir to maintain atmospheric pressure.

cylinders

Cylinders (Fig. 49) are bored and honed steel tubes enclosing a piston connected to a rod that extends out the end of the cylinder.

Working surfaces are ground and finely finished, with seals and gaskets incorporated to prevent leakage.

A cylinder with pressure applied in only one direction is a single-acting cylinder (e.g. some elevation functions; the weight of the unit maintains pressure on the return). A double-acting cylinder receives input pressure on each side of the piston alternately.

Fig. 49: Accumulator and cylinder hydraulic symbols

Breather

Cylinder, single acting

Cylinder, double acting

Cylinder, single acting telescopic with dry pocket and load holding valve with external thermal atmosphere relief

Cylinder, single acting telescopic with dry pocket and load holding valve with internal thermal atmosphere relief

Cylinder, single acting with dry pocket

Accumulator

Cylinder, single acting with external spring

Cylinder, double acting with load holding valve with internal thermal atmosphere relief

_____________________________________________________________ A6474X308 Rev. 0 5.71

Hydraulic _______________________________________________________ filters and strainers

Filters and strainers are designed to protect a hydraulic oil system from harmful levels of particulate contamination. High levels of contaminants accelerate wear of components, cause improper functioning, and add to system sluggishness. Other problems such as seizure of parts, higher temperatures due to increased fluid friction, leakage, and loss of control may occur. Contamination also contributes to oxidation and chemical breakdown of the fluid. Filter and strainer hydraulic symbols are shown in Fig. 50.

The primary cause of hydraulic component failure is system contamination. Please see the troubleshooting section in this chapter to better learn how to prevent contamination.

When the non by-passing 3 micron filter element starts clogging with trapped particles the radio system/solenoid functions will slow down indicating it is time to change the 3 micron element. For filter element maintenance and changing schedules, see the Maintenance section in this Chapter.

WARNING! Never run the machine without the proper filter elements in place.

Running the machine with incorrect or no filters may result in hydraulic system contamination, machine failure, erratic operation and injury.

y-strainer, hydraulic

There is a y-strainer (Fig. 50) in the supply line of the hydraulic oil fill circuit. The y-strainer contains a replaceable element to filter out contaminants when adding oil to the system. Nevertheless, oil stocked to be added to this system should be kept in closed containers to prevent contamination of the hydraulic system.

y-strainer, main water

There is a y-strainer (Fig. 50) on the water inlet supply circuit with a replaceable stainless steel element that screens out particles from the mine water. The screen should be removed and either cleaned or replaced as required.

Fig. 50: Filter and y-strainer hydraulic symbols

Filter, bypassing

Filter, non-bypassing

Y-strainer, hydraulic

_________________________________________________________________ 5.72 Bucyrus – Model 25C Continuous Miner

_______________________________________________________ Hydraulic flow meter orifice

A flow meter (Fig. 51) is a visual device which indicates the volume of fluid passing through it per unit time.

An orifice (Fig. 51) is a device that restricts flow.

pressure/return manifold

A pressure manifold (Fig. 51) has one inlet port and many outlet ports to supply flow to many circuits. A return manifold has many inlet ports and only one outlet port for flow to return to tank. Note: You can have the same part number for a pressure or return manifold.

pressure gauge

A pressure gauge (Fig. 51) is a visual device used to indicate the pressure in a hydraulic or water circuit.

pump

The purpose of a pump (Fig. 51) is to produce flow; it does not pump pressure. Pressure is caused by a resistance to flow. All system components have some resistance to flow. Hydraulic cylinders, which power machine functions, are the major components causing this resistance.

Each circuit is protected by a relief valve so that the pressure in the system will not exceed the rating of its components. To ensure that everything works correctly and in proper sequence, relief valve pressure settings closely match the load requirements.

The miner is equipped with a multi-section gear-type fixed displacement hydraulic pump assembly. Each section consists of two closely-meshed gears inside a tightly-fitted housing.

quick disconnect female/male coupling

A quick disconnect (Fig. 51) is a coupling which can quickly join or separate lines.

Fig. 51: Hydraulic symbols

Pressure/return manifold

Orifice

Pressure gauge

Pump, hydraulic two stage

Flow meter

Pump, jet

Quick disconnect male half coupling

Quick disconnect female half coupling

_____________________________________________________________ A6474X308 Rev. 0 5.73

Hydraulic _______________________________________________________ Valves The hydraulic symbols for the different types of valves are given in Fig. 52. ball valve

check valve directional control valve

A valve that checks flow by the seating of a ball. Ball valves are typically operated by hand.

A valve that allows fluid flow in one direction only.

A directional control valve is typically solenoid operated and is used to extend/retract a cylinder.

flow control valve

A valve with a primary function of controlling flow rate.

flow control valve with internal check

A valve with a primary function of controlling flow rate in one direction and allowing free flow in opposite direction.

load holding valve

The purpose of the load holding valve is to prevent the accidental lowering of a hydraulic cylinder, whether by sudden or gradual circuit depressurization, either during operation or maintenance. A load holding valve (also called a "load locking valve") may be a pilot-operated check valve, a counterbalance valve, or an overcenter valve.

A load holding valve locks a load in any position without allowing drift.

It may provide static overload relief and thermal expansion relief with open-center control valves, as are on the cutter head raise circuit, or be combined with an atmospheric relief, as on the conveyor raise circuit of the miner. Cartridge style valves allow installation directly into the cylinder.

In the event of hydraulic system failure or a deliberate system shutdown (as during maintenance), the absence of pilot pressure to the spring-loaded valve automatically closes off the return line and prevents fluid from leaving the cylinder (and thereby stops the piston from moving). The load holding valve is used on the miner, in conjunction with mechanical blocking, when the cutter head or conveyor must be elevated for extended periods of time so that repairs can be effected beneath.

WARNING! Do not rely on the load holding valve when working under the cutter head or the conveyor. Always mechanically block the conveyor or the cutter head if it must be elevated. Serious injury or death may result from not blocking the load.

An overcenter valve is merely a counterbalance valve with a pilot override on the relief valve section. The load raises by free oil flow through the bypass check section. With the control valve centered in NEUTRAL, the load is locked (the relief must be set at least 1.3 times higher than the maximum load induced pressure or system pressure).

_________________________________________________________________ 5.74 Bucyrus – Model 25C Continuous Miner

_______________________________________________________ Hydraulic There is a pilot-operated check valve incorporated in the load holding valve in each conveyor raise/lower cylinder, and a pilot load holding valve attached to each cutter head raise/lower cylinder (for a total of four holding valves). Each one prevents its respective cylinder from lowering its load in the absence of a specific pilot pressure. This pressure is induced only when the LOWER control of that particular function is engaged.

The load holding valves for the conveyor and cutter head incorporate a relief function which bypasses the pilot-operation whenever the pressure setting is exceeded.

There are no adjustments required on the load holding valves.

WARNING! The load holding valves on the cutter head and conveyor cylinders are preset and DO NOT require adjustment. Adjustment of these valve may result in very serious injury or even death.

It is often difficult without actual pressure testing using a gauge to determine failure of any of the four holding valves. When both holding valves in either function fail, be it the conveyor or cutter head raise circuit, the load measurably drifts down over a short period of time when the power to the unit is off. Sometimes this drift down is fast enough to be detected visually.

This drift down can be indicative of other hydraulic problems, especially damaged or worn cylinder packing's. If, however, the load holding valves are at fault, do not attempt to adjust the valve(s). Replace the valves while the cutter head or conveyor raise cylinders are completely retracted and the cutter head or conveyor is fully lowered. pressure reducing valve (pressure regulator)

Pressure reducing valves are normally open and are used to maintain reduced pressure in the down stream circuit. Normally actuated by pressure sensed in the down stream circuit, the valve closes as pressure reaches the valve setting, preventing further pressure buildup.

shuttle valve

A shuttle valve has two inlets and one outlet, which allows it to operate a function from either of two sources (never at the same time). For example, a function may be operated from a manual control or by radio control via solenoid.

_____________________________________________________________ A6474X308 Rev. 0 5.75

Hydraulic _______________________________________________________ relief valve

A properly set relief valve is a protection device that maintains the safe limit of system pressure in the hydraulic circuit to which it is installed.

When the system pressure rises to the set limit, the relief valve opens, providing a return to the tank until the system pressure returns to the proper setting.

Some relief valves are atmospheric. These valves are used for overpressure protection only. Should the preset pressure be reached, they discharge oil into the air. An example of this is on the conveyor raise circuit where the pressure is set to relieve at 3,000 psi, which is well above expected operating pressures.

There are a number of relief valves in the hydraulic system that are set for individual sub-circuit protection (conveyor elevation, gathering head, etc.) Each pump section also has a main relief valve for protection against over-pressurization. The main hydraulic pump section is typically set at 3000 psi. The pilot section is typically set at 600 psi. If your system has 3 pump sections, consult your system schematic in your Bucyrus parts manual for the auxiliary pump section relief valve setting.

For relief valve adjustment procedures, see the Adjustment section of this chapter.

solenoid pilot valve, main control valve (with radio option)

Each section of the main control valve is piloted by a solenoid valve that is mounted on top of that particular section. Reduced pilot pressure is supplied to these 2-way normally closed valves to control the main spool inside the larger working section of the directional control valve.

Energizing the solenoid opens the pilot valve to allow the pilot pressure to move the spool in the proper direction to achieve the desired function of the directional control valve.

When the coil in the front is energized, the spool shifts and allows oil flow to “A” port (front = closest working port to handle). If the coil in the back is energized, the spool shifts and allows oil flow to “B” port (back = furthest working port from handle). Unless a detent spool is being used, the spool will spring return to the neutral position when the coil is de-energized.

solenoid pilot valve, hydraulic control (with radio option)

These 2-way normally closed valves are used to supply reduced pilot pressure that controls a number of functions on the machine. These functions include the control of hydraulically piloted water valves for the Dust/Cooling, Fire and Scrubber Spray System circuits. They also are used to control the Breaker ON/Breaker OFF function.

water valve, hydraulic piloted

A valve that is piloted open with hydraulic pressure to allow water to pass through it.

water valve, detent hydraulic piloted

A valve that is piloted open with hydraulic pressure to allow water to pass through it and stays open until manually closed.

_________________________________________________________________ 5.76 Bucyrus – Model 25C Continuous Miner

_______________________________________________________ Hydraulic Fig. 52: Valve hydraulic symbols

Anti-chatter/maintenance valve

Flow control valve

Out

Ball valve

Check valve

Flow control valve with internal check

Conveyor chain take-up valve

Gathering head float valve

Directional control valve

Pressure reducing valve

In

Pressure regulator valve

Relief valve

Water valve, detent

Water valve,

Shuttle valve

Solenoid valve 2-unit

hydraulic operated hydraulically piloted _____________________________________________________________ A6474X308 Rev. 0 5.77

Hydraulic _______________________________________________________ Hydraulic pump assembly circuit Hydraulic power for all of the hydraulically actuated functions originates with the pump assembly (Fig. 53). This pump assembly is made up of single-stage pump with a piggy-back hydraulic pump or 2-section tandem pump. The pump outlets are designated EF (main flow) and CF (pilot flow). The pump assembly is typically mounted on the right side of the machine frame.

Oil is supplied from the oil tank reservoir to the suction side of pump through a 2 inch suction line to a 2 inch locking ball valve.

IMPORTANT! The 2 inch locking ball valve must be locked open in normal operation.

The 2 inch locking ball (shut-off) valve to the pump is to assist the field personnel in changing the pump. The ball valve will reduce loss of hydraulic oil and minimize contamination of the hydraulic circuit. After changing the pump, always be sure the shut-off valve is turned to open and the locking device is replaced.

Fig. 53: Hydraulic pump circuit

_________________________________________________________________ 5.78 Bucyrus – Model 25C Continuous Miner

_______________________________________________________ Hydraulic Main flow - primary pressure circuit The main flow-primary pressure circuit (Fig. 54) is powered by hydraulic pump gear section EF. The EF gear section is rated at 32 gpm at a pressure of 3,500 psi. The main control valve operates the cutter head, conveyor raise and swing, gathering head, and stabilizer shoe cylinders along with oil tank fill. After passing through the 2” locking ball valve and pump gear section EF, oil enters a 10 micron by-passing pressure filter, through the pump control manifold, and then continues to the main control valve whose relief is set at 3,500 psi. The pump control manifold unloads the primary pressure system and diverts flow back to tank when no function on the main control valve is active. When a function is activated, the pump control manifold will divert flow the main control valve. The pump control manifold also facilitates the optional high speed cutter head raise. On the return side of the system, oil exits the main control valve. There is a tee to allow external filling of the reservoir (see conveyor raise/lower circuit). Oil enters a 10 micron bypassing return filter before entering the oil reservoir. Once in the reservoir, the oil is forced to flow through and around baffle plates for cooling and de-aerating before re-entering the suction line. Also, located in the reservoir are floor magnets which will trap ferrous metal particles.

The schematic shown in Fig. 54 is a typical primary pressure circuit.

Always refer to the schematic in the Bucyrus parts book for your machine.

Fig. 54: Main flow-primary pressure circuit

_____________________________________________________________ A6474X308 Rev. 0 5.79

Hydraulic _______________________________________________________ Pilot pressure circuit Reference Fig. 55.

The pilot hydraulic section is a closed-center system powered by gear section CF. It supplies oil flow to the following: ■

hydraulic tension conveyor chain take-up (optional)

■

gathering head float circuit, and

■

all solenoid valves, which control –

the scrubber

–

dust sprays

–

fire sprays

–

breaker on and off

–

all main control valve functions

The pilot gear section is rated at 7 gpm at 600 psi. After passing through the 2” ball valve and pump gear section CF, oil enters a 10micron by-passing pressure filter, to an accumulator teed into the circuit, and then to the pilot/water manifold. The pilot/water manifold contains pressure reducing valves and needle valves that regulate pressure to the conveyor chain take-up and the pilot control of the main control valve.

The schematic shown is Fig. 55 is typical for a pilot pump circuit. Always refer to the schematic in the Bucyrus parts book for your machine.

Fig. 55: Pilot pressure circuit

_________________________________________________________________ 5.80 Bucyrus – Model 25C Continuous Miner

_______________________________________________________ Hydraulic Tank Ports Bucyrus filters the oil system on all new Continuous Miners according to a minimum ISO code 19/17/14 for cleanliness. There is a quick disconnect (w/plug) to hook up a filtering cart and can also be used underground for contamination clean-up of the hydraulic system. Return oil from hydraulic components connect to a return manifold and directly to tank. The oil tank reservoir includes the oil level switch, a dipstick and two air reservoirs. The air reservoirs are two accumulators at atmospheric pressure (no pre-charge) that provide a controlled means of air entering and exiting the hydraulic oil tank during operation of the hydraulic system. This is to facilitate clean hydraulic oil.

_____________________________________________________________ A6474X308 Rev. 0 5.81

Hydraulic _______________________________________________________ Cutter head cylinder circuit Reference Fig. 56 DANGER! The area under and around the raised cutter head is dangerous.

Securely block the head before performing maintenance on or below it. Failure to block the raised cutter head could result in serious injury or even death.

Oil is supplied by hydraulic pump section EF thru a 10- micron bypassing pressure filter, through the pressure control manifold, and to the cutter head working section on the main control valve. By remote solenoid control, the spool allows oil to enter the cutter head cylinder circuit.

The cutter head cylinder is a double-acting cylinder with load holding cartridge. There are two (2) cutter head cylinders, one on each side of the machine.

There are two (2) port reliefs in the working section on the main control valve. Both port reliefs are set at 2,800 psi. To raise the cutter head (extend the cylinders), press “SHEAR UP” on the remote control. Oil goes to the extend port of the cylinders free flowing thru the check valve of the load holding cartridge to extend the cylinders.

To lower the cutter head (retract the cylinders), press “SHEAR DOWN” on the remote control. Oil goes to the retract port of the cylinders and also pilots open the load holding cartridge allowing oil to exit the extend ports on the cylinders and then through the main control valve and a 10-micron bypassing return filter into the oil tank.

DANGER! Do not adjust, modify, or remove the load holding cartridge valve mounted in the cutter head cylinders . It is a safety feature to prevent accidental lowering of the cutter head.

DANGER! This load holding valve, like those on the stabilizer cylinders is preset. DO NOT ADJUST IT. If it malfunctions, replace it immediately.

WARNING! You could be seriously injured or killed by falling loads. Block the miner before performing maintenance and always observe the safe working load limits of all lifting and blocking devices.

This schematic shown is Fig. 56 is a typical cutter head cylinder raise circuit. Always refer to the schematic in the Bucyrus parts book for your machine.

_________________________________________________________________ 5.82 Bucyrus – Model 25C Continuous Miner

_______________________________________________________ Hydraulic Fig. 56: Cutter head cylinder circuit

_____________________________________________________________ A6474X308 Rev. 0 5.83

Hydraulic _______________________________________________________ Conveyor raise/lower circuit - oil tank fill Reference Fig. 57 conveyor raise/lower

Oil is supplied by hydraulic pump section EF through a 10-micron bypassing pressure filter, through the pressure control manifold, and to the conveyor raise/lower working section on the main valve control. By remote solenoid control, the spool allows oil to enter the conveyor raise/ lower cylinder circuit. The conveyor raise/lower cylinder is a singleacting cylinder with a load holding cartridge. There is a two (2) conveyor raise/lower cylinders. There is a port relief in the working section on the main control valve for raising the conveyor which is set at 1,800 psi.

Press “CONVEYOR UP” on the remote control to extend the cylinders and raise the conveyor. Oil flows to the extend port of the cylinders free flowing through the check valve of the load holding cartridge to extend the cylinders. Press “CONVEYOR DOWN” on the remote control to retract the cylinders and lower the conveyor. Oil goes to the retract port of the cylinders and pilots open the load holding cartridge, allowing oil to exit the cylinders. Oil continues to the main control valve and then travels thru a 10-micron bypassing return filter to tank.

oil tank fill

The oil tank fill operates from the conveyor lower circuit. Oil goes to lower the conveyor and tees off to a diversion valve that is closed. With the conveyor in the down position, the diversion valve is manually opened. By remote solenoid control, the spool allows oil to enter the conveyor lower cylinder circuit and runs the oil tank fill. Oil passes thru the diversion valve to a jet pump, which creates a venturi (vacuum) effect pulling oil from the clean oil reservoir through a y-strainer and a check valve joining the return oil going thru 10-micron bypassing return filter to tank.

IMPORTANT! Ensure that the suction hose is tightly plugged to prevent dirt and contaminants from entering the hydraulic system when not in used.

IMPORTANT! The power fill is activated by opening the diversion valve and engaging conveyor down function.

The schematic is typical conveyor raise/lower circuit. Always refer to the schematic in the Bucyrus parts book for your machine.

_________________________________________________________________ 5.84 Bucyrus – Model 25C Continuous Miner

_______________________________________________________ Hydraulic Fig. 57: Conveyor raise/lower - oil tank fill circuit

_____________________________________________________________ A6474X308 Rev. 0 5.85

Hydraulic _______________________________________________________ Conveyor swing circuit Reference Fig. 58 Oil is supplied by hydraulic pump section EF through a 10-micron bypassing pressure filter, through the pressure control manifold, and to the conveyor swing working section on the main control valve. By remote solenoid control, the spool allows oil to enter the swing circuit.

The swing cylinder is a double-acting cylinder with a range that will allow the conveyor tail to move 45 degrees off the centerline of machine in both directions. There are two (2) port reliefs in the working section on the main control valve both of which are set at 1,800 psi. The purpose of the port reliefs is to protect the swing cylinder from damage in either right or left direction in the event of an excessive external load due to the impact of the conveyor tail with the rib, haulage vehicle, or some other object.

Press the conveyor swing button to the left on the remote control and the cylinder will retract, moving the conveyor tail to left. Press the conveyor swing button on the remote control to the right and the cylinder will extend, moving the discharge conveyor to the right. The left and right movement is based off standing at the rear of machine looking forward to the cutter head.

The schematic shown is Fig. 58 is a typical conveyor swing cylinder circuit. Always refer to the schematic in your Bucyrus America, Inc. Parts Book for your machine.

_________________________________________________________________ 5.86 Bucyrus – Model 25C Continuous Miner

_______________________________________________________ Hydraulic Fig. 58: Conveyor swing cylinder circuit

_____________________________________________________________ A6474X308 Rev. 0 5.87

Hydraulic _______________________________________________________ Gathering head raise/hold/float-lower circuit Reference Fig. 59 Oil is supplied by hydraulic pump EF through a 10 micron by-passing pressure filter, through the pump control manifold, and to the gathering head working section on the main control valve. By remote solenoid control, the spool allows oil to enter the gathering head raise circuit. When raising the gathering head pan, oil free flows through the gathering head float valve (check valve) and splits to both cylinders. At any time during raising the gathering head, the operator can stop the gathering head pan and the pan will hold in position.

The gathering head lower function is controlled through a working section of the main control valve and the gathering head float valve block.

The gathering head raise cylinders are single acting. Each has a dry pocket providing additional stoke beyond its pressure-extend limit in the event that the gathering head is trammed into an obstruction forcing it to raise beyond its normal travel limit. When in the float condition, the cylinders carry some of the gathering head pan weight to prevent the gathering head leading edge from digging into the soft bottom of the mine and moves the machine’s center of gravity forward when mining.

The pilot pressure oil supply for the gathering head float comes from hydraulic pump CF through a 10 micron by-passing pressure filter to the water/pilot manifold, then to relief valve set 600 psi, and then to the gathering head float valve. The pilot pressure oil is make-up oil for the gathering head cylinders.

When the pan goes over a roll it may raise quickly, extend the gathering head cylinders and create a vacuum in the pilot oil supply. In extreme cases, the pilot pressure may decrease to the point where the solenoid controlled main control valve may not have sufficient pilot pressure to shift. It is therefore possible to experience a momentary loss of radio control of the machine.

To minimize the chance of this occurrence, a restrictor orifice is installed in the pilot supply for the valve block. This orifice is protected from contamination by an upstream filter.

A downstream check valve keeps system pressure from entering the pilot pressure lines. An adjustable needle valve allows for the bleeding off of pressure for maintenance.

The schematic shown in Fig. 59 is a typical gathering head circuit. Always refer to the schematic in the Bucyrus parts book for your machine.

_________________________________________________________________ 5.88 Bucyrus – Model 25C Continuous Miner

_______________________________________________________ Hydraulic Fig. 59: Gathering head circuit

_____________________________________________________________ A6474X308 Rev. 0 5.89

Hydraulic _______________________________________________________ Stabilizer shoe cylinders circuit Reference Fig. 60 Oil is supplied by hydraulic pump section EF thru a 10-micron bypassing pressure filter, through the pump control manifold, and to the stabilizer shoe working section on the main control valve. By remote solenoid control, the spool allows oil to enter the stabilizer shoe circuit.

The stabilizer shoe cylinder is a double-acting cylinder. There are two stabilizer shoe cylinders.

There are two port reliefs in the working section on the main control valve: the port relief to lower the stabilizer shoe is set at 3,500 psi and the port relief to raise the stabilizer shoe is sat at 1,200 PSI. Press “STAB UP” on the remote control to extend the cylinders and lower the stabilizer shoe. Press “STAB DOWN” on the remote control to retract the cylinders and raise the stabilizer shoe.

The schematic shown is Fig. 60 is a typical stabilizer shoe cylinder circuit. Always refer to the schematic in the Bucyrus parts book for your machine.

_________________________________________________________________ 5.90 Bucyrus – Model 25C Continuous Miner

_______________________________________________________ Hydraulic Fig. 60: Stabilizer shoe circuit

_____________________________________________________________ A6474X308 Rev. 0 5.91

Hydraulic _______________________________________________________ Conveyor chain take-up circuit Reference Fig. 61 The pilot pressure circuit is powered by hydraulic pump gear section A2 which is rated at 7 gpm at 600 psi. From the pump, oil passes through a 10 micron by-passing pressure filter, to the water/pilot manifold where oil is distributed to the conveyor chain take-up pressure reducing valve which is set at 200 psi, and then to the conveyor chain take-up cylinders.

IMPORTANT! Never run the conveyor with the needle valves, “NV1” and NV2”, open. Injury or death may occur.

The conveyor chain take-up cylinder assemblies consist of the cylinder with a removable rod with wear rings and a spring. The oil pressure keeps tension on conveyor chain and the spring takes up the dither when the conveyor chain is running.

The schematic shown is Fig. 61 is a typical conveyor chain take-up circuit. Always refer to the schematic in the Bucyrus parts book for your machine.

_________________________________________________________________ 5.92 Bucyrus – Model 25C Continuous Miner

_______________________________________________________ Hydraulic Fig. 61: Conveyor chain take-up circuit

_____________________________________________________________ A6474X308 Rev. 0 5.93

Hydraulic _______________________________________________________ Dust-scrubber sprays hydraulic circuit Reference Fig. 62 The pilot hydraulic pressure circuit is powered by hydraulic pump gear section CF which is rated at 7 gpm at 600 psi. From the pump, oil passes through a 10 micron by-passing pressure filter and to the pilot/ water manifold. Contained within the pilot/water manifold are the water valves that distribute water to the scrubber, dust sprays, fire suppression, and trickle circuits and provides hydraulic power to the hydraulic tension conveyor chain take-up and to the three pilot pressure circuits.

The pilot pressure oil passes through a 3 micron non-bypassing filter and is controlled by a pressure regulator that is normally set to 600 psi.

The water valves are actuated via remote control solenoid valves which are supplied by a pressure reducing valve internal to the pilot/water manifold and that is set at 600 psi.

The scrubber and trickle valves are automatic functions while the dust sprays are automatic but can be opened or closed via the remote control. Fire suppression is manual actuation by remote control or by physically opening a valve handle. All four water valves have a manual override by physically rotating a handle to open a valve.

The schematic shown in Fig. 62 is a typical dust-scrubber sprays circuit. Always refer to the schematic in the Bucyrus parts book for your machine.

_________________________________________________________________ 5.94 Bucyrus – Model 25C Continuous Miner

_______________________________________________________ Hydraulic Fig. 62: Dust and scrubber sprays hydraulic circuit

_____________________________________________________________ A6474X308 Rev. 0 5.95

Hydraulic _______________________________________________________

_________________________________________________________________ 5.96 Bucyrus – Model 25C Continuous Miner

__________________________________________________________ Water Water system overview Water is supplied to the continuous miner for the following purposes: ■

deluge water fire protection

■

cooling water for motors and tram controller case

■

water for dust suppression

■

air cleaning via the scrubber system

■

washdown hoses

The water supplied by the mine must meet the following requirements: ■

flow rate of 30 gpm minimum for cooling

■

total flow rate: based on customer dust plan

■

pressure of 250 psi (dynamic) minimum, 500 psi maximum

Bucyrus America, Inc. offers straight, left hand, right hand, or bidirectional cutter head spray manifolds. This section describes straight ahead sprays.

The schematics in this section are for reference only. Always refer to the schematic in the Bucyrus parts book for your machine.

______________________________________________________________ A6474X308 Rev. 0 5.97

Water___________________________________________________________ Water supply circuit The water manifold supplies water to all the water circuits (Fig. 63).

Mine water is connected to a ball valve typically mounted on the right rear corner of the machine. From the ball valve the water then passes through a filter, an optional flow meter, and then to the water manifold.

From the water manifold, water is directed to the individual circuits on the machine through valves integrated into the water manifold.

Fig. 63: Water supply circuit

_________________________________________________________________ 5.98 Bucyrus – Model 25C Continuous Miner

__________________________________________________________ Water Deluge water fire circuit The deluge fire suppression circuit (Fig. 64) can be operated by manual or remote solenoid control (see Electrical section in this chapter).

When the solenoid coil is energized, it shifts a spool, allowing hydraulic oil to travel to a 2-way, 2-position water valve. The hydraulic fluid shifts the spool, allowing the water to pass through it to the deluge fire spray manifolds. For the hydraulic portion of this circuit, see the Hydraulic section of this chapter. The water valve has a detent spool, which keeps the valve open. The 2-way, 2-position valve can be operated manually and must be manually reset to reset the fire suppression circuit.

In addition, there are two ball valves used to manually operate the fire suppression circuit typically located on the right hand side of the machine. The valves must be manually turned off to reset the fire suppression system.

The optional left hand washdown hose water is supplied by the deluge fire suppression system.

The fire suppression circuit must be tested once per shift, minimum (see Maintenance section in this chapter).

Fig. 64: Deluge water fire circuit

______________________________________________________________ A6474X308 Rev. 0 5.99

Water___________________________________________________________ Scrubber sprays and sump dump circuit The scrubber spray circuit (Fig. 65) can be operated by manual or remote solenoid control (see Electrical section in this chapter). When the scrubber spray solenoid coil is energized, it shifts a spool, allowing hydraulic oil to flow to the hydraulic pilot operated normally closed water valve. The hydraulic oil shifts a spool, allowing water to pass though it to the scrubber spray circuit. For the hydraulic portion of this circuit, see the Hydraulic section of this chapter.

The scrubber sprays automatically turn on when the scrubber motor starts. The valve can also be actuated by turning the manual valve handle.

There is a flow control valve that controls the cleaning sprays located in the scrubber duct work. The scrubber screen cleaning sprays are controlled by a pressure regulated valve with a gauge and an adjustable flow control valve. The pressure regulator is normally set at 50 psi.

The final portion of this circuit is used to empty the excess water from the scrubber sump box (slurry water). Located in the bottom of the scrubber sump box are a stir spray nozzle, a flow control valve, a jet pump, and a water strainer. The flow control valve is used to control the amount of water stirring, which keeps the water strainer from becoming clogged and keeps the jet pump clean to discharge the slurry water. The pressure regulator valve and gauge are used to operate this circuit, which is normally set at 75 psi. .

_________________________________________________________________ 5.100 Bucyrus – Model 25C Continuous Miner

__________________________________________________________ Water Fig. 65: Scrubber spray and sump dump circuit

______________________________________________________________ A6474X308 Rev. 0 5.101

Water___________________________________________________________ Dust-cooling left hand chassis circuit The dust-cooling circuit can be operated by manual or remote solenoid control (see Electrical section in this chapter). When the dust-cooling solenoid coil is energized, it shifts a spool, allowing hydraulic oil to flow to the hydraulic pilot operated normally closed water valve. The hydraulic oil shifts a spool, allowing water to pass though it to the dust cooling circuit. For the hydraulic portion of this circuit, see the Hydraulic section of this chapter.

The dust-cooling valve can also be actuated by turning the manual valve handle.

The dust-cooling left hand chassis circuit (Fig. 66) continues from the dust cooling water supply circuit. From the dust-cooling pressure manifold, the water flows through the pump motor, the tram motor, the gathering head motor, and the cutter head motor. Water branches off of the gathering head motor to the pan sprays and from the cutter head motor to the head spray, throat spray, side spray, and relief valve.

The throat spray manifold helps keep dust from flowing up the conveyor as the coal is being transported. There is an atmospheric relief located before the (optional) dust spray direction (left or right) diverter valve in case pressure builds up from clogged spray nozzles.

The dust-cooling circuit shown in Fig. 66 is typical for a Bucyrus miner containing straight ahead spray manifolds and side sprays. The circuit for your machine may vary depending on your dust plan and unique requirements. Always refer to the schematic in your Bucyrus America parts book for your machine.

_________________________________________________________________ 5.102 Bucyrus – Model 25C Continuous Miner

__________________________________________________________ Water Fig. 66: Dust-cooling left hand chassis circuit

______________________________________________________________ A6474X308 Rev. 0 5.103

Water___________________________________________________________ Dust-cooling right hand chassis circuit The dust-cooling circuit can be operated by manual or remote solenoid control (see Electrical section in this chapter). When the dust-cooling solenoid coil is energized, it shifts a spool, allowing hydraulic oil to flow to the hydraulic pilot operated normally closed water valve. The hydraulic oil shifts a spool, allowing water to pass though it to the dust cooling circuit. For the hydraulic portion of this circuit, see the Hydraulic section of this chapter.

The dust-cooling valve can also be actuated by turning the manual valve handle.

The dust-cooling right hand chassis circuit (Fig. 67) continues from the dust cooling water supply circuit. From the dust-cooling pressure manifold, the water flows to the tram motor, tram case, gathering head motor and cutter head motor. Water branches off of the cutter head motor for the pan sprays, throat sprays, head sprays, and relief valve.

The atmospheric relief is in place in the event that pressure builds up from clogged spray nozzles.

The dust-cooling circuit shown in Fig. 67 is for a typical Bucyrus miner containing straight ahead sprays and side sprays. The circuit for your machine may vary depending on your dust plan and unique requirements. Always refer to the schematic in your Bucyrus America parts book for your machine.

_________________________________________________________________ 5.104 Bucyrus – Model 25C Continuous Miner

__________________________________________________________ Water Fig. 67: Dust-cooling right hand chassis circuit

______________________________________________________________ A6474X308 Rev. 0 5.105

Water___________________________________________________________

_________________________________________________________________ 5.106 Bucyrus – Model 25C Continuous Miner

_______________________________________________________ Electrical Electrical system The following pages contain a brief description of the electrical components and assemblies located on the continuous miner.

WARNING! This section is intended only to familiarize the user with the electrical components of the continuous miner. all electrical maintenance should only be performed by a qualified electrician with knowledge of the functions of the components involved.

WARNING! Before removing the cover from any electrical enclosure or attempting any maintenance or troubleshooting, the main power must be disconnected and locked out at the main power center.

Basic principles An electrical circuit provides a means of changing electrical energy into some other form of energy. An electrical circuit may cause electrical energy to change into mechanical energy (electric motor), into heat, or light (light bulb). Just as the components in a hydraulic circuit control the flow of hydraulic fluid, many electrical components are used in an electrical circuit to direct or limit the flow of electrical energy so it can be utilized to do a particular job on the miner. Other components in an electrical circuit are protective devices to avoid damage to equipment and injuries to personnel.

Schematics A schematic diagram is an illustration which shows the electrical relationship of the various components and their circuits. A schematic diagram does not show the physical location of the components. In an electrical schematic, components are shown in their de-energized position. A set of normally open (NO) contacts close when the coil is energized and a set of normally closed (NC) contacts open when the coil is energized. Related components share the same designation. In tracing a particular circuit, it may be helpful to think of the flow of electricity as being similar to the flow of water through a hose. When a set of contacts are open, the current cannot flow across them. When the contacts close, current can flow. When three lines are connected in a tee, the current will flow in whatever direction it can. Like water, electrical current will follow the path of least resistance through the circuit.

Finally, for a circuit to work, the electrical current must make a complete loop, similar to hydraulic fluid going through a circuit and returning to tank.

_______________________________________________________________ A6474X308 Rev. 0 5.107

Electrical________________________________________________________ Fig. 68: Standard electrical symbols

_________________________________________________________________ 5.108 Bucyrus – Model 25C Continuous Miner

_______________________________________________________ Electrical Trailing cable A trailing cable with three power conductors, labeled L1, L2, L3, two (2) ground conductors (G), and a ground check conductor (GC) supplies power to the machine. A three-conductor 2/0 to 4/0 cable is used with the 950V machines.

Cables are designed with a fire-proof, tough outer jacket to withstand the constant abuse of flexing, reeling, and the exposure to sharp objects on the mine floor. They are not designed to withstand being run over by mobile equipment, especially Continuous Miners. Trailing cables exposed to moving equipment are required to be hung to prevent damage to insulation.

IMPORTANT! Hang trailing cables to prevent damage from moving equipment!

WARNING! Never run over an unprotected trailing cable. Damaged cables should be repaired immediately.

The trailing cable may have breaks in its insulation. These defects in the insulation could cause exposure to high electrical currents. Never handle an energized trailing cable without the properly rated personal protective equipment (electrically insulated gloves and shoes or boots).

Never let the energized trailing cable come in contact with unprotected (non-insulated) parts of your body.

DANGER! Never handle energized trailing cable without proper protective equipment. Contact with an energized trailing cable with compromised insulation could result in death by electrocution.

Trailing cables on reels can present a hazard. The reels keep the trailing cable under tension at all times. Starting and stopping of the equipment causes a tension change on the trailing cable causing the cable to move or flex constantly. The closer to the machine, the more noticeable the movement. Anyone standing near or crossing over the trailing cable could be tripped or struck by the trailing cable as it flexes.

WARNING! Always use caution when standing near or crossing trailing cables. The trailing cable may move as the machine moves.

Temporary splices Trailing cables may only be repaired under certain conditions and following specific guidelines which are outlined in MSHA 30 CFR Part 75, Subpart G (Trailing Cables).

_______________________________________________________________ A6474X308 Rev. 0 5.109

Electrical________________________________________________________ General The electrical operation of the miner is controlled by the interaction of (3) three circuits, each with a different voltage rating.

Line Circuit: 950 VAC used to power the electric motors which run the pump, cutter head, conveyor, scrubber fan, and tram tracks..

120 VAC Control Circuit: 120 VAC used for the main contactors, area lights, control system, and methane monitoring circuit.

24 VDC Control Circuit: 24 VDC used for low voltage control equipment and communication signals.

Light Circuit: 12 VAC for the headlights and the low oil level circuit.

_________________________________________________________________ 5.110 Bucyrus – Model 25C Continuous Miner

_______________________________________________________ Electrical Power circuit with control Electric power is supplied to the control transformer and is available to the methane monitor and to all contactors after the trailing cable is connected, the circuit breakers CB1 and CB2 are turned on, and when CB2 contacts close in the control circuit.

The schematic shown in Fig. 69 is typical of a power schematic. Always refer to the schematic in the Bucyrus parts book for your machine.

Fig. 69: Power circuit with control

_______________________________________________________________ A6474X308 Rev. 0 5.111

Electrical________________________________________________________ Methane monitor circuit The methane monitor detects methane gas when the continuous miner is powered up. Before any motor or function occurs, the methane monitor checks for methane gas. If the methane level is below the preset value, the methane monitor relay will close. The methane monitor is powered from the control transformer.

The schematic shown in Fig. 70 is a typical methane monitor circuit.

Always refer to the schematic in the Bucyrus parts book for your machine.

Fig. 70: Methane monitor circuit

_________________________________________________________________ 5.112 Bucyrus – Model 25C Continuous Miner

_______________________________________________________ Electrical Control headlights and area lights circuit The light switch has three positions: manual, off & radio. When the power is turned on to the continuous miner, the methane monitor relay is closed and the light switch is off. When the light switch is turned to the manual position, the headlights and the area lights will come on.

When the light switch is turned to the radio position, the headlights only (not the area lights) can be turned on and off with the radio.

The schematic shown in Fig. 71 is a typical lighting circuit. Always refer to the schematic in the Bucyrus parts book for your machine.

Fig. 71: Control headlights and area lights circuit

_______________________________________________________________ A6474X308 Rev. 0 5.113

Electrical________________________________________________________ Low oil circuit The low oil circuit indicates when the oil is low in the hydraulic oil tank.

The float switch energizes the LOR (low oil relay) and turns on the LOL (low oil light) in the case that the oil level becomes too low. The electrical circuit components are not located within an explosion proof enclosure are considered intrinsically safe circuits. A permissible ISC (intrinsically safe circuit) is incapable of producing a spark or a thermal effect.

The schematic shown in Fig. 72 is a typical low oil circuit. Always refer to the schematic in the Bucyrus parts book for your machine.

Fig. 72: Low oil circuit

_________________________________________________________________ 5.114 Bucyrus – Model 25C Continuous Miner

_______________________________________________________ Electrical Pump motor power circuit with control The pump motor can be started once the main and auxiliary circuit breakers, “CB1” and “CB2”, are closed and the methane monitor and emergency stop relays, “MMR” and “ESR” are closed. The pump motor must be started, closing the smart contactor, before any other function or motor on the machine can be activated.

The pump motor control system incorporates thermistors in the motor.

The thermistors send a signal to the control system, which is converted to a temperature. The control system can shutdown the pump motor, and thereby all machine functions, if the motor temperature exceeds a preset value.

The schematic shown in Fig. 73 is a typical pump motor circuit. Always refer to the schematic in the Bucyrus parts book for your machine.

Fig. 73: Pump motor circuit with control

_______________________________________________________________ A6474X308 Rev. 0 5.115

Electrical________________________________________________________ Fig. 73: Pump motor circuit with control, continued

_________________________________________________________________ 5.116 Bucyrus – Model 25C Continuous Miner

_______________________________________________________ Electrical Cutter motor power circuit with control The pump motor must be running before the cutter motors will start. To start the cutter motors, the “SHIFT” key is pressed and held and then the “CUTTER ON” key is pressed. This completes the circuit across coil “A” and starts the left cutter motor, as well as starting the Time Delay 2, “TD2”, timer for the “B” contactor right cutter motor. Both cutter motors do not start at the same time. When the timer times out, the circuit across coil “B” is completed and the right cutter motor will start.

The holding circuit interlock “A” and “B” must be closed. There are motor mates and thermistors on both motors that provide feedback to the control system on the operating state of the motors. In the event that an operating parameter exceeds a preset value, the operating system can shutdown the motors. To manually stop the cutter motors, depress “CUTTER STOP” switch.

The schematic shown in Fig. 74 is a typical cutter motor circuit. Always refer to the schematic in the Bucyrus parts book for your machine.

Fig. 74: Cutter motor circuit with control

_______________________________________________________________ A6474X308 Rev. 0 5.117

Electrical________________________________________________________ Fig. 74: Cutter motor circuit with control, continued

_________________________________________________________________ 5.118 Bucyrus – Model 25C Continuous Miner

_______________________________________________________ Electrical Conveyor (gathering head) motor circuit with control The pump motor must be running before the conveyor (gathering head) motors will start. The conveyor motors are started by pressing and holding the “SHIFT” key on the remote and then pressing the “CONV ON” key. This completes the circuit across coil conveyor forward (CF) and will start both conveyor motors. To stop the conveyor motors, press the “CONV OFF” key. There are motor mates and thermistors on both motors that provide feedback to the control system on the operating state of the motors. In the event that an operating parameter exceeds a preset value, the operating system can shutdown the motors.

The schematic shown in Fig. 75 is a typical conveyor motor circuit. Always refer to the schematic in the Bucyrus parts book for your machine.

Fig. 75: Conveyor (gathering head) motor circuit with control

_______________________________________________________________ A6474X308 Rev. 0 5.119

Electrical________________________________________________________ Fig. 75:Conveyor (gathering head) motor circuit with control, continued

_________________________________________________________________ 5.120 Bucyrus – Model 25C Continuous Miner

_______________________________________________________ Electrical Scrubber motor circuit with control The pump motor must be running before the scrubber motor will start.

The scrubber motor is started by pressing the “SHIFT” key and then “FAN ON” key, completing the circuit across coil “E”.

The schematic shown in Fig. 76 is a typical scrubber motor circuit. Always refer to the schematic in the Bucyrus parts book for your machine.

Fig. 76: Scrubber motor circuit with control

_______________________________________________________________ A6474X308 Rev. 0 5.121

Electrical________________________________________________________ Fig. 76: Scrubber motor circuit with control, continued

_________________________________________________________________ 5.122 Bucyrus – Model 25C Continuous Miner

_______________________________________________________ Electrical Tram motor circuit with control Circuit breakers CB1, CB2, and CBT must be closed and he pump motor must be running before the tram motors will start. The miner is trammed via the remote control. In the event that the miner loses remote control signal, the miner can be trammed via the emergency tram pendant.

The schematic shown in Fig. 77 is a typical tram motor circuit. Always refer to the schematic in the Bucyrus parts book for your machine.

Fig. 77: Tram circuit with control

_______________________________________________________________ A6474X308 Rev. 0 5.123

Electrical________________________________________________________ Fig. 77: Tram circuit with control, continued

_________________________________________________________________ 5.124 Bucyrus – Model 25C Continuous Miner

_______________________________________________________ Electrical Machine emergency stop circuit Power to the motor control circuits is isolated by an emergency stop relay, “ESR”. Relay “ESR” is controlled by two machine stop switches, on located at the operator’s station on the front of the controller case and the other on the off side of the machine. The second pole on each switch is also monitored by the control system, which will prevent motor start if either machine emergency stop is pressed.

The schematic shown in Fig. 78 is a typical machine emergency stop circuit. Always refer to the schematic in the Bucyrus parts book for your machine.

Fig. 78: Machine emergency stop circuit

_______________________________________________________________ A6474X308 Rev. 0 5.125

Electrical________________________________________________________ Main control valve solenoid circuit Power is supplied to the main control valve from the 120VAC control circuit. The solenoid on the main control valve control cutter head raise and lower, conveyor swing, conveyor lift, stabilizer shoe raise and lower, the scrubber, the dust/fire sprays, and breaker on/off functions.

The schematic shown in Fig. 79 is a typical main control valve bank solenoid circuit. Always refer to the schematic in the Bucyrus parts book for your machine.

Fig. 79: Main control valve solenoid circuit

_________________________________________________________________ 5.126 Bucyrus – Model 25C Continuous Miner

____________________________________________________ Maintenance Instructions on the maintenance Maintenance at regular intervals increases the operational safety and prolongs the service life of the machine. Observe the safety instructions in chapter 2 “Your safety”.

Important notes Please observe the following: ■

In order to avoid individual components not being serviced or being only inadequately serviced during maintenance work on the machine as a whole, we recommend that a general maintenance plan be drawn up. You can, for example, draw up a checklist using this operation manual and the manuals of the other components.

■

Inadequate maintenance can result in machine damage which leads to considerable costs.

■

Use only suitable and approved tools for maintenance work.

■

Use only original Bucyrus spare parts when replacing components.

■

All electrical work must be supervised and inspected by a certified electrician.

■

Anyone performing maintenance on this equipment must be trained to operate it and be familiar with this Bucyrus America, Inc. guide.

Before maintenance Please observe the following: ■

Shutdown the machine on level ground.

■

Disconnect the electrical power. The circuit breaker must be in the "OFF" position. If work is to be done inside the electrical controller, the power should be disconnected.

WARNING! Before performing maintenance on the machine the circuit breaker must be in the “OFF” position and the power should be disconnected at the main power source. Follow all Federal and Mine safety regulations for lockout/tagout procedures. Accidental machine movement or electrical shock can result in serious injury or death to you or other personnel.

______________________________________________________________ A6474X308 Rev. 0 5.127

Maintenance_____________________________________________________ ■

Only work on the miner in an area where the roof is properly supported.

■

Block any and all elevated assemblies before working under them.

Make sure that the blocking can support the weight of the assembly without slipping or failing.

■

Relieve all hydraulic pressures and position the levers and controls in Neutral or Off.

■

Test the controls to ensure that the unit will not move.

WARNING! Do not move any hydraulic control lever unless you are certain that everyone is completely clear of any machine movement.

Accidental machine movement can cause serious injuries or even death to you or the maintenance person.

■

Test the air for methane before and during any maintenance or repair work.

■

Do not perform maintenance on a circuit while there is a load resting on the hydraulic cylinder. Booms must be securely blocked if maintenance is to be performed with the boom in the raised position.

WARNING! Never disconnect a hydraulic hose if the circuit is pressurized or if there is a load on the circuit. If a hose is disconnected while the circuit is pressurized or a load is on the circuit, the load will fall causing damage to the machine or serious injury or death to you or other workers.

WARNING! You could be seriously injured or even killed by falling loads.

Observe the safe working load limits of lifting or blocking devices and keep a safe distance from suspended loads.

■

Do not perform maintenance in a congested area. This could endanger the maintenance person or others in the vicinity.

■

Whenever a potential problem is uncovered during a periodic maintenance check, it is imperative that it be corrected immediately by a qualified maintenance technician.

■

Cleanliness cannot be overemphasized as the essential ingredient of a good maintenance program. Machines should be kept as free as possible of dirt and debris which could impede performance or infiltrate systems and cause premature wear or failure.

_________________________________________________________________ 5.128 Bucyrus – Model 25C Continuous Miner

____________________________________________________ Maintenance Torque values When installing bolts, refer to the torque values on the drawings in the Bucyrus America, Inc. part book for your machine. If a torque value is not listed, refer to Chapter 6 of this manual for standard torque values.

Lubricants and fluid capacities Get capacities

Table 3: Lubricants and fluid capacities Location

Specification

Approximate capacity

Notes

Hydraulic oil tank GH Assembly CLA Primary GH Assembly CLA POT Tram Drive Assembly Input Cutter Head Gear Case Reach Cutter Head Gear Case Final Cutter Head Gear Case Motor Lube Hoses

Spec. 100-1 Spec. 100-15 Spec. 100-15 Spec. 100-15 Spec. 100-15 Spec. 100-15 Spec. 100-15 Spec. 100-14

72 gal (273 L) 1 gal (3.79 L) 2.5 gal (9.46 L) 3 gal (11.36 L) 3.7 gal (14.01 L) 6 gal (22.71 L) 3.5 gal (13.25 L) Variable

1

Notes: 1. All motor lube hoses are to be filled with high temperature electric motor grease (Spec. 100-14) before assembling them to the electric motor to ensure that there are no air gaps between the grease nipple and the point where the grease enters the motor.

______________________________________________________________ A6474X308 Rev. 0 5.129

Maintenance_____________________________________________________ Table 4: Lubrication and maintenance schedule Item

Description

Places

Lubricant

Specification

Every Shift 1

Cutter head lift cylinder pins, upper

2

Lithium based grease

Spec. 100-3

2

Cutter head lift cylinder pins, lower

2

Lithium based grease

Spec. 100-3

3

Conveyor swing cylinder pin, front

1

Lithium based grease

Spec. 100-3

4

Conveyor swing cylinder pin, rear

1

Lithium based grease

Spec. 100-3

5

Cutter head frame pivot pin, right

1

Lithium based grease

Spec. 100-3

6

Cutter head frame pivot pin, left

1

Lithium based grease

Spec. 100-3

7

Cutter head bits

Inspect

8

Scrubber screen

Clean

9

Daily Conveyor roller

1

Lithium based grease

Spec. 100-3

10

Gathering head pivot pin, left

1

Lithium based grease

Spec. 100-3

11

Gathering head pivot pin, right

1

Lithium based grease

Spec. 100-3

12

Crawler idler roller

2

Lithium based grease

Spec. 100-3

13

Conveyor raise cylinder pin, upper

2

Lithium based grease

Spec. 100-3

14

Conveyor swing pivot pins

Lithium based grease

Spec. 100-3

15

Gathering head cylinder pin, upper

2

Lithium based grease

Spec. 100-3

16

Gathering head cylinder pin, lower

2

Lithium based grease

Spec. 100-3

17

Stabilizer shoe pin

2

Lithium based grease

Spec. 100-3

18

Conveyor chain take-up pin

2

Lithium based grease

Spec. 100-3

19

CLA head pot assembly (Check)

2

High demulsibility EP gear oil

Spec. 100-15

20

CLA head transfer case (Check)

2

High demulsibility EP gear oil

Spec. 100-15

21

Tram gear case (Check)

2

High demulsibility EP gear oil

Spec. 100-15

22

Input cutter head gear case (Check)

2

High demulsibility EP gear oil

Spec. 100-15

23

Reach cutter head gear case (Check)

2

High demulsibility EP gear oil

Spec. 100-15

24

Final cutter head gear case (Check)

2

High demulsibility EP gear oil

Spec. 100-15

25

Hydraulic oil level (Check)

1

AW hydraulic oil

Spec. 100-1

26

Weekly Return filter element (Change)

1

27

Pilot pressure filter element (Change)

1

28

Pressure filter element (Change)

1

29

Crawler chain (Inspect)

2

30

Conveyor chain (Inspect)

31

Fasteners (nuts, bolts, screws)

Inspect

32

Electrical cables, conduits, and glands

Inspect

33

Hydraulic/water hoses and connections

Inspect

34

Lighting

Inspect

35

Reflectors and warning tags

Inspect

36

Machine stop switch (Inspect)

37

Scrubber

1

2 Clean

_________________________________________________________________ 5.130 Bucyrus – Model 25C Continuous Miner

____________________________________________________ Maintenance Table 4 (continued): Lubrication and maintenance Item

Description

Places

Lubricant

Specification

2 2 2 2 2 Inspect 2 2 2 2 2 2 2 1

High demulsibility EP gear oil High demulsibility EP gear oil High demulsibility EP gear oil High demulsibility EP gear oil High demulsibility EP gear oil

Spec. 100-15 Spec. 100-15 Spec. 100-15 Spec. 100-15 Spec. 100-15

Sample Sample High demulsibility EP gear oil Sample Sample Sample Sample Sample

See Note 1 See Note 1 Spec. 100-15 See Note 1 See Note 1 See Note 1 See Note 1 See Note 1

High temperature lithium complex grease High temperature lithium complex grease High temperature lithium complex grease High temperature lithium complex grease

Spec. 100-14

38 39 40 41 42 43 44 45 46 47 48 49 50 51

Monthly CLA head pot assembly (Change) CLA head transfer case (Change) Input cutter head gear case (Change) Reach cutter head gear case (Change) Final cutter head gear case (Check) CLAs Input cutter head gear case Reach cutter head gear case Final cutter head gear case (Check) CLA head pot assembly CLA head transfer case Tram gear case Crawler idler roller Main hydraulic tank

52

Every three months Cutter motor bearings

4

53

Gathering head motor bearings

4

54

Pump motor bearings

2

55

Scrubber motor bearings

2

56

Every six months Tram gear case (Change)

2

High demulsibility EP gear oil

Spec. 100-15

57 58 59

Hydraulic oil (Change) Water filter (strainer) (Change) Breathers (Change)

1 1 All

AW hydraulic oil

Spec. 100-1

Spec. 100-14 Spec. 100-14 Spec. 100-14

Note 1: When the oil sample and oil change interval are identical, a sample of the old oil is to be taken and sent for analysis prior to changing the oil (see the Oil sampling procedure in this chapter). Always inspect breathers when taking hydraulic oil samples.

______________________________________________________________ A6474X308 Rev. 0 5.131

Maintenance_____________________________________________________ Fig. 80: Lubrication chart 7

23,41,45 22,40,44

19,38,47 20,39,38 16 6,10,11,15 12,50,56 29

37

21,49

25,26, 58 8

27 7 28

4

14 13

3

18

30

9

9

_________________________________________________________________ 5.132 Bucyrus – Model 25C Continuous Miner

____________________________________________________ Maintenance Specific lubrication and maintenance procedures Every shift cutter head lift cylinder pins (upper and lower)

Lubricate the right and left cylinder pins (upper and lower) through the grease fittings located on each cylinder (Fig. 81). Pump approximately 3 cu. in. (50 cu. cm.) into each fitting.

Fig. 81: Cutter head cylinder pin location

Cutter head cylinder pin (upper) (2)

Cutter head cylinder pin (lower) (2) (remote lube block)

______________________________________________________________ A6474X308 Rev. 0 5.133

Maintenance_____________________________________________________ conveyor swing cylinder pin (front and rear)

Lubricate the front and rear conveyor swing cylinder pins through the grease fittings located on each end of the cylinder (Fig. 82). Pump approximately 3 cu. in. (50 cu. cm.) into each fitting.

Fig. 82: Conveyor swing cylinder pin lubrication

Conveyor swing cylinder pin, rear

cutter head pivot pin (left and right)

Conveyor swing cylinder pin, front

Lubricate left and right cutter head pivot pins through the grease fittings located on the left and right front lubrication blocks (Fig. 83). Pump approximately 3 cu. in. (50 cu. cm) of grease into each fitting.

Fig. 83: Cutter head pivot pins

Cutter head frame pivot pin lube block

_________________________________________________________________ 5.134 Bucyrus – Model 25C Continuous Miner

____________________________________________________ Maintenance cutter head bits

Inspect the cutter head bits to ensure that they will rotate in their holders and for damaged or missing bits (Fig. 84). Replace bits immediately if any are missing or damaged.

Fig. 84: Cutter head bits (typical) Bit holder

Bit

______________________________________________________________ A6474X308 Rev. 0 5.135

Maintenance_____________________________________________________ scrubber cleanout

Cleanout the scrubber every shift.  Open the scrubber screen access cover (Fig. 85).  Remove the scrubber screen and wash.  Remove the demistor cell and wash.  Using the washdown hose, spray out the scrubber. Spray forward and out the front of the scrubber.  Wash out the demistor sump.

Fig. 85: Scrubber screen access cover

Scrubber screen access cover

_________________________________________________________________ 5.136 Bucyrus – Model 25C Continuous Miner

____________________________________________________ Maintenance Daily conveyor roller

Lubricate the conveyor roller through the grease fittings located on the shaft (Fig. 86). Pump approximately 3 cu. in. (50 cu. cm.) into each fitting.

Fig. 86: Conveyor roller lubrication

Grease fitting (behind flight)

gathering head pivot pins (right and hand)

Grease fitting (behind flight)

Lubricate the left and right upper and lower gathering head cylinder pins through the grease fittings located on the left and right front lubrication blocks (Fig.87). Pump approximately 3 cu. in. (50 cu. cm.) of grease into each fitting.

Fig. 87: Gathering pivot pin (typical both sides)

Gathering head hinge pin

______________________________________________________________ A6474X308 Rev. 0 5.137

Maintenance_____________________________________________________ crawler idler roller (right and left)

Lubricate the left and right crawler idler rollers (Fig. 88) through the grease fittings located on the outside face of the crawler idler roller.

Fig. 88: Crawler idler roller

Crawler idler roller

conveyor raise cylinder pin (right and left)

Lubricate the conveyor raise cylinder pins (right and left) through the grease fittings located on the lubrication block on the right side of the machine (Fig. 89). Pump approximately 3 cu. in (50 cu. cm) of grease into each fitting.

Fig. 89: Conveyor lift pins

Lubrication block

_________________________________________________________________ 5.138 Bucyrus – Model 25C Continuous Miner

____________________________________________________ Maintenance conveyor swing pivot pins (top and bottom)

Lubricate the top and bottom conveyor swivel pin located on the pins (Fig. 90). Pump approximately 3 cu. in (50 cu. cm) of grease into each fitting.

Fig. 90: Conveyor swivel pins

Conveyor swivel pin (top)

Conveyor swivel pin (bottom)

gathering head raise cylinder pins (left and right)

Lubricate the gathering head raise cylinder pins (Fig. 91) through the grease fittings located on each end of the cylinder. Pump approximately 3 cu. in (50 cu. cm) of grease into each fitting.

Fig. 91: Gathering head raise cylinder pins Gathering head raise cylinder pin (upper)

Gathering head raise cylinder pin (lower)

______________________________________________________________ A6474X308 Rev. 0 5.139

Maintenance_____________________________________________________ stabilizer shoe pin (right and left)

Lubricate the stabilizer shoe pins (right and left) through the grease fittings located on the lubrication block on the right side of the machine (Fig. 92). Pump approximately 3 cu. in (50 cu. cm) of grease into each fitting.

Fig. 92: Stabilizer shoe grease fittings Stabilizer cylinder pivot, rh

Stabilizer cylinder pin, rh Stabilizer cylinder pin, lh Stabilizer cylinder pivot, lh Stabilizer shoe pivot

conveyor chain take-up pin (left and right)

Lubricate the conveyor chain take-up pin (Fig. 93) through the grease fitting located on the pin. Pump approximately 3 cu. in (50 cu. cm) of grease into each fitting.

Fig. 93: Conveyor chain take-up pin

Conveyor chain take-up pin

_________________________________________________________________ 5.140 Bucyrus – Model 25C Continuous Miner

____________________________________________________ Maintenance CLA head pot assembly (right and left)

Level the miner and place the gathering head on grade before checking or adding lubricant. Check the oil level in the pot assembly (Fig. 94). If oil is needed, add oil through the fill hole until oil comes out of the breather.

CLA head transfer case (right and left)

Level the miner and place the gathering head on grade before checking or adding lubricant. Check the oil level in the hydraulic transfer case (Fig. 94). If oil is needed, add oil through the fill hole until oil comes out of the breather.

Fig. 94: CLA head pot assembly and transfer case lubrication Transfer case check plug

Pot check plug

Transfer case fill plug Pot fill plug

tram gear case (right and left)

With the miner in a level position, check the oil level in both tram gear cases by looking at the sight glass located on the side of each gear case (Fig. 95). Oil should be visible in each sight glass. If oil level is low, add oil through the fill plug hole.

Fig. 95: Tram gear case oil level

Oil fill

Oil check

______________________________________________________________ A6474X308 Rev. 0 5.141

Maintenance_____________________________________________________ input cutter gear case reach cutter gear case

With the gathering head lowered to ground level and the cutter head boom level with ground, check the oil level in both input and reach cutter gear cases through the sight glasses located on each side of the cutter head assembly (Fig. 96). If oil level is low, add oil through the fill plugs located on each side of the gathering head.

Fig. 96: Input and reach cutter head gear case oil levels Input fill plug (one per side)

Reach fill plug (one per side)

Input sight glass (typical both sides)

Reach sight glass (typical both sides)

final cutter gear case

With the cutter head boom level with ground, check the oil level in both of the main cutter head gear cases by removing the check plug located on the front of each gear case (Fig. 97). Oil should flow from check plug hole when plug (s) is removed. If oil level is low, add oil through the fill plug hole located on top of each gear case.

Fig. 97: Final cutter head gear case oil levels Oil fill plug (one per side)

Oil check plug (one per side)

_________________________________________________________________ 5.142 Bucyrus – Model 25C Continuous Miner

____________________________________________________ Maintenance hydraulic oil level

Check the hydraulic oil level using the read out on the main page of the graphics display on the operator’s case on the right hand side of the machine (Fig. 98).

If the oil level is low, add oil as follows: Hydraulic oil power fill procedure  Open the diversion valve (Fig. 958.  Check that the hydraulic tank overflow is obstruction free (Fig. 98).

WARNING! If the hydraulic overflow is blocked during power fill operations, the hydraulic tank will become pressurized during the power fill procedure and damage to the air reservoirs may result.  Activate the “CONVEYOR DOWN” function on the remote control to begin power fill.  Add oil until oil flow from the overflow.  Verify that the oil level is OK on t he main page of the graphics display.  Closes the diversion valve.

Fig. 98: Hydraulic oil level

Hydraulic oil level

Hydraulic oil fill hose

Hydraulic oil overflow

______________________________________________________________ A6474X308 Rev. 0 5.143

Maintenance_____________________________________________________ Weekly pressure filter

Change the pressure filter element (Fig. 99). If the element is extremely dirty, a more frequent change interval may be required.

pilot pressure filter

Change the pilot pressure filter element (Fig. 99). If the element is extremely dirty, a more frequent change interval may be required.

return filter

Change the return filter element (Fig. 99). If the element is extremely dirty, a more frequent change interval may be required.

Fig. 99: Hydraulic filter locations

Return filter

Pilot pressure filter

Pressure filter

_________________________________________________________________ 5.144 Bucyrus – Model 25C Continuous Miner

____________________________________________________ Maintenance crawler track tension

Check the crawler tracks for proper tension. If adjustment is necessary, see the Crawler track adjustment procedure in this chapter.

To check for proper tension (Fig. 100):  Raise the complete crawler assembly off of the ground and securely block under the machine. The machine must be securely supported off the ground.

WARNING! Observe the safe working load limits of all lifting and blocking devices. You could be seriously injured or killed by falling loads.  Chain sag should be 2-1/2 to 3-1/2 inches at the center of the crawler.

Fig. 100: Crawler track tension measurement Bottom of tractor wear shoe

conveyor chain tension

2-1/2 to 3-1/2 inches (64 to 90 mm gap)

Top of tram track

Check the conveyor chain tension with the machine running. The conveyor chain should rise about 51 mm (2 inches) or less above the gathering head foot shaft sprocket as the chain emerges from under the conveyor pan (Fig. 101). If adjustment is necessary, see the Conveyor chain tension adjustment procedure in this chapter.

Fig. 101: Conveyor chain tension measurement

Chain measurement area

______________________________________________________________ A6474X308 Rev. 0 5.145

Maintenance_____________________________________________________ fasteners

Due to the machine being subjected to continual shock loading and vibration, close attention to all mounting bolts and screws is required.

Loose fasteners will cause premature wear and failure to bearings, couplings, etc. Inspect and tighten as required fasteners on the following: ■ cutter head gear case ■ cutter head motors ■ center drums ■ end drums ■ tram cases ■ tram motors ■ gathering head CLAs ■ gathering head pots ■ gathering head motors

electrical cables, conduits, and glands hoses and fittings

Visually inspect all electrical cables and glands for signs of wear or damage.

Visually inspect and hydraulic and water hoses and fittings for signs of wear, damage, or leakage. This inspection should be performed with the machine running.

WARNING! Use extreme caution when inspecting for leaks with the machine running. Unexpected machine movement, or contact with moving parts, could result in injury.

WARNING! Escaping fluids under pressure can penetrate skin and cause serious personal injury. Do not attempt to locate hydraulic leaks by feeling around hoses and fittings with bare hands. "Pin-hole" leaks can penetrate the skin.Observe the following precautions to avoid hydraulic hazards: ■ Always relieve pressure before disconnecting hoses.

■ Check for leaks with a piece of cardboard. Do not use hands to check for leaks!

■ Do not exceed working pressure of hydraulic hoses.

■ Visually inspect hoses regularly and replace if damaged.

_________________________________________________________________ 5.146 Bucyrus – Model 25C Continuous Miner

____________________________________________________ Maintenance lighting

Turn on the lights and visually inspect for bulbs that need to be replaced.

reflectors and warning tags

Visually inspect the condition and readability of all warning tags, labels, and reflectors for signs of wear or damage. Replace any reflector or tag that is missing or damaged.

machine stop switches

Check the machine stop switches located on each side of the machine for proper operation. Start the machine and strike the machine stop switch. The machine pump motor will shutdown, in turn shutting down all other motors. Repeat for the other switch.

scrubber cleaning

Clean the scrubber (Fig. 102) as follows:   Lower the gathering head and cutter head assemblies until they touch the floor.  Lower the conveyor assembly until it is level with the floor.  Disconnect the trailing cable to de-energize the miner.

WARNING! Follow all Federal and mine regulations regarding lockout/tagout procedures. Failure to do so may result in serious injury or death.  Insert a hose in the scrubber air intake at the front of the miner.

Thoroughly flush the scrubber inlet duct.  Remove any accumulated debris from inside the duct. Insert the hose into the duct and thoroughly flush it with water.

Fig. 102: Scrubber cleaning

Scrubber intake

______________________________________________________________ A6474X308 Rev. 0 5.147

Maintenance_____________________________________________________ Monthly CLA head pot assembly

Change the oil in both CLA head pot assemblies (Fig. 103).  Level the miner, raise the gathering head pan, and secure in place.  Clean dirt and debris from around the drain plug located under the gear case.  Remove the drain plug and allow oil to completely drain from the gear case.  Clean and reinstall drain plug.  Clean dirt and debris from around the check plug and remove the plug.  Clean dirt and debris from around the fill plug and remove the plug.  Slowly add oil through the fill plug until oil begins to flow from the check plug hole. Allow sufficient time for the oil to travel through the gear case when filling.  Clean and reinstall the check and fill plugs.

CLA head transfer case

Change the oil in both CLA head transfer cases (Fig. 103).  Level the miner, raise the gathering head pan, and secure in place.  Clean dirt and debris from around the drain plug located under the gear case.  Remove the drain plug and allow oil to completely drain from the gear case.  Clean and reinstall drain plug.  Clean dirt and debris from around the check plug and remove the plug.  Clean dirt and debris from around the fill plug and remove the plug.  Slowly add oil through the fill plug until oil begins to flow from the check plug hole. Allow sufficient time for the oil to ravel through the gear case when filling.  Clean and reinstall the check and fill plugs.

NOTICE! If the gear case is scheduled for oil drain and refill, obtain the oil sample prior to the oil change.

IMPORTANT! Always collect oil samples using a siphon pump. Do not remove the drain plug and collect oil by allowing it to run out into the bottle.

_________________________________________________________________ 5.148 Bucyrus – Model 25C Continuous Miner

____________________________________________________ Maintenance Fig. 103: CLA pot assembly and transfer case Transfer case check plug

Pot check plug

Transfer case fill plug Pot fill plug

______________________________________________________________ A6474X308 Rev. 0 5.149

Maintenance_____________________________________________________ input cutter head gear case reach cutter head gear case

Change the oil in both input and reach cutter head gear cases (Fig.104).  Position the cutter head horizontally (flat back in a vertical position).

Clean dirt and debris from around the drain plug located under the gear case.  Remove the drain plug and allow oil to completely drain from the gear case.  Clean and reinstall the drain plug.  Clean dirt and debris from around the check plug and remove the plug.  Clean dirt and debris from around the fill plug and remove the plug.  Slowly add oil through the fill plug until oil begins to flow from the check plug hole. Allow sufficient time for the oil to travel throughout the gear case when filling.  Clean and reinstall the check and fill plugs.

Fig. 104: Input and reach cutter head gear case Input fill plug (one per side)

Rech fill plug (one per side)

Input sight glass (typical both sides)

Reach sight glass (typical both sides)

NOTICE! If the gear case is scheduled for oil drain and refill, obtain the oil sample prior to the oil change.

IMPORTANT! Always collect oil samples using a siphon pump. Do not remove the drain plug and collect oil by allowing it to run out into the bottle.

_________________________________________________________________ 5.150 Bucyrus – Model 25C Continuous Miner

____________________________________________________ Maintenance final cutter head gear case

Change the oil in both main cutter head gear cases (Fig. 105).  Lower the cutter head completely to the ground. Clean dirt and debris from around the drain plug, located under the gear case.  Remove the drain plug and allow oil to completely drain from the gear case.  Clean and reinstall the drain plug.  Clean dirt and debris from around the check plug and remove the plug.  Clean dirt and debris from around the fill plug and remove the plug.  Slowly add oil through the fill plug until oil begins to flow from the check plug hole. Allow sufficient time fro the oil to travel throughout the gear case when filling.  Clean and reinstall the check and fill plugs.

Fig. 105: Main cutter head gear case Oil fill plug (one per side)

Oil check plug (one per side)

______________________________________________________________ A6474X308 Rev. 0 5.151

Maintenance_____________________________________________________ CLAs

Inspect the CLAs (Fig. 106) for damage. If a CLA needs replaced, see CLA removal and installation procedure in this chapter.

Fig. 103: CLAs

CLA

CLA

Oil sampling plan This plan contains specific instructions to be followed in order to correctly collect gear case lubricant samples, and preparation of the samples for laboratory analysis. Adherence to these instructions will insure that all oil sample analysis reports give an accurate picture of the oils condition as well as wear trends of gears, bearings, etc. Accurate reporting and analysis of oil samples will prove extremely beneficial providing a tool to allow planning of scheduled down-time and prevention of costly equipment breakdown.

Preparation prior to sample collection For each machine to be sampled, you will need a supply of sample collection bottles and identification labels (Fig. 104) sufficient to sample each identified gear case (every sixty shifts).

One sample bottle and collection hose is required for each gear case to be sampled. Label each container with the identifying name of the gear case (crawler gear case, left or cutter head gear case, right front, etc.).

Collection of oil samples NOTICE! If the gear case is scheduled for oil drain and refill, obtain the oil sample prior to the oil change.

IMPORTANT! Always collect oil samples using a siphon pump. Do not remove the drain plug and collect oil by allowing it to run out into the bottle.

_________________________________________________________________ 5.152 Bucyrus – Model 25C Continuous Miner

____________________________________________________ Maintenance IMPORTANT! Always use the collection hose provided with each bottle. Always discard hose immediately following collection of the oil and do not use it for the next sample. To do so will contaminate the next sample with oil from the previous sample.

After taking sample, check and refill gear case back to proper fill level.

Following collection of all oil samples, record the specific brand and product name of the lubricant that has been installed in each gear case.

Recommended gear cases to be sampled: ■

Input cutter head gear case (left and right)

■

Main cutter head gear case (left and right)

■

Input gathering head gear case (left and right)

■

Main gathering head gear case (left and right)

■

Tram gear case (left and right)

■

Main hydraulic oil tank

Fig. 107: Oil sampling procedure Oil fill plug

Typical siphon pump and bottle

Oil level

Place end of siphon tube approximately half way into sump

Note: Hold sample pump and bottle below oil level

______________________________________________________________ A6474X308 Rev. 0 5.153

Maintenance_____________________________________________________ Every three months IMPORTANT! For motor bearings that require high temperature lithium complex grease, Bucyrus provides a special “button” style lubrication fitting to prevent the accidental use of multi-purpose lithium complex grease at these locations. cutter motor bearings

Lubricate the left and right cutter head motor bearings (Fig. 108) with high temperature lithium complex grease through the grease fittings located on each side of the cutter head assembly . To lubricate the motors:  Remove the plugs (enter and exit).  Lubricate both motor bearings using the fitting until new grease appears out of the exit side of the bearing (bottom plug).  Operate the motor for five minutes.  Inspect for any grease leakage in the area around the bearing.  Replace the plugs..

NOTICE! Incorrect grease or over greasing of the electric motor may cause serious damage to the motor. Follow the greasing procedure outlined above.

Fig. 108: Cutter motor bearing lubrication Entry plug

Exit plug

_________________________________________________________________ 5.154 Bucyrus – Model 25C Continuous Miner

____________________________________________________ Maintenance gathering head motor bearings

Lubricate the left and right gathering head motor bearings with high temperature lithium complex grease through the two grease fittings located on each motor.

To lubricate the motors:  Open the cover (Fig. 109) to access the motor.  Inspect the grease fittings on the exit side of the front and rear motor bearing.

If the exit side motor bearing ports are equipped with spring load relief fittings, then Lubricate both motor bearings using the button type grease fitting until new grease appears out of the relief ports on the exit side of the bearing.  Operate the motor for five (5) minutes and then inspect for grease leaks in the bearing area.

If the exit side motor bearing ports are equipped with plugs, then:  Remove the plug and lubricate both motor bearings using the button type grease fitting until new grease appears out of the relief ports on the exit side of the bearing.  Operate the motor for five (5) minutes and then inspect for grease leaks in the bearing area.  Replace the plugs in the ports.

NOTICE! Incorrect grease or over greasing of the electric motor may cause serious damage to the motor. Follow the greasing procedure outlined above.

Fig. 109: Gathering head motor bearing lubrication Bearing grease fittings located behind cover

______________________________________________________________ A6474X308 Rev. 0 5.155

Maintenance_____________________________________________________ IMPORTANT! For motor bearings that require high temperature lithium complex grease, Bucyrus provides a special “button” style lubrication fitting to prevent the accidental use of multi-purpose lithium complex grease at these locations. pump motor bearings

Lubricate the pump motor (Fig. 110) with high temperature lithium complex grease through the two (2)grease fittings located the right side of the machine . To lubricate the motors:  Swing the rub rail and the operator’s case out to expose the pump motor.  Remove the cover to access the motor.  Inspect the grease fittings on the exit side of the front and rear motor bearing.

If the exit side motor bearing ports are equipped with a spring loaded relief fitting :  Lubricate both motor bearings using the “button” fittings until new grease appears out of the relief port on the exit side of the bearing.  Operate the motor for five minutes.  Inspect for any grease leakage in the area around the bearing.

If the grease fitting on the exit side of the motor bearing is fitted with a plug:  Remove the plug.  Lubricate both motor bearings using the “button” fitting until new grease appears out of the exit side of the bearing.  Operate the motor for five minutes.  Inspect for any grease leakage in the area around the bearing.  Replace the plug.

NOTICE! Incorrect grease or over greasing of the electric motor may cause serious damage to the motor. Follow the greasing procedure outlined above.

_________________________________________________________________ 5.156 Bucyrus – Model 25C Continuous Miner

____________________________________________________ Maintenance Fig. 110: Pump motor bearings

Pump motor location

Operator’s case (swing open to expose pump motor)

Rub rail (swing open to allow operator’s case to swing out)

______________________________________________________________ A6474X308 Rev. 0 5.157

Maintenance_____________________________________________________ IMPORTANT! For motor bearings that require high temperature lithium complex grease, Bucyrus provides a special “button” style lubrication fitting to prevent the accidental use o f multi-purpose lithium complex grease at these locations. scrubber motor bearings

Lubricate the scrubber motor bearings (Fig. 111) with high temperature lithium complex grease through the grease fittings located on the scrubber side of the machine. To lubricate the motors:   Remove the cover to access the motor.  Remove grease plug (s) on exit side of bearing (s).  Lubricate bearing using “button” fitting until new grease appears out of open port on exit side of bearing (s).  Operate motor (s) for five (5) minutes.  Replace grease plug (s) in all port (s).

NOTICE! Incorrect grease or over greasing of the electric motor may cause serious damage to the motor. Follow the greasing procedure outlined in previous instructions.

Fig. 111: Scrubber motor bearings Scrubber motor

_________________________________________________________________ 5.158 Bucyrus – Model 25C Continuous Miner

Maintenance_____________________________________________________ Every six months tram gear cases

Change the oil in both tram gear cases (Fig. 112).  Remove the drain plug and allow oil to completely drain from the gear case.  Clean and reinstall the drain plug.  Remove the fill plug located on top of the gear case.  Add oil through the fill plug hole until oil is visible in the sight glass.

When filling, allow sufficient time for the oil to travel throughout the gear case.  Clean and reinstall the fill plug.

Fig. 112: Tram gear case

Oil fill

Oil check

_________________________________________________________________ 5.159 Bucyrus – Model 25C Continuous Miner

Maintenance_____________________________________________________ hydraulic oil

Change the oil in the hydraulic oil tank (Fig. 113).  Clean all dirt and debris from around the fill cap and the drain plug.  Remove the drain plug and allow the oil tank to completely drain.  Clean and reinstall the drain plug.  Inspect and clean oil overflow, making sure there are no obstructions to overflow.

WARNING! The hydraulic oil tank overflow must be obstruction free during the power fill procedure to prevent pressurization of the hydraulic tank. Obstructing or blocking the overflow will result in hydraulic oil tank pressurization and may damage the air reservoirs (Kleenvent reservoirs).  Fill the tank with oil using the power fill pump until the oil level reaches the full level as indicated on the dipstick. The hydraulic tank capacity is 73 gal (273 L), hydraulic system capacity is 82 gal (310 L). To activate the power fill:  Open the diversion valve.  Engage the conveyor down function.  After filling, start the machine and engage all cylinders for the full length of travel (full extend and retract) in order to purge the hydraulic system of air.  Check the oil level on the graphics display on the operator’s case on the right hand side of the machine. Add additional oil as required until oil level is “OK”.

Fig. 113: Hydraulic oil change Hydraulic oil fill hose

Hydraulic oil overflow

Hydraulic oil level display

_________________________________________________________________ 5.160 Bucyrus – Model 25C Continuous Miner

____________________________________________________ Maintenance water filter (strainer)

Change the water circuit filter (Fig. 114).

Fig. 114: Water filter Water filter

gear case breathers

Change the breathers on the main and input cutter gear cases, the CLA head pot and transfer gear cases, and the tram gear cases (Fig. 115).

Fig. 115: Gear case breather locations CLA transfer case breather

CLA pot breather

Breather

Input cutter gear case breather

CLA head pot and transfer case breathers

______________________________________________________________ A6474X308 Rev. 0 5.161

Maintenance_____________________________________________________

_________________________________________________________________ 5.162 Bucyrus – Model 25C Continuous Miner

___________________________________________ Adjustment procedures Setting hydraulic pressures ■

Always refer to the hydraulic schematic in the Bucyrus America, Inc. parts book supplied with your miner.

■

Most relief valves are set to factory specifications and should require no further adjustment. If a problem occurs which requires the reliefs to be adjusted, make certain the correct procedures are followed and all work is performed by a qualified person.

■

Remember when adjusting relief valves that turning the adjusting screw in (clockwise) will increase the pressure setting.

WARNING! Use extreme caution when performing test procedures and making adjustments. Unless noted in the procedures, all controls are to be in the neutral position.

The miner is equipped with a multi-station gauge on the right hand side of the machine to aid in setting relief pressures. The gauge will read the following pressures: ■

main pump pressure,

■

pilot pressure,

■

load sense pressure,

■

regulated pilot pressure,

■

gathering head assist valve pressure, and

■

conveyor chain take-up pressure.

There will be occasions when relief valves, or other pressure control valves, must be set or adjusted. Setting relief valve pressure is necessary when a relief valve is replaced with a new unit or when an existing relief valve needs to be adjusted, for example, during the course of troubleshooting a hydraulic system fault. This section describes the proper procedure for setting the relief valves.

IMPORTANT! Always use the proper tools when adjusting valve cartridges.

IMPORTANT! Do not start any motors - CLA, cutter head, pump, or traction motors - until all pressures are set. Start the pump motor as directed.

______________________________________________________________ A6474X308 Rev. 0 5.163

Adjustment procedures ___________________________________________ Load holding valve adjustment The load holding valve is factory preset and should not be field adjusted.

Always refer to the Bucyrus parts manual for your machine when ordering load holding valves for the cutter or conveyor cylinders.

Never rely on the load holding valve as a means of supporting the cutter boom or conveyor boom while making repairs. Always support the cutter boom and conveyor boom with adequate material before working around or underneath the cutter or conveyor.

WARNING! Never rely on the load holding valve as a means of supporting the cutter or conveyor boom while making repairs. Severe injury or death could result.

Adjustment procedures should start with the pilot pressure circuit because this system is a “closed center circuit” and will build pressure as soon as the pump is started. The main flow-primary pressure circuit is an “open-center circuit” and no pressure is present in this circuit until a function is activated.

Reference the Hydraulic section of this chapter and the schematic in your parts manual for detailed information on each hydraulic circuit.

_________________________________________________________________ 5.164 Bucyrus – Model 25C Continuous Miner

___________________________________________ Adjustment procedures Pilot pump circuit relief valve adjustments The following procedure is for start up of new and rebuilt machines.

Reference Fig. 116.

IMPORTANT! Reference the Hydraulic section in this chapter for individual circuit information. Always refer to the hydraulic schematic in your Bucyrus America, Inc. parts manual for your miner.

WARNING! Two people are required to adjust pressure settings. One person will make the adjustments while the second person must remain at the “E-STOP” at all times during the adjustment procedure.

Failure to do so may result in serious injury or death.  Turn the multi-gauge to position 2: Pilot pressure   Reduce pilot pressure circuit Loosen the nut on the relief valve cartridge (cartridge “N” located in the pilot/water manifold) and turn the screw out (counter-clockwise) using an Allen wrench to prevent over pressuring the gauge on this circuit.  Conveyor chain take-up circuit Open the needle valve “NV2” by turning the knob counterclockwise, opening flow to tank.  Close needle valve “NV1” by turning the knob clockwise.  Start the pump motor (see Startup procedure in this chapter) and adjust the pilot relief valve.  Loosen the nut on the valve cartridge and, using an Allen wrench, turn the screw in (clockwise) to increase pressure or out (counter-clockwise) to decrease pressure. Multi-gauge positions 2 and 4 should read 600 psi.

IMPORTANT! Before making any further adjustments, verify that the hydraulic oil is at operating temperature.

______________________________________________________________ A6474X308 Rev. 0 5.165

Adjustment procedures ___________________________________________  Adjust the conveyor chain take-up valve  Close the needle valve “NV2” by turning the knob clockwise, opening flow to the take-up cylinders. Multi-gauge position 6 should read 200 psi.  Remove the hex socket head plug to adjust the inner spool.

Using an Allen wrench, turn the screw in (clockwise) to increase pressure or out (counter-clockwise) to decrease pressure.  Replace the hex socket head plug.

Relief valve replacement  Pilot relief valve replacement: Set the pilot relief to 600 psi, per Step 3, making sure that the conveyor chain take-up knob is closed (turn clockwise to close).  Conveyor chain take-up valve replacement: Set the pilot relief to 175 psi, per Step 4, making sure the conveyor chain take-up knob is closed (turn clockwise to close).

Fig. 116: Pilot/water manifold

Pilot/water manifold

Pilot relief valve

“NV1”

“NV2”

_________________________________________________________________ 5.166 Bucyrus – Model 25C Continuous Miner

___________________________________________ Adjustment procedures Tram track adjustment  Lower the conveyor tail section until it is level with the floor.  Raise the gathering head and cutter head and block both assemblies following standard blocking procedures.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all blocking devices.  Lower the gathering head and cutter head onto the blocking so that the front end of the miner lifts off the floor.  Extend the stabilizer completely so that the rear end of the miner lifts off the floor.  Securely block under the machine. The machine must be securely supported off the ground with the tram track free to turn.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load of all blocking devices.  Raise the stabilizer, gathering head, and cutter head assemblies so that the weight of the miner rests on the blocking.  Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine lockout/tagout regulations.

WARNING! Follow all Federal and mine lockout/tagout regulations and procedures. Failure to do so could result in machine damage or serious injury or death to personnel.  Double check the tractor frame support blocking now that the weight of the tractor frame is completely upon it.  Evaluate the tram track for proper tension (Fig. 117). The tram track is at the proper tension when it hangs approximately 2 1/2” to 3 1/2” from the bottom wear shoes when the tractor frame is blocked off the floor. Using this evaluation, determine whether step 13, 14, or 15 provides the appropriate sub-procedure to correct improper track tension.

Fig. 117: Tram track adjustment Bottom of tractor wear shoe

2-1/2 to 3-1/2 inches (64 to 90 mm gap)

Top of tram track

______________________________________________________________ A6474X308 Rev. 0 5.167

Adjustment procedures ___________________________________________

  Remove the hex head capscrews and lock washers that secure the front rub rail to the tractor frame (Fig. 118) and open the front rub rail cover.

Fig. 118: Rub rail removal Capscrew and lock washer

View A

Tram rub rail

Capscrew and lock washer View A

 Remove the cover plate to allow access to the idler assembly.   Locate the front idler take-up jack grease fitting and attach the grease gun to the fitting.  If the tram track tension is too tight, readjust the idler position using the following steps: ■

Pump grease into the take-up jack to extend the cylinder and remove pusher plate pressure on the idler shims.

■

Remove one or more idler adjustment shims from the idler slide channel.

■

Open the pressure release valve for the front idler take-up jack and allow the jack to contract. The pusher plate will slide backwards until it is stopped by the remaining idler shims.

■

Pump grease into the idler take-up jack to extend the cylinder, move the idler assembly forward and tighten the tram track until it is at the correct tension. The tram track is at the proper tension when it hangs 2 1/2” to 3 1/2” from the bottom wear shoes when the tractor frame is blocked off the floor.

_________________________________________________________________ 5.168 Bucyrus – Model 25C Continuous Miner

___________________________________________ Adjustment procedures

  If the tram track is too loose, readjust the idler position using the following steps: ■

Pump grease into the idler take-up jack to extend the cylinder, move the idler assembly forward and tighten the tram track until it is at the correct location. The tram track is at the proper tension when it hangs 2 1/2” to 3 1/2” from the bottom wear shoes when the tractor frame is blocked off the floor.

■

Insert shims (Fig. 119) into the idler slide channel until the space between the tractor frame and the pusher plate is filled.

■

Open the pressure release valve for the front idler take-up jack and allow the cylinder to contract. The idler adjustment shims will keep the idler stationary and the track tensioned.

■

Evaluate the resulting track tension and repeat these steps until the track reaches proper tension.

CAUTION! Shims must be inserted completely into the idler slide channel. A shim that is not correctly seated on the idler slide channel’s inside surface provides uneven support that can cause idler slant. A slanted idler can cause uneven wear and stress on the tram track and can cause improper operation of or damage to the tram system.

IMPORTANT! Check that the shims are correctly seated on the idler slide channel’s inside surface by looking at the channel’s inside surface from the opposite side of the miner through the space between the gathering head and the idler assembly.

Fig. 119: Tram track adjustment Take-up cylinder Pressure relief valve

Shims

Pusher plate

Idler assembly

______________________________________________________________ A6474X308 Rev. 0 5.169

Adjustment procedures ___________________________________________

  If the tram track tension is still too loose when the entire 5” shim set is inserted into the idler slide channel, re-adjust the idler position after removing a tram track link using the following steps:  Pump grease into the take-up jack to extend the cylinder and remove the pusher plate pressure on the idler shims.  Remove all of the idler adjustment shims from the idler slide channel.  Open the pressure release valve for the front idler take-up jack and allow the cylinder to contract.  The tram track tension should now be reduced and separation of the tram track will be easier.  Locate a tram track link near the tram idler.  Using the hammer and punch, remove the four roll pins of the two tram track pins (Fig. 120) that secure the tram track link to the track.  Using the hammer and punch, remove the tram track pins to disconnect the link from the track. Remove the disconnected link.  Store the tram track link, one of the tram track pins and two of the roll pins in a safe place.  Connect the two ends of the tram track and using the hammer and punch, secure the two end links together with the remaining tram track pin.  Using the hammer and punch, secure the tram track pin between the two links with the remaining two roll pins.  Pump grease into the idler take-up jack to extend the cylinder, move the idler assembly forward and tighten the tram track until it is at the correct tension. The tram track is at the proper tension when it hangs approximately 2 1/2” to 3 1/2” from the bottom wear shoes when the tractor frame is blocked off the floor.  Insert shims into the idler slide channel until the space between the tractor frame and the pusher plate is filled.  Open the pressure release valve for the front idler take-up jack and allow the cylinder to contract. The idler adjustment shims will keep the idler stationary and the track tensioned.  The idler adjustment shims will keep the idler stationary and the track tensioned.  Evaluate the resulting track tension and repeat until the track reaches proper tension.

_________________________________________________________________ 5.170 Bucyrus – Model 25C Continuous Miner

___________________________________________ Adjustment procedures Fig. 120: Tram track adjustment Pad

Track retention pin

Lock pin

 When the tram track has been adjusted to the proper tension, remove the grease gun from the idler take-up jack grease fitting.  Open the pressure release in order to take pressure off of the takeup cylinder.  Close the front rub rail cover and secure the front rub rail to the tractor frame with hex head capscrews and lock washers.  Connect the trailing cable to energize the miner.  Raise the tractor frame off the blocking by lowering the stabilizer and gathering head and cutter head assemblies.  Carefully remove the support blocking from under the tractor frame.  Lower the tractor frame onto the floor by raising the stabilizer and gathering head and cutter head assemblies.  Carefully remove the blocking from underneath the raised stabilizer, gathering head, and cutter head assemblies.

______________________________________________________________ A6474X308 Rev. 0 5.171

Adjustment procedures ___________________________________________ Tail shim adjustment As the conveyor wears the tail section may sag relative to the conveyor front section. The conveyor has been designed to allow correction of the sag by adding shims.  Lower the cutter head and gathering head assemblies until they touch the floor.  Position the conveyor tail section directly behind the miner and raise it to its highest position.  Insert blocking under the tail section and lower the tail onto the blocking. The conveyor should be at an angle with the rear end of the tail section slightly higher than the front.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all blocking devices.  Insert blocking between the top of the tractor frame and the bottom of the conveyor, leaving about 2” of space between the blocking and the conveyor bottom.  Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine lockout/tagout regulations.

WARNING! Follow all Federal and mine lockout/tagout regulations and procedures. Failure to do so could result in machine damage or serious injury or death to personnel.  Loosen the hex head capscrews that secure the shims between the shim retainer and the conveyor lower pivot plate (Fig. 121).

Fig. 121: Shim removal

Hex head capscrews

Lower pivot plate

Shim retainer

Shims

_________________________________________________________________ 5.172 Bucyrus – Model 25C Continuous Miner

___________________________________________ Adjustment procedures

  Connect the trailing cable to energize the miner.

WARNING! The following steps releases the shims, which will fall free. Watch out for falling shims when loosening the capscrews.  Slowly lower the conveyor slightly so that the front section rests on the frame support blocking. The slotted shims will now fall free.  Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine lockout/tagout regulations.

WARNING! Follow all Federal and mine lockout/tagout regulations and procedures. Failure to do so could result in machine damage or serious injury or death to personnel.  Replace the removed shims (Fig. 122) and add the number of shims required to level the conveyor front and tail sections.  Tighten the hex head capscrews.

Fig. 122: Tail shim adjustment

Hex head capscrews

Shim retainer

Lower pivot plate

Shims

 Connect the trailing cable to energize the miner.  Raise the conveyor tail from the blocking.  Remove both sets of blocking and lower the conveyor tail until it is level with the floor.  Check the gap and alignment (Fig. 123) at the juncture of the conveyor front and tail sections for alignment. If the sections are not horizontally aligned, then add or subtract shims as required.

______________________________________________________________ A6474X308 Rev. 0 5.173

Adjustment procedures ___________________________________________ Fig. 123: Tail shim adjustment Correct gap and alignment Conveyor tail section

Conveyor front section

Add shims Conveyor tail section

Conveyor front section

Remove shims Conveyor tail section

Conveyor front section

 Re-insert the blocking between the top of the tractor frame and the bottom of the conveyor following mine standard blocking procedures.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all blocking devices.  Securely retighten the hex head capscrews.

_________________________________________________________________ 5.174 Bucyrus – Model 25C Continuous Miner

___________________________________________ Adjustment procedures Chain tension adjustment - hydraulic take-up If the machine is equipped with a hydraulic chain take-up, the only adjustment is to the conveyor chain take-up valve. If the valve needs adjusted, see Conveyor chain take-up valve adjustment procedure in this chapter.

______________________________________________________________ A6474X308 Rev. 0 5.175

Adjustment procedures ___________________________________________ Sump tramming (tramming forward while cutting) Tramming is limited by the control system as shown in Table 5.

Table 5: Tramming limitations Cutters not Running Tramming Operation

Speed Limitation

Both remote control levers forward or reverse

Tram speed selected (1,2, or 3)

One lever forward, one reverse (split track tramming)

Both motors limited to 1st speed

One lever engaged (forward or reverse), on lever home (single track tramming)

Speed of engaged motor limited to 1st or 2nd speed

Cutter Running and Cutter Amps < cutter in Face Parameter Tramming Operation

Speed Limitation

Both remote control levers forward

FWD CLEANUP speed regardless of speed selected

Both remote control levers reverse

Tram speed selected (1,2, or 3)

One lever forward, one lever reverse (split track tramming)

Speed of motor going forward limited to FWD CLEANUP speed regardless of speed selected Speed of motor going reverse limited to REV SLEW speed regardless of speed selected

One lever forward, one lever home (single track tramming)

FWD CLEANUP speed regardless of speed selected

One lever reverse, one lever home (single track tramming)

REV SLEW speed regardless of speed selected

Cutters Running and Cutter Amps > Cutter in Face Parameter Tramming Operation

Speed Limitation

Both remote control levers forward

Speed limited by control system

Both remote control levers reverse

Tram speed selected (1,2, or 3)

One lever forward, one lever reverse (split track tramming)

Speed of motor going forward limited by control system Speed of motor going reverse limited to REV SLEW speed regardless of speed selected

One lever forward, one lever home (single track tramming)

Speed is limited by control system

One lever reverse, one lever home (single track tramming)

REV SLEW speed regardless of speed selected

_________________________________________________________________ 5.176 Bucyrus – Model 25C Continuous Miner

___________________________________________ Adjustment procedures The controller settings can be adjusted through the graphics display AC traction parameters page, “SUMP SETUP MENU” (Fig. 124) which is accessed with a password. This screen allows the operator to tune the machine for individual min conditions. A description of the parameters are given in Table 6.

Fig. 124: “SUMP SETUP MENU”, AC traction parameters page

______________________________________________________________ A6474X308 Rev. 0 5.177

Adjustment procedures ___________________________________________ Table 6: AC traction adjustable parameters Menu LH Tram Config

RH Tram Config

Sump Settings

Parameter

Description

Value

LEFT FWD SPEED 1 (%)

Traction drive target speed forward - 1st speed

0 - 45%

1%

20

LEFT FWD SPEED 2 (%)

Traction drive target speed forward - 2nd speed

35 - 80%

1%

40

LEFT FWD SPEED 3 (%)

Traction drive target speed forward - 3rd speed

50 - 100%

1%

72

LEFT REV SPEED 1 (%)

Traction drive target speed reverse - 1st speed

0 - 45%

1%

20

LEFT REV SPEED 2 (%)

Traction drive target speed reverse - 2nd speed

35 - 80%

1%

40

LEFT REV SPEED 3 (%)

Traction drive target speed reverse - 3rd speed

50 - 100%

1%

72

RIGHT FWD SPEED 1 (%)

Traction drive target speed forward - 1st speed

0 - 45%

1%

20

RIGHT FWD SPEED 2 (%)

Traction drive target speed forward - 2nd speed

35 - 80%

1%

40

RIGHT FWD SPEED 3 (%)

Traction drive target speed forward - 3rd speed

50 - 100%

1%

72

RIGHT REV SPEED 1 (%)

Traction drive target speed reverse - 1st speed

0 - 45%

1%

20

RIGHT REV SPEED 2 (%)

Traction drive target speed reverse - 2nd speed

35 - 80%

1%

40

RIGHT REV SPEED 3 (%)

Traction drive target speed reverse - 3rd speed

50 - 100%

1%

72

MAX LH SUMP SPEED (%)

Determines maximum forward speed available when system has determined that the machine is cutting in the face

16 - 45%

1%

20

16 - 45%

1%

20

Determines minimum forward speed available when system has determined that the machine is cutting in the face

0 - 27%

1%

2

0 - 27%

1%

2

Determines the rate of change in forwar4d sump direction from minimum to maximum speeds when system has determined that the machine is cutting in the face

0 - 100%

1.00%

1

MAX RH SUMP SPEED (%) MIN LH SUMP SPEED (%) MIN RH SUMP SPEED (%) SUMP SPEED DELTA (%)

Change Default

_________________________________________________________________ 5.178 Bucyrus – Model 25C Continuous Miner

___________________________________________ Adjustment procedures Table 6, continued: AC traction adjustable parameters Menu

Parameter

Description

Value

Sump Settings, continued

MAX SUMP CUTTER CURRENT (A)

Determines maximum threshold for cutter current that determines if the machine is increasing or decreasing speed output

110 250A

1A

170

MIN SUMP CUTTER CURRENT (A)

Determines minimum threshold for cutter current that determines if the machine is increasing or decreasing speed output

20 - 200A

1A

120

STOP CURRENT (A)

Determines the threshold for cutter current at which the machine will halt until the current level drops below the Stop current value

250 400A

1A

350

SHEAR UP STOP CURRENT (A)

Sets the threshold for cutter current that determines when to stop shear up control. When the current falls below this, shear up will restart

0 - 500A

1A

250

SHEAR DOWN STOP CURRENT (A)

Sets the threshold for cutter current that determines when to stop shear down control. When the current falls below this, shear down will restart

0 - 500A

1A

250

CUTTER IN COAL CURRENT (A)

Determines the point at which the machine will engage automatic sumping/ traction control. Above this point, algorithm will activate

60 - 250A

1A

120

FWD CLEAN UP Determines the forward speed that will be SPEED (%) available when the cutters are running before the cutter in face current threshold has been reached

0 - 50%

1%

35

HIGH SPEED When set to YES, inhibits the maximum PREVENT (YES/ reverse speed to 2nd speed when cutters NO) are running

YES/NO

N/A

NO

REVERSE ANTI SLEW SPEED (%)

20 - 70%

1%

35

Determines the speed in the reverse direction when tramming in single track or pirouette when the system has determined that the machine is cutting in the face

Change Default

______________________________________________________________ A6474X308 Rev. 0 5.179

Adjustment procedures ___________________________________________ Table 6, continued: AC traction adjustable parameters Menu VFD Setup

Traction Setup

Machine Setup

Parameter

Description

Value

Change Default

CURRENT LIMIT AC traction drive current limit as a per(A) AC ONLY centage of full load. Determines the value at which the traction drives protect against overload

100 200%

1%

180

RECTIFIER DC AC traction rectifier DC bus braking limit.

BUS REF (V) AC Braking will activate when the DC bus ONLY exceeds this value during regeneration.

Rectifier IGBT will dump energy into bus resistors to keep the bus voltage below this level

1600 2000V

1V

1800

LH TRAM TRIM (%) DC ONLY

Left tram reference adjustment for DC traction drives. Due to inherent mismatch of drive components, firing angle is trimmed with this value to assure that the machine trams straight in all speeds

-10 +10%

1%

0

RH TRAM TRIM (%) DC ONLY

Right tram reference adjustment for DC traction drives. Due to inherent mismatch of drive components, firing angle is trimmed with this value to assure that the machine trams straight in all speeds

-10 +10%

1%

0

CUTTER SOL CURRENT (mA)

Digital output current to shear solenoid when cutter head running. Ignored when in proportional mode or auto shear active

0 - 800mA

1mA

450

PAN SOL CURRENT (mA)

Digital output to pan solenoid at all times.

Ignored in proportional mode

0 - 800mA

1mA

450

Using these parameter, the machine will automatically control the machine cut sequence to provide optimal traction/motor control.

To set the traction parameters: 1. Enter the ump configuration menu in the engineering menu and record all existing parameter values.

2. Start the cutter head and observe and record the running current in free air for the cutter motors.

3. Set the “CUTTER IN FACE CURRENT” approximately 30 amps above the free air current observation (step 2).

4. Operate the miner in the face and, using the graphics screen for cutting operations, observe the peak current reached during sumping operation. Set this value as the “SUMP TRAM MAX CUTTER CURRENT” value.

5. Set the “SUMP TRAM MIN CUTTER CURRENT” approximately 30 amps below the max value (step 4). _________________________________________________________________ 5.180 Bucyrus – Model 25C Continuous Miner

___________________________________________ Adjustment procedures 6. At this time, set the left and right hand max sump speeds at 20% and set the left and right had min sump speeds at 5% below max.

7. Start raising the max sump tram cutter current in small increments until the cutter current levels out or peaks in sumping operations.

This value now becomes the “SUMP TRAM MAX CUTTER CURRENT”.

8. Set the “SUMP TRAM MIN CUTTER CURRENT” value 30 amps below the value obtained in step 7.

9. Start raising the sump speeds (left and right hand) until the crawlers appear to start breaking traction. This is the max sump speed.

10. Set the min sump speed (left and right hand) 5% below the max sump speed (step 9).

The miner may start with a lurching motion when sumping at this time.

If this occurs, start raising the “SUMP DELTA” value in small increments until this action subsides.

Clean up speed allows faster tram when approaching the face with cutters running and pulling only free air current.

Once the “in face” current is met, the algorithm for the sump configuration is activated.

These parameter values should be the optimum values for this machine in your cutting conditions. The following example illustrates the parameter setting procedure.

IMPORTANT! This example is for illustration only. Parameters must be determined for each individual application.

Parameter settings: Left and right max sump speed: 15% Left and right min sump speed: 10% Sump Delta: 4 Max Cutter Current: 140 amps Min Cutter Current: 110 amps Forward clean up %: 20% Forward and Reverse speeds: 20, 40, and 72% Cutter in Coal: 80 amps

______________________________________________________________ A6474X308 Rev. 0 5.181

Adjustment procedures ___________________________________________

_________________________________________________________________ 5.182 Bucyrus – Model 25C Continuous Miner

________________________________________ Replacement of wear parts Instructions on the replacement of wear parts It is essential that wear parts are replaced before they reach the lowest wear limit. Inspect the wear parts at regular intervals.

CAUTION! Because these maintenance techniques are specialized, they should be performed only be qualified personnel.

CAN solenoid replacement CAN solenoid removal

When removing the CAN solenoid, follow all Federal, State, and mine safety regulations, including but not limited to: WARNING! Follow all Federal and mine regulations for lockout/tagout. Failure to do so may result in serious injury or death. To remove a CAN solenoid: 1. Disconnect and lock out electrical power to the miner. Follow all applicable Federal and mine regulations regarding lockout/tagout procedures.

2. Remove the four (4) mounting Allen screws (Fig. 124).

3. Loosen the CAN connector screws and slide over retainer plate (Fig. 124) on both sides of the solenoid.

Fig. 124: CAN mounting screws

Mounting screws (4)

Retaining plate

CAN connector screws

4. Pull out the connectors. Note: The connector may be difficult to pull. Use caution and do not damage the o-ring (explosion proof seal) by trying to pry out the connector.

5. Remove the solenoid section.

______________________________________________________________ A6474X308 Rev. 0 5.183

Replacement of wear parts _________________________________________ 6. Record the ID selector number (Fig. 125) from the section that was removed. The new solenoid ID must match this ID. The ID designations are two digits: the first digit is the setting for the X10 dial and the second digit is the setting for the X1 dial (Fig. 125).

The IDs are: 01 = Cutter Head 02 = Conveyor Swing 03 = Conveyor Lift 04 = Stabilizer 05 = Gathering Head Fig. 125: CAN solenoid ID

x10 dial

x1 dial

_________________________________________________________________ 5.184 Bucyrus – Model 25C Continuous Miner

________________________________________ Replacement of wear parts CAN solenoid installation

To install a CAN solenoid: 1. Verify that the ID on the new solenoid matches the ID on the solenoid that was removed. Reference Fig. 127 for solenoid arrangement on the hydraulic manifold and Fig. 128 for the water manifold solenoid arrangement.

2. Position the solenoid on the stack and secure with mounting screws (Fig. 126).

3. Insert the connector plug into the solenoid. Note that the index key in the solenoid must align with the index notch on the connector plug (Fig. 126).

IMPORTANT! Use caution when installing the plug into the solenoid and do not damage the o-ring (explosion proof seal).

Index key notch connector plug

Index key pin solenoid

Retaining plate

Retaining plate screws

4. Loosen the retaining plate screws and slide the plate over to secure the connector in the solenoid.

5. Tighten the retaining plate screws WARNING! The retainer must be secured for the connection to be flameproof.

Failure to secure the retainer will result in a non-permissible machine.

______________________________________________________________ A6474X308 Rev. 0 5.185

Replacement of wear parts _________________________________________ Fig. 127: Hydraulic manifold solenoid arrangement

Solenoid valve

Address (Slice ID)

Functions

Cutter Head

00

Coil A - Extend (lower) Coil B - Retract (raise)

Conveyor Swing

01

Coil A - Extend (right) Coil B - Retract (left)

Conveyor Lift

02

Coil A - Extend (raise) Coil B - Retract (lower)

Gathering Head

03

Coil A - Extend (raise) Coil B - Retract (lower)

Stab Cylinders

04

Coil A - Extend (raise) Coil B - Retract (lower)

_________________________________________________________________ 5.186 Bucyrus – Model 25C Continuous Miner

________________________________________ Replacement of wear parts Fig. 128: Water manifold solenoid arrangement

Solenoid valve

Address (Slice ID)

Functions

Dust/Fire

05

Coil A - Activate Dust Coil B - Activate Fire

Scrubber

06

Coil A - Activate Scrubber Coil B - No Function

Breaker On/Off

07

Coil A - Breaker On Coil B - Breaker Off

______________________________________________________________ A6474X308 Rev. 0 5.187

Replacement of wear parts _________________________________________ AC Drive encoder replacement AC drive encoder removal

When removing the AC drive encoder, follow all Federal, State, and mine safety regulations, including but not limited to: WARNING! Follow all Federal and mine regulations for lockout/tagout. Failure to do so may result in serious injury or death.  To remove the tram motor AC drive encoder (Fig. 129): 1. Disconnect and lock out electrical power to the miner.

2. Remove the cover from end of the tram motor.

3. Remove the four screws that hold the rotor cover in place and remove the cover to expose the rotor and stator.

4. Remove the four screws that secure the rotor.

4. Remove the four screws that secure the stator.

5. Remove the stator and rotor from the motor.

AC drive encoder installation

When installing the AC drive encoder, follow all Federal, State, and mine safety regulations, including but not limited to: WARNING! Follow all Federal and mine regulations for lockout/tagout. Failure to do so may result in serious injury or death.

To install the encoder (Fig. 129): 1. Mount the stator over the motor shaft and secure with four bolts.

Apply thread locking compound to the bolts and tighten to 34 N-m (25 ft-lb).

2. Mount the rotor inside the stator, making sure that the encoder and rotor are aligned on the front most edge (Fig. 130). Apply thread locking compound to the bolts and tighten to greater than 8 N-m (70 in-lb).

3. Ensure the wheel does not have excessive wobble (greater than 0.010 inch). Rotate the motor shaft by hand. It should rotate freely and not touch the frame at any time. If everything is mechanically correct, the resulting stator to rotor air gap will be a nominal 0.019 inches.

4. Mount the rotor cover and secure with four screws.

_________________________________________________________________ 5.188 Bucyrus – Model 25C Continuous Miner

________________________________________ Replacement of wear parts Fig. 129: Motor encoder Motor shaft

Rotor cover

Stator Rotor

______________________________________________________________ A6474X308 Rev. 0 5.189

Replacement of wear parts _________________________________________ Fig. 130: Encoder rotor and stator alignment

_________________________________________________________________ 5.190 Bucyrus – Model 25C Continuous Miner

________________________________________ Replacement of wear parts Caution: Reversing power and common will not damage the unit. However, applying power to any of the senor outputs may cause damage.

Refer to Table 7, for signal coding. Note: pinouts are for sensors with the MS3102E-18-IT# connector.

Table 7: Encoder signal coding Signal

Connector Pin

Pigtail Cable

MS3102E-18-IT#

Common

1

Black

F

B

2

Green

B

A

3

Blue

A

Z*

4

Violet

C

No Connection

5

-------

E

Vcc (5-15 VDC)

6

Red

D

/B

7

Yellow

I

/A

8

Gray

H

/Z*

9

Orange

J

Shield

10

Braid

G

* Applies only to units with index pulse capability Note: the shield in the sensor module is isolated from the frame of the encoder for maximum noise immunity. The shield wire or pin should be connected to the shield of the cable and that of the drive or other receiving device.

Encoder connections The encoder connections should be made inside the traction enclosure and the traction case. Each motor encoder is interface to each drive via the CN2 connectors (reference Table 8).

Note : 1. The encoder leads are phased AT THE TRACTION CASE END. 2. The electrician should not deviate from the machine schematics.

3. Both motors should be wired the same with the phase reversal performed inside the traction case.

______________________________________________________________ A6474X308 Rev. 0 5.191

Replacement of wear parts _________________________________________ Table 8: CN2 Traction case connection CN2 Male Plug Left

Left is wired 944 945 942 943

CN2 Male Plug Right

Pin No.

Wire No.

Wire Marker

Description

CN2-S

948

RTD1

RTD RED (2 OR 3 WIRE)

CN2-P

949

RTD2A

CN2-R

949

CN2-M

Color

Pin No.

Wire No.

BLK

CN2-S

958

RTD WHITE (3 WIRE ONLY)

WHT

CN2-P

959

RTD2B

RTD WHITE (2 OR 3 WIRE)

RED

CHS-R

959

946

TSTAT+

TSTAT+

GRN

CN2-M

956

CN2-N

947

TSTAT-

TSTAT-

ORG

CN2-N

957

CNS-A

920

24V

LOGIC COM (24+)

BLU

CN2-A

930

CN2-B

920

ENABLE

MASTER ENABLE

WHT/BLK CN2-B

930

CN2-f

920

CANLSB

CAN ADDRESS LSB

RED/BLK

CN2-f

N/C

CN2-g

N/C

CAMMSB CAN ADDRESS MSB

GRN/BLK

CN2-g

930

CN2-C

921

EFWD

MANUAL TRAM FWD

ORN/BLK

CNS-C

931

CN2-D

922

EREV

MANUAL TRAM REV

BLU/BLK

CN2-D

932

CN2-T

N/C

SPARE

SPARE

BLK/WHT CN2-T

N/C

CN2-E

N/C

RLYNO

RELAY NO

RED/WHT CN2-E

N/C

CN2-Y

N/C

RLYNC

RELAY NC

GRN/WHT CN2-Y

N/C

CN2-L

N/C

RLYCOM RELAY COM

GLU/WHT CN2-L

N/C

CN2-b

N/C

SHD

DIGITAL SHIELD

SHIELD

CN2-b

N/C

CN2-Z

940

ENCV+

ENCODER SUPPLY +

BLK

CN2-Z

950

CN2-G

944

ENCA

ENCODER A

WHT

CN2-G

952

CN2-H

945

ENCA\

ENCODER A\

RED

CN2-H

953

CN2-J

942

ENCB

ENCODER B

GRN

CN2-J

954

CH2-K

943

ENCB\

ENCODER B\

ORG

CN2-K

955

CN2-a

941

ENCV-

ENCODER SUPPLY -

BLU

CN2-a

951

CN2-F

962

SHD

ENCODER SHIELD

SHIELD

CN2-F

963

CN2-U

972

5V

TRAM REF SUPPLY (+5V)

BLK

CN2-U

973

CN2-V

972

REF

MANUAL YRAM REF

WHT

CN2-V

973

CN2-W

N/C

0V

ANALOG COMMON

RED

CN2-W

N/C

CN2-X

N/C

SHD

ANALOG SHIELD

SHIELD

CN2-X

N/C

Right is wired 952 953 954 955

_________________________________________________________________ 5.192 Bucyrus – Model 25C Continuous Miner

________________________________________ Replacement of wear parts Fig. 131: Overall schematic phase representation

Right and left encoders are wired identically at the motor end

Motor phases should be phase separately from the encoder wiring

Motor

Drive

Encoder

Left

Right

Left

Right

RED

940

940

CN2-Z

CN2-Z

BLK

941

941

CN2-a

CN2-a

BLU

942

942

CN2-J

CN2-G

GRY

943

943

CN2-K

CN2-H

BRN

944

944

CN2-G

CN2-J

YEL

945

945

CN2-H

CN2-K

SHD

SHD

SHD

SHD

SHD

______________________________________________________________ A6474X308 Rev. 0 5.193

Replacement of wear parts _________________________________________ Traction drive (VFD) removal and installation traction drive (VFD) removal

To remove a traction drive (VFD): 1. Disconnect and lock out electrical power to the miner. Follow all applicable Federal and mine regulations regarding lockout/tagout procedures.

WARNING! Follow all Federal and mine regulations for lockout/tagout. Failure to do so may result in serious injury or death.

2. Remove the pin that secures the rub rail in place in front of the VFD case (Fig. 132) and swing the rub rail out.

3. Remove the bolts that secure the VFD cover in place (Fig. 132) and remove the cover.

Fig. 132: Rub rail and cover Cover bolts

Rub rail

Cover

Rub rail pin

4. Locate the five (5) power connections on the top of the VFD (Fig. 131).

5. Identify and tag the power cables to make sure they get reconnected correctly.

6. Remove the hex head nuts (Fig. 133) that secure the power cables to the VFD and remove all five (5) cables.

7. Disconnect the ground wire on the front of the VFD (Fig. 133).

8. Identify and tag all communication cables going to the drive (Fig. 133) to make sure they get reconnected correctly.

9. Remove the bolts that secure the VFD to the case. The drive is now free to remove from the case.

_________________________________________________________________ 5.194 Bucyrus – Model 25C Continuous Miner

________________________________________ Replacement of wear parts Fig. 133: VFD connections Communication cables

Mounting bolts

Hex nut (5)

Power connection (5)

Ground wire

______________________________________________________________ A6474X308 Rev. 0 5.195

Replacement of wear parts _________________________________________ traction drive (VFD) installation

To install a traction drive (VFD): Note: There is a Thermal Interface Kit, Bucyrus part number 906546, that includes the materials necessary to apply the thermal compound.

The kit includes the thermal compound, polyester mesh, plastic applicator, sand paper, solvent, WD40, white cleaning cloths, and electronic cleaning wipes.

1. Clean the VFD and enclosure mounting surfaces to ensure all burrs/defects are removed. Use WD40 and 1200 grit sandpaper to ensure the surface is smooth and defect free (Fig. 134).

2. Using a solvent, clean both the VFD and enclosure mounting surfaces to ensure that all dust, oil, rust, moisture, previous thermal compound, etc. is removed.

3. Apply thermal joint compound (Wakefield Engineering 120 Series). a. Apply thermal past to the VFD base plate only. Do not apply to the enclosure mounting surface. b. Spread paste using a plastic straight edge to minimize damage to the interface. c.

The thickness of the compound film should be approximately 0.8 mm (0.031 (1/32) inches). (Application of a polymer screen will assure this thickness and prevent error.) Coverage should be sufficient to turn the base plate 90 % whit, be free of inclusions, and should be evenly applied (Fig. 134).

d. If the surface is unable to hold both the surface flatness and roughness criteria, ensure that the thermal compound is applied such that it bonds the component to the enclosure. This is verified by applying the compound as instructed, installing the component, and then removing the component. The thermal paste is correct when a branch like structure become visible in the paste (Fig. 135).

4. Place the component on the enclosure surface and ensure that the thermal compound has bonded to both surfaces by slightly sliding the component side-to-side and front-to-back.

5. Install the bolts to secure the drive to the mounting plate (Fig. 136).

6. Connect the ground wire to the VFD (Fig. 136).

7. Reconnect the power leads to the VFD (Fig. 136).

8. Reconnect the communication cables to the VFD (Fig. 136).

9. Replace the cover on the traction case and secure with bolts (Fig. 132).

10. Close the rub rail and secure (Fig. 132).

_________________________________________________________________ 5.196 Bucyrus – Model 25C Continuous Miner

________________________________________ Replacement of wear parts Fig. 134: Thermal compound application

standard base plate condition

polished base plate condition

thermal compound application Fig. 135: Sufficient thermal compound application

______________________________________________________________ A6474X308 Rev. 0 5.197

Replacement of wear parts _________________________________________ Fig. 136: VFD connections Communication cables

Mounting bolts

Hex nut (5)

Power connection (5)

Ground wire

_________________________________________________________________ 5.198 Bucyrus – Model 25C Continuous Miner

________________________________________ Replacement of wear parts

Cutter head (boom) assembly The cutter head assembly (Fig. 137) can be removed as an assembly or in individual components.

Fig. 137: Cutter head assembly End drum

Center drum

Boom

Shear cylinder

Boom pivot pin Drum drive gear case

Drum drive motor

cutter head assembly removal

When removing the cutter head assembly, follow all Federal, State, and local safety regulations and observe the following: WARNING! You could be seriously injured or even killed by falling loads. Observe the safe working load limits of lifting and blocking devices and keep a safe distance from suspended loads.

WARNING! Follow all Federal and mine regulations for lockout/tagout. Failure to do so may result in serious injury or death. 

______________________________________________________________ A6474X308 Rev. 0 5.199

Replacement of wear parts _________________________________________ To remove the cutter head assembly (Fig. 138): 1. Attach an appropriate lifting device to the boom assembly. Take up the slack in the lift assembly so that the weight is supported as the assembly is unpinned from the miner.

2. Lower the gathering head and the cutter head to the floor and position the conveyor tail section level with floor.

3. Disconnect and lock out the electrical power to the miner. Follow all applicable Federal and mine regulations regarding lockout/tagout procedures.

4. Disconnect the power cables and water hoses from the cutter motors (see Cutter motor removal procedure in this chapter). Be sure to tape up the power cables since electrical power will be connected to the miner.

5. Disconnect the water hoses to the dust suppression sprays.

6. Remove the two (2) boom pivot pins (see Boom pivot pin removal procedure in this chapter.

7. Connect electrical power to the miner.

8. Extend the shear cylinders to push the boom pivots out of their tractor frame clevises.

9. Block the boom and shear cylinders to keep them stationary during their pin removal.

10. Disconnect power to the miner. Follow all applicable Federal and mine regulations regarding lockout/tagout procedures.

11. Remove the shear cylinder boom clevis pins (see Shear cylinder removal procedure in this chapter).

12. Connect electrical power to the miner.

13. Retract the shear cylinders to pull their bearings free from the boom clevises.

14. Disconnect power to the miner. Follow all applicable Federal and mine regulations regarding lockout/tagout procedures.

15. Raise the rear of the boom assembly until it is above the top edge of the gathering head backboard.

16. Slowly tram the mine backwards until the cutter boom pivot points clear the front of the gathering head.

_________________________________________________________________ 5.200 Bucyrus – Model 25C Continuous Miner

________________________________________ Replacement of wear parts Fig. 138: Cutter head assembly removal and installation Cutter boom pivot

Shear cylinder

cutter head assembly installation

Cutter boom

Shear cylinder clevis pin

When installing the cutter head assembly, follow all Federal, State, and local safety regulations and observe the following: WARNING! You could be seriously injured or even killed by falling loads. Observe the safe working load limits of lifting and blocking devices and keep a safe distance from suspended loads.

WARNING! Follow all Federal and mine regulations for lockout/tagout. Failure to do so may result in serious injury or death.

To install the cutter head assembly (Fig. 138)  1. Slowly tram the miner forward toward the raised end of the boom until the pivot pins clear the gathering head backboard.

2. Lower the boom pivot points until the shear cylinders can reach their boom clevises. Block the boom to keep it in a secure position.

3. Extend the shear cylinders until their rod end bearings can be inserted into the cutter boom clevises.

4. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations regarding lockout/tagout procedures.

5. Position the right cylinder’s rod end bearing in the boom clevis.

WARNING! Do not test the alignment of the shear cylinder rod end bearings and the cutter boom clevis using your fingers. Shifting of the aligned pieces could cause serious injury. 

______________________________________________________________ A6474X308 Rev. 0 5.201

Replacement of wear parts _________________________________________ IMPORTANT! The pin should be inserted so that its retaining channel remains outside the bushing.

6. Insert the rod end pin through the aligned clevis bushings and rod end bearing.

7. Insert the pin retaining plate and secure to the boom clevis with hex head capscrews and lock washers.

8. Repeat the previous three steps from the left shear cylinder.

9. Connect the trailing cable to energize the miner.

10. Once the shear cylinders are secured to the cutter boom, re-move the boom blocking to allow the cylinders to move the boom.

11. Contract the shear cylinders to pull the cutter boom pivot points into position in the tractor frame boom pivot clevises.

IMPORTANT! In addition to the shear cylinders, the stabilizer and gathering head can also be used to adjust the cutter boom’s position to allow easier insertion of the cutter boom pivot pins.

12. Install both cutter boom pivot pins.

13. Replace the motor cooling water and scrubber spray water hoses onto the cutter head boom.

14. Replace the electrical power cables onto the cutter head boom.

_________________________________________________________________ 5.202 Bucyrus – Model 25C Continuous Miner

________________________________________ Replacement of wear parts Boom pivot pin removal and installation boom pivot pin removal

When removing the boom pivot pin, follow all Federal, State, and local safety regulations and observe the following: WARNING! Follow all Federal and mine regulations for lockout/tagout. Failure to do so may result in serious injury or death.  To remove the boom pivot pin: 1. Lower the conveyor tail section until it is level with the floor and gathering head and cutter head until they rest on the floor.

2. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations regarding lockout/tagout procedures.

3. Locate the boom pivot pin (accessible from top of machine).

IMPORTANT! Pressure from the cutter boom onto the pivot pin can make its removal very difficult. The shear cylinders can be used to find the boom position that puts the least pressure on the pin.

CAUTION! When the pivot pin pull point is found, block the cutter boom to prevent it from dropping or moving when the pivot pin is removed.

4. Remove the hex head capscrews and lockwashers that secure the boom pivot pin retaining plate to the tractor frame.

5. Remove the pin retaining plate and its support block.

6. Insert a slide hammer adapter into the threaded hole in the end of the boom pivot pin.

IMPORTANT! Pressure from the cutter boom onto the boom pivot pin can make its removal very difficult. The shear cylinders can be used to find the boom position that puts the least pressure onto the pin. This position can be determined by striking the pin, slightly contracting or extending the shear cylinder, then striking the pin again and comparing the “ring”; as boom pressure on the pin decreases, the “ring” of the pin when it is struck becomes lower. When the “ring” of the pin becomes short and low, pin removal is much easier.

CAUTION! Use extreme caution when adjusting the boom with the shear cylinder to find the pivot pin’s pull point.

7. When the pivot pin’s pull point is found, block the cutter boom to keep it from dropping or moving when the pin is pulled.

8. Attach the slide hammer to its adapter and pull the boom pivot pin.

______________________________________________________________ A6474X308 Rev. 0 5.203

Replacement of wear parts _________________________________________ boom pivot pin installation

To install the boom pivot pin: 1. Position the boom pivot pin so that the end with the two flats (the end without the adapter) is inserted first. The single flat of the pin’s opposite end must face the four retaining plate holes.

IMPORTANT! On the back of the tractor frame clevis there is a welded strap that keeps the boom pivot pin from rotating. One of the flats of the boom pivot pin must parallel this strap or the pin cannot be completely inserted.

2. Use the hammer to insert the boom pivot pin through the aligned tractor frame clevis and boom pivot bushings.

IMPORTANT! If it is extremely difficult to insert the boom pivot pin through the aligned tractor frame clevis and boom pivot bushings, extend or contract the shear cylinders to improve the alignment between the clevis and boom.

CAUTION! Use extreme caution when adjusting the clevis and boom alignment with the shear cylinders.

3. Replace the support block over the four threaded holes in the tractor frame.

4. Place the retaining plate onto the support block. The end of the retaining plate L-extension should be positioned against the flat of the boom pivot pin.

5. Insert and tighten the hex head capscrews lockwashers to secure the boom pivot pin retaining plate to the tractor frame.

_________________________________________________________________ 5.204 Bucyrus – Model 25C Continuous Miner

________________________________________ Replacement of wear parts Shear cylinder removal and installation shear cylinder removal

When removing the shear cylinder, follow all Federal, State, and local safety regulations and observe the following: WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all blocking devices. Do not stand near the blocked cutter head.

WARNING! Replacement of the shear cylinder involves working around a raised cutter head assembly. Never work under any raised assembly without proper blocking. Always block between the raised assembly and the tractor frame in addition to between the raised assembly and the floor.

WARNING! Follow all Federal and mine lockout/tagout regulations and procedures. Failure to do so could result in machine damage or serious injury or death to personnel.

WARNING! Never disconnect a hydraulic hose if the circuit is pressurized or if there is a load on the circuit. If a hose is disconnected while the circuit is pressurized or a load is on it, the load will fall, causing damage to the machine or serious injury or death to personnel.

To remove the shear cylinder: 1. Lower the gathering head until it touches the floor and lower the conveyor tail section until it is level with the floor. Advance the conveyor chain so that its flights do not block the shear cylinder piston end pin access plates on the conveyor bed.

2. Raise the cutter head assembly until it reaches its highest point.

Place blocking underneath the cutter head. Lower the assembly onto the blocking at a level where the shear cylinder is partially but not fully contracted.

3. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine lockout/tagout regulations.

4. Attach an appropriate lifting device to the shear cylinder. Take up all slack in the lifting device so that the weight of the cylinder is supported by the lifting device.

CAUTION! The shear cylinder is very heavy. Verify its weight can be supported.

5. On the boom clevis of the shear cylinder’s piston end, locate the piston end pin and its retaining bracket.

______________________________________________________________ A6474X308 Rev. 0 5.205

Replacement of wear parts _________________________________________ 6. Remove the hex head capscrews and lock washers that secure the pin retaining plate to the cutter boom.

7. Remove the retaining plate.

8. Insert the slide hammer’s adapter into the threaded hole in the end of the pin.

9. Attach the adapter to the slide hammer and pull the pin from the clevis bushings.

10. Connect the trailing cable to energize the miner.

WARNING! Stand clear of the blocked cutter head assembly during shear cylinder contraction.

11. Slowly retract the shear cylinder until the piston end comes free from its clevis.

12. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine lockout/tagout regulations.

13. Raise and lower the shear cylinder to release any pressure from the shear cylinder.

WARNING! The next steps disconnect the shear cylinder from the tractor frame. The shear cylinder is extremely heavy. Be prepared to support its weight before performing the following steps.

14. Locate the miner’s front rub rail and remove the hex head capscrew and lock washer that secures the rub rail to the tractor frame (Fig. 139) and open the rub rail.

Fig. 139: Rub rail

Rub rail (open to access front idler take-up)

_________________________________________________________________ 5.206 Bucyrus – Model 25C Continuous Miner

________________________________________ Replacement of wear parts

 15. Locate the front idler take-up jack bracket assembly which is mounted directly to the rear of the idler shim channel .

16. Pull the flip pin from the half link to release the take-up jack bracket from the tractor frame.

17. Lower the end of the bracket until it clears the half link and pull the bracket straight out to remove it from the tractor frame.

18. Locate the shear cylinder’s rod end pin and pin retaining plate.

19. Remove the hex head capscrews and lockwashers that secure the pin retaining plate to the frame.

20. Remove the pin retaining plate.

21. Locate the shear cylinder pin.

22. Insert the slide hammer adapter into the threaded hole in the end of the pin.

23. Attach the adapter to the slide hammer and pull the pin.

24. Disconnect, tag, and cap the grease hoses going to the cylinder.

25. Disconnect, tag, and cap the hydraulic hoses going to the cylinder.

26. Remove the hydraulic fittings from the shear cylinder and store in a clean place.

27. The shear cylinder is now free to lift clear of the miner.

______________________________________________________________ A6474X308 Rev. 0 5.207

Replacement of wear parts _________________________________________ shear cylinder installation

When installing the shear cylinder, follow all Federal, State, and local safety regulations and observe the following: WARNING! Follow all federal and mine lockout/tagout regulations and procedures. Failure to properly lock out the machine man result in machine damage or serious injury or death to personnel.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all lifting and blocking devices.

To install the shear cylinder: 1. Verify that the miner is de-energized and that the trailing cable is disconnected and locked out.

2. Verify that the cutter head assembly is sufficiently and securely blocked.

3. Using an appropriate lifting device, position the shear cylinder rod end close to the frame mounting clevis.

4. Insert the hydraulic fittings into the cylinder and reconnect hydraulic hoses.

5. Reattach all grease lines to the cylinder.

6. Position the shear cylinder’s rod end into the frame clevis.

7. Insert the shear cylinder rod end pin, retaining channel end first, through the aligned frame clevis and rod end. Rap the pin with a hammer until the retaining channel emerges from the gushing on the other side of the clevis.

8. Insert the pin retaining plate in the pin’s channel to secure the pin in the clevis.

9. Insert and tighten the hex head capscrews and lock washers that secure the pin retaining plate to the frame clevis.

10. Replace the take-up jack bracket assembly into the frame and secure by inserting the flip pin through the half link.

11. Close the front rub rail and secure to the frame with hex head capscrews and lock washers.

12. Connect the trailing cable to energize the miner.

WARNING! The following steps will result in the movement of the unsecured shear cylinder. Stand clear of the shear cylinder and the blocked cutter head assembly during extension of the shear cylinder.

_________________________________________________________________ 5.208 Bucyrus – Model 25C Continuous Miner

________________________________________ Replacement of wear parts 13. Slowly extend the shear cylinder so that the piston end is near the boom mounting clevis.

14. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine lockout/tagout regulations.

15. Position the shear cylinder’s piston end bearing in the boom clevis.

16. Insert the pin through the aligned mounting clevis and bushing, ensuring that the retaining channel remains outside the bushing.

17. Insert the pin retaining plate in the pin’s channel to secure the pin in the clevis.

18. Insert and tighten the hex head capscrews and lock washers to secure the pin retaining plate to the boom clevis.

19. Reconnect the trailing cable and cycle the shear cylinder to ensure correct operation.

______________________________________________________________ A6474X308 Rev. 0 5.209

Replacement of wear parts _________________________________________ Center drum removal and installation center drum removal

When removing the cutter drum, follow all Federal, State, and local safety regulations and observe the following: WARNING! Replacement of the cutter head center drum involves working around a raised cutter head assembly. Never work under any raised assembly without proper blocking. Always block between the raised assembly and the tractor frame in addition to between the raised assembly and the floor.

WARNING! This procedure involves disconnecting and reconnecting the miner’s trailing cable. Always be aware of whether or not the miner is energized. Never perform maintenance on an energized miner.

WARNING! Follow all Federal and mine lockout/tagout regulations and procedures. Failure to do so could result in machine damage or serious injury or death to personnel.

WARNING! You can be seriously injured or killed by falling loads. Make sure the lifting device is capable of lifting the drum weight. Use care when handling the cutter drum.

To remove the center drum (Fig. 140):  1. Lower the gathering head completely until its touches the floor.

Lower the conveyor tail assembly until it is level with the floor.

2. Rotate the cutter head slowly until one of the center drum seams appears directly in front and one appears directly in rear of the cutter head.

3. Lower the cutter head assembly until it touches the floor.

4. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine lockout/tagout regulations.

5. Attach an appropriate lifting device to the upper half of the center drum.

6. Remove the thirty (30) bolts and nuts that secure the two center drum halves together. Store the nuts and bolts in a safe place to use in reassembly.

_________________________________________________________________ 5.210 Bucyrus – Model 25C Continuous Miner

________________________________________ Replacement of wear parts 7. Using a pry bar and other force as necessary, break the seal between the center drum so that the top half is free from the bottom half.

8. Lift the upper half of the center drum off of the lower half.

9. Measure and record the following dimensions (as shown on Fig. 141) to two (2) places of accuracy: LD1 = _________ LD2 = _________ GD1 = (LD1 - LD2)/2 = _______ 10. Remove the alignment keys and store in a safe place for use in reassembly.

11. Connect the trailing cable to energize the miner.

12. Slowly raise the cutter head assembly until it completely clears off of the lower half of the center drum.

13. Slowly tram the miner back away from the lower half of the center drum.

______________________________________________________________ A6474X308 Rev. 0 5.211

Replacement of wear parts _________________________________________ Fig. 140: Center cutter drum removal/installation Bolt locations

Center drum upper half

Spacer

Shim Shim Shim Capscrew

Alignment keys

Center drum lower half

_________________________________________________________________ 5.212 Bucyrus – Model 25C Continuous Miner

________________________________________ Replacement of wear parts Fig. 141: Center drum removal and installation

______________________________________________________________ A6474X308 Rev. 0 5.213

________________________________________ Replacement of wear parts

 center cutter drum installation

To install the center cutter drum (Fig. 140): 1. Slowly position the miner so that the cutter head assembly is positioned in the lower half of the center cutter drum.

2. Using the calculated value of GD1 found during removal, select a combination of shims and spacers to allow for a float gap (GB) between the center drum and the gear case struts that is between 0.40 and 1.00 mm (one set of shims and spacers per side). Note that the shims should be located between spacers.

3. Record the following to two (2) places of accuracy: GD = Total sum length of spacers and shims = ________ GB = GD1 (found during removal) - GD = _________ GB must be between 0.40 and 1.00 mm 4. Apply thread locker (Loctite 271) to a 5/8-11 UNC X 2.00 inch hex head cap screw and use the screw to secure the spacer/shim pack to the boom assembly.

5. Place the center drum keys in position in the lower half of the center drum.

6. Slowly lower the upper half of the center drum onto the lower half using the match marks scribed on the outside of the drum halves to ensure correct alignment.

7. Insert the thirty (3) hex head bolts and nuts through the two halves of the center drum and torque to 1,350 ft-lbs (1,830 N-M) using the pattern shown in Fig. 142.

8. Check the total float and verify it is within 0.40 to 1.00 mm. If float is outside these parameters, take the drum apart and insert new spacer/shim pack to obtain the correct total float. Reassemble and torque bolts to 1,350 ft-lbs using the pattern shown in Fig. 142.

9. When the total float is verified between 0.40 and 1.00 mm, tighten the bolts and nuts to a final torque of 2,800 ft-lbs (3,796 N-m) using the pattern shown in Fig. 142.

______________________________________________________________ A6474X308 Rev. 0 5.214

Replacement of wear parts _________________________________________ Fig. 142: Center drum bolt torque pattern

_________________________________________________________________ 5.215 Bucyrus – Model 25C Continuous Miner

Replacement of wear parts _________________________________________ End drum removal and installation end drum removal

When removing the end drum, follow all Federal, State, and local safety regulations and observe the following: WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of lifting devices and keep a safe distance from suspended loads.

WARNING! Follow all Federal and mine lockout/tagout regulations and procedures. Failure to do so could result in machine damage or serious injury or death to personnel.

To remove an end drum (Fig. 143): 1. Lower the gathering head completely until it touches the floor.

Lower the conveyor tail assembly until it is level with the floor.

2. Raise the cutter head assembly to its highest position. Place blocking underneath the cutter head assembly and lower the cutter head assembly onto the blocking.

Fig. 143: End drum removal

Alignment key Bolt cap plate

End drum Bolts

_________________________________________________________________ 5.216 Bucyrus – Model 25C Continuous Miner

________________________________________ Replacement of wear parts

 3. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine lockout/tagout regulations.

4. Remove the bolt cap plate.

5. Remove the fourteen M30-2.0 6g X75 hex head capscrews that secure the end drum to the cutter drum drive gear case.

6. Using the pry bar and other necessary force, remove the end drum from the cutter head assembly.

7. Retrieve the two alignment keys and store in a safe place for use in installation of the end drum. end drum installation

When installing the end drum, follow all Federal, State, and local safety regulations and observe the following: WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of lifting devices and keep a safe distance from suspended loads.

WARNING! Follow all Federal and mine lockout/tagout regulations and procedures. Failure to do so could result in machine damage or serious injury or death to personnel.

To install an end drum (Fig. 143): 1. Place the end drum alignment keys into the required position.

2. Install the end rum on the gear case. Ensue that the timing mark of the end drum is aligned with the timing mark on the center drum.

3. Thread fourteen (14) reusable M30-2.0X75 hex head bolts into the end drum and torque to 878 ft-lbs (1,190 N-m) using sequence pattern shown in Fig. 144.

4. Individually remove the fourteen (14) reusable M30-2.0X75 bolts in sequence pattern shown in Fig. 136 and replace with identical bolts for final assembly. Before threading bolts, apply thread locker (Loctite 277) to the bolts. Torque bolts to 1,755 ft-lbs (2380 N-m).

5. Place bolt cap plate, with holes positioned over bolt heads, on the end of the end drum and tack weld in place. Fill holes as shown in Fig. 145.

______________________________________________________________ A6474X308 Rev. 0 5.217

Replacement of wear parts _________________________________________ Fig. 144: End drum bolt torque pattern

Fig. 145: Bolt cap plate

_________________________________________________________________ 5.218 Bucyrus – Model 25C Continuous Miner

________________________________________ Replacement of wear parts Drum drive motor drum drive motor removal

When removing the drum drive motor, follow all Federal, State, and local safety regulations and observe the following: WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all blocking devices. Do not stand near the blocked cutter head.

WARNING! Follow all Federal and mine lockout/tagout regulations and procedures. Failure to do so could result in machine damage or serious injury or death to personnel.

To remove the drum drive motor: 1. Lower the gathering head until it touches the floor. Lower the conveyor tail assembly until it is level with the floor.

2. Level the cutter head assembly and place blocking underneath.

3. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine lockout/tagout regulations.

4. Remove the hex head caps crews and lockwashers that secure the junction box cover and remove the cover and O-ring.

5. Locate the three taped power connections. Tag the connections for reconnection and then strip off the three layers of tape covering these lug connections.

IMPORTANT! Before detaching the lugs, mark the wires to facilitate reconnection during motor installation.

6. Tag the lugs for correct reconnection then remove the hex head capscrew, flat washer, lock washer and hex head nut that secure the three power cable lugs to the three motor lugs.

7. Remove the socket head capscrews and lockwashers that secure the stuffing box’s half-moon clamp to the junction box.

8. Remove the clamp and slide the stuffing box out of the junction box.

The power cable should be completely disconnected from the motor.

WARNING! While the power cable is detached from the motor, the trailing cable should not be reconnected to energize the miner. Damage to the miner, personal injury or death could result.

______________________________________________________________ A6474X308 Rev. 0 5.219

Replacement of wear parts _________________________________________

 9. To prevent damage to the power cable lugs and gland assembly, cover the power cable and secure it to the miner in a safe location.

10. To protect the motor’s electrical connections, replace the motor junction box cover and secure it using hex head capscrews and lock washers.

11. Disconnect the two cooling water hoses from the front and rear motor cooling water fittings and plug the hose ends to keep them clean.

12. Remove the two water fittings from the motor and store in a clean place and plug the two motor cooling water ports to keep them clean.

13. Place blocking under the motor to support it as it is pulled out of the gear case.

14. Remove the ten (10) bolts and washers that secure the motor to the gear case.

15. Using four (4) of the bolt holes as pusher holes, insert four bolts and push the motor out of the gear case.

16. Using appropriate pulling devices, pull the motor from the gear case, making sure to keep the motor properly blocked and supported as it is pulled from the case. drum drive motor installation

When installing the drum drive motor, follow all Federal, State, and local safety regulations and observe the following: WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all blocking devices. Do not stand near the blocked cutter head.

WARNING! Follow all Federal and mine lockout/tagout regulations and procedures. Failure to do so could result in machine damage or serious injury or death to personnel.

WARNING! Federal law requires that mining equipment electrical connections must be inspected by a certified electrician before the equipment can be operated.

WARNING! This procedure involves attaching an electrical power cable to the cutter head drum drive motor. The trailing cable must be disconnected to safely perform this operation or serious injury or death will result.

WARNING! You can be seriously injured or killed by a falling load. Follow the safe working load limits of all blocking devices.

_________________________________________________________________ 5.220 Bucyrus – Model 25C Continuous Miner

________________________________________ Replacement of wear parts To install the drum drive motor: 1. Block up cutter head drum drive motor into position against the rear of the boom so that the motor’s mounting holes align with the boom’s threaded motor mounting holes.

2. Install the two motor cooling water fittings into the front and rear cooling water ports of the motor.

3. Attach the two motor cooling water hoses to the fittings.

4. Remove the hex head capscrews and lock washers that secure the junction box cover and remove the cover and o-ring.

5. Insert the three lugs of the power cable (with gland and stuffing box already installed) into the motor’s junction box.

6. Replace the stuffing box’s half-moon clamp in its channel to secure the stuffing box in the junction box.

7. Tighten the two socket head capscrews to secure clamp to the junction box.

8. Inside the junction box, locate the motor’s lug connections and match the motor lug connections to the corresponding power cable lugs.

9. Attach the first motor lug to its corresponding power cable lug by inserting a hex head capscrew through the motor lug, through the power cable lug, through a flat washer, and through a lock washer.

Secure the capscrew with a hex nut.

10. Repeat this step for the other two lugged connections.

11. When all three connections have been secured, wrap each of the three connections with a layer of rubber tape, then a layer of black tape and then a layer of glass tape.

12. Replace the junction box o-ring and cover.

13. Insert the hex head capscrews and lockwashers to secure the junction box cover and tighten.

14. An MSHA certified electrician must inspect all work and check for permissibility.

15. Slide the motor into the gear case.

16. Coat the ten (10) bolts with thread locker (Loctite 271) and install the bolts and washers to secure the motor to the gear case.

Torque the bolts to 403 ± 57 lb-ft (540 ± 70 N-m).

______________________________________________________________ A6474X308 Rev. 0 5.221

Replacement of wear parts _________________________________________ Fig. 146: Drum drive motor (typical both sides)

Junction box cover

Motor Capscrews (10)

_________________________________________________________________ 5.222 Bucyrus – Model 25C Continuous Miner

________________________________________ Replacement of wear parts Drum drive torque limiting clutch drum drive motor torque limiting clutch removal

When removing the drum drive motor torque limiting clutch, follow all Federal, State, and local safety regulations and observe the following: WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all blocking devices.

WARNING! Follow all Federal and mine lockout/tagout regulations and procedures. Failure to do so could result in machine damage or serious injury or death to personnel.

To remove the drum drive torque limiting clutch (Fig. 147): 1. Lower the gathering head completely until it touches the floor and lower the conveyor tail section until it is level with the floor.

2. Raise the cutter head assembly to its highest position and block appropriately. Lower the cutter head assembly onto the blocking.

3. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine lockout/tagout regulations.

4. Locate the clutch housing on the rear of the cutter head drum drive motor assembly (Fig. 148).

5. Remove the hex head capscrews and lock washers that secure the clutch housing to the motor housing.

6. Remove the clutch housing to expose the clutch assembly.

7. At the center of the clutch assembly, locate the drum drive shaft.

8. Using the screwdriver, remove the retaining ring that secure the drum drive shaft inside the clutch assembly.

9. Pull the drum drive shaft from the motor and clutch assemblies.

10. Store the drum drive shaft in a clean, safe place.

11. Using wire cutters, remove the lock wire that secures the lock nuts on the outside of the pressure plate.

12. Remove the lock nuts (Fig. 149) on the outside of the pressure plate.

13. Remove the pressure plate and the output hub assembly (with seal and bearing) from the clutch.

14. Using a screwdriver, remove the fillister head machine screw that retains the center drive hub.

15. Loosen the clutch retaining nut and slide the clutch off of the motor.

______________________________________________________________ A6474X308 Rev. 0 5.223

Replacement of wear parts _________________________________________ Fig. 147: Drum drive torque limiting clutch

Clutch cover

Shaft

Shaft retaining ring

Fig. 148: Drum drive shaft removal

Lock nuts

Retaining ring Drum drive motor assembly

Clutch assembly

Drum drive shaft

_________________________________________________________________ 5.224 Bucyrus – Model 25C Continuous Miner

________________________________________ Replacement of wear parts Fig. 149: Pressure plate removal

Bearing Seal Output hub assembly Pressure plate

Input assembly Lock nut

Fig. 150: Drum drive shaft installation Drum drive motor assembly

Spring shafts

Output assembly

Lock nuts

Drum drive shaft

Retaining ring Input assembly

______________________________________________________________ A6474X308 Rev. 0 5.225

Replacement of wear parts _________________________________________ drum drive motor torque limiting clutch installation

When removing the drum drive motor torque limiting clutch, follow all Federal, State, and local safety regulations and observe the following: WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all blocking devices.

WARNING! Follow all Federal and mine lockout/tagout regulations and procedures. Failure to do so could result in machine damage or serious injury or death to personnel.

To install the drum drive torque limiting clutch: 1. Position the clutch on the motor.

2. Insert and tighten the fillister head machine screw that retains the center drive hub.

3. Place the seal and then the bearing onto the output hub (with friction disc).

4. Place the output assembly against the input assembly.

5. Slide the pressure plate onto the input assembly’s spring shafts.

6. Secure the pressure plate to the spring shafts with the lock nuts and torque appropriately.

7. Lock wire the lock nuts to secure their position.

8. Slide the drum drive shaft (Fig. 150) through the clutch assembly, through the motor, and into the cutter head drum drive gear case.

The shaft may require some adjustment so that its end fits into the gear case.

9. When the drum drive shaft is positioned in the motor and clutch assemblies, insert the retaining ring to secure it in place.

10. Place the clutch housing against the motor housing.

11. Secure the clutch housing to the motor housing with the hex head capscrews and lock washers.

_________________________________________________________________ 5.226 Bucyrus – Model 25C Continuous Miner

________________________________________ Replacement of wear parts Drum drive gear case removal and installation drum drive gear case removal

When removing the drum drive gear case, follow all Federal, State, and local safety regulations and observe the following: WARNING! You could be seriously injured or killed by falling loads. Always observe the safe working load limits of blocking devices.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.

To remove the drum drive gear case (Fig. 151): 1. Remove the cutter head center drum (See Center cutter drum removal procedure in this chapter).

2. Remove the water spray manifold.

3. Remove the cutter head end drum (See End cutter drum removal procedure in this chapter).

4. Carefully lower the cutter head assembly (now with the cutter drum drive gear case exposed) onto blocking.

5. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine lockout/tagout regulations.

6. Remove both the drum drive key retainers and the drum drive keys from their key slots in the center drum drive shaft. Store the keys and retainers in a safe place.

7. Remove the drum drive clutch (see Drum drive clutch removal procedure in this chapter).

8. Locate the clutch housing and the drum drive shaft access cover plate on the side of the cutter drum drive motor.

9. Securely block the cutter drum drive gear case to support it when it becomes separated from the boom.

10. Remove the weld strap holding the gear case mounting bolts in place.

11. Remove the fourteen (14) bolts (seven along the top and seven along the bottom) that secure the gear case to the frame.

12. Connect the trailing cable to energize the miner.

13. Slowly tram the miner in reverse away from the blocked gear case.

______________________________________________________________ A6474X308 Rev. 0 5.227

Replacement of wear parts _________________________________________ Fig. 151: Drum drive gear case

Motor Gear case

_________________________________________________________________ 5.228 Bucyrus – Model 25C Continuous Miner

________________________________________ Replacement of wear parts drum drive gear case installation

When installing the drum drive gear case, follow all Federal, State, and local safety regulations and observe the following: WARNING! You could be seriously injured or killed by falling loads. Always observe the safe working load limits of blocking devices.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.

To install the drum drive gear case: 1. Securely block the gear case so that the miner’s boom can be trammed forward into position behind it.

2. Insert four guides into the cutter boom face, spacing the guides equally over the boom face.

3. Mark the holes on the exterior of the gear case mounting brace that corresponds to the positions of the guides on the boom face.

4. Connect the trailing cable to energize the miner.

5. Using the guide pins to direct placement, tram the miner forward until the gear case is positioned against the cutter boom face. The guide pins should come out of the marked holes in the mounting brace.

WARNING! Use extreme caution when tramming the miner forward to position the boom face against the gear case.

6. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine lockout/tagout regulations.

7. Insert the hex head capscrews into the open holes (those not blocked by the guides) in the cutter drum drive gear case mounting brace.

8. Remove the alignment guides and insert the remaining four hex head capscrews through the gear case mounting brace and into the threaded holes in the cutter boom face.

9. Using the pattern shown in Fig. 152, torque the fourteen (14) capscrews in two steps as follows: Step 1: 500 lb-ft (675 N-m) Step 2: 2,138 ± 150 lb-ft (2,900 ± 200 N-m)

______________________________________________________________ A6474X308 Rev. 0 5.229

Replacement of wear parts _________________________________________ Fig. 152: Cutter head gear case bolt torque pattern

10. Install the cutter drum motor (see Cutter motor installation procedure in this chapter).

11. Install the drum drive clutch (see Drum drive clutch installation procedure in this chapter).

12. Locate the fill plugs and fill the gear case to the proper level with lubricant.

13. Replace the plugs.

14. Examine the cutter drum drive gear case and cutter boom face for leaking oil, which indicates improper installation or gear case damage.

15. Install the cutter head end drum (see Cutter head end drum installation procedure in this chapter).

16. Install the cutter head center drum (see Center drum installation procedure in this chapter).

17. Connect the water spray manifold.

_________________________________________________________________ 5.230 Bucyrus – Model 25C Continuous Miner

________________________________________ Replacement of wear parts Gathering head assembly The gathering head assembly (Fig. 153) consists of the gathering pan, the continuous loading arms (CLAs), lift cylinders, and drive motors.



Fig. 153: Gathering head assembly

Foot shaft location

Continuous loading arms (CLA) (2) CLA key

Lift cylinder location

Gear case (under CLA)

gathering head assembly removal

To remove the gathering head assembly

 When removing the gathering head assembly, follow all Federal, State, and local safety regulations and observe the following:  WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of blocking devices.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.  1. Lower the conveyor tail section until it is level with the floor. Lower the gathering head until it rests on the floor. Place blocking under the rear of the gathering head to stabilize its position during and after removal of the pivot pins and disconnection of the lift cylinders.

2. Raise the cutter head to its highest point and place blocking underneath it. Lower the cutter head onto the blocking.

______________________________________________________________ A6474X308 Rev. 0 5.231

Replacement of wear parts _________________________________________ 3. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

4. Double check that the cutter head is securely blocked.

5. Separate the conveyor chain and remove the foot shaft (see Foot shaft removal procedure in this chapter).

6. Remove the retaining pin that secures each of the front rub rails to the tractor frame and open both front rub rails.

7. Remove the electrical power cables from the gathering head.

8. Disconnect, tag, and cap the motor cooling water and scrubber spray water hoses from the gathering head.

9. Remove the hex head capscrews and lockwashers that secure the right gathering head pivot pin retaining plate to the tractor frame (Fig. 154).

10. Remove the hex head capscrews and lock washers that secure the pin retaining plate to the gathering head pivot pin and remove the retaining plate.

Fig. 154: Gathering head pivot pin Hex head capscrews (retaining plate to tractor frame)

Pivot pin retaining plate

Gathering head pivot pin

Hex head capscrews (retaining plate to pivot pin)

_________________________________________________________________ 5.232 Bucyrus – Model 25C Continuous Miner

________________________________________ Replacement of wear parts

 11. Using a slide hammer, pull the pivot pin.

12. Repeat the previous three (3) steps for the left gathering head pivot pin.

13. Remove the hex head capscrews and lock washers that secure the piston pin retaining bar on the right gathering head lift cylinder to the gathering head side panel and remove the retaining bar (Fig. 155).

14. Repeat the previous step for the left gathering head lift cylinder.

Fig. 155: Gathering head lift cylinder piston pin retaining bar Piston pin

Lock washer

Gathering head lift cylinder

Retaining bar

Hex head capscrew



15. Connect the trailing cable to energizer the miner.

WARNING! Stand clear of the blocked cutter head and gathering head assemblies during the contraction of the gathering head lift cylinders.

16. Slowly contract the lift cylinders until the piston ends come free from their gathering head clevises.

CAUTION! When separating the gathering head from the tractor frame, ensure that the disconnected ends of the conveyor chain smoothly slide out of the gathering head.

17. Lift the cutter head off the blocking and slowly tram the miner in reverse until the cutter head clears the backboard of the gathering head.

______________________________________________________________ A6474X308 Rev. 0 5.233

Replacement of wear parts _________________________________________ gathering head assembly installation

When installing the gathering head assembly, follow all Federal, State, and local safety regulations and observe the following: WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of blocking and lifting devices .

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.

To install the gathering head assembly: 1. Position the gathering head assembly at the front of the tractor frame. Block up the rear of the gathering head so that it’s pivot points are at the level of the tractor frame clevises.

2. Raise the cutter head assembly to its highest point.

3. Slowly tram the miner forward until the gathering head pivot points are inserted into the tractor frame clevises.

CAUTION! When tramming the miner toward the gathering head, be careful that the conveyor chain and gathering head lift cylinders do not become pinched between the tractor frame and the gathering head.

4. Place blocking underneath the cutter head and lower the cutter head onto the blocking.

5. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

6. Thread the lower end of the conveyor chain into the gathering head assembly return pan so that the end appears on the foot shaft return plate. Place the upper end of the conveyor chain down the front of the gathering head entrance pan.

7. Connect the trailing cable to energize the miner.

8. Extend the gathering head lift cylinders so that the piston end bearings can be inserted into the gathering head lift cylinder clevises.

9. Disconnect the trailing cable to de-energize the miner.

10. Insert the piston end bearing of the right gathering head lift cylinder into the gathering head clevis.

11. Using the hammer, insert the piston end pin through the aligned clevis bushings and the rod end bearing.

_________________________________________________________________ 5.234 Bucyrus – Model 25C Continuous Miner

________________________________________ Replacement of wear parts

 IMPORTANT! Insert the pin far enough to avoid obstructing the placement of the pin retaining bar.

12. Place the pin retaining bar over the end of the pin and insert and tighten the two hex head capscrews and lock washers that secure the piston pin retaining bar to the gathering head side panel.

13. Repeat the previous three steps for the left gathering head lift cylinder.

CAUTION! Use caution when using the lift cylinders and stabilizer to adjust the alignment of the clevis and pivot pins.

14. Use the gathering head lift cylinders and tractor frame stabilizer to align the tractor frame clevis and the gathering head pivot points to make inserting pivot pins easier.

15. Gently tap the right gathering head pivot pin through the aligned tractor frame clevis and gathering head pivot bushings.

IMPORTANT! The pin must be inserted far enough so that it does not obstruct positioning of the retaining plate flat against the tractor frame.

16. Place the pivot pin retaining plate so that edge with two cutouts located in the corners is positioned against the backup strip. The edge of the plate with two cutouts and a hole for the pin’s grease fitting must be positioned over the pivot pin.

17. Insert and tighten the two hex head capscrews and lock washers to secure the pivot pin retaining plate to the gathering head pivot pin.

18. Insert and tighten the hex head capscrews and lock washers to secure the pivot pin retaining plate to the tractor frame.

19. Repeat the previous three steps for the left gathering head pivot pin.

20. Replace the motor cooling water and scrubber spray water hoses onto the gathering head assembly.

21. Replace the electrical power cables onto the gathering head assembly.

22. Close the front rub rails and insert and tighten a hex head capscrew and lock washer to secure the front rub rail closed against the tractor frame.

23. Replace the foot shaft into the gathering head (see Foot shaft removal and installation procedure in this chapter) and reconnect the conveyor chain.

______________________________________________________________ A6474X308 Rev. 0 5.235

Replacement of wear parts _________________________________________ Gathering head drive motor removal and installation gathering head drive motor removal

When removing the gathering head drive motor, follow all Federal, State, and local safety regulations and observe the following: WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all lifting and blocking devices.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.

To remove the gathering head drive motor: 1. Lower the gathering head completely until it touches the floor.

Lower the conveyor tail assembly until it is level with the floor.

2. Raise the cutter head assembly to its highest position. Place blocking underneath the cutter head assembly. Lower the cutter head assembly onto the blocking.

3. Disconnect the trailing cable to de-energize the miner.

4. If necessary, remove the CLA to allow access to the motor (See CLA removal and installation procedure in this chapter).

5. Remove the hex head capscrews and lock washers that secure the upper deck cover (Fig. 156) to the gathering head assembly.

6. Remove the upper deck cover. The gear case and drive shaft end of the motor should be exposed.

7. Locate the side cover of the gathering head motor and remove the hex head capscrews and lock washers that secure the side cover to the gathering head assembly.

8. Remove the cover to expose the end of the motor.

9. Remove the square-headed pipe plug on the end of the gathering head motor.

10. Remove the retaining ring that secures the shaft end plug inside the motor housing (Fig. 157).

11. Using a slide hammer, pull the drive shaft end plug out.

12. Pull the drive shaft from the motor and store in safe place.

13. Use the adjustable wrench to replace the pipe plug into the end of the motor.

14. Remove the hex head capscrews and lock washers that secure the motor junction box cover.

_________________________________________________________________ 5.236 Bucyrus – Model 25C Continuous Miner

________________________________________ Replacement of wear parts 15. Remove the cover and its o-ring.

16. Locate the three taped power connections inside the junction box and strip the tap covering each lug connection.

17. Tag each connection and remove the hex head capscrew, flat washer, lock washer, and hex head nut that secures each of the power cable lugs.

18. Remove the socket head capscrews and lock washers that secure the stuffing box’s half-moon clamp to the junction box.

19. Remove the clamp and slide the stuffing box out of the junction box. The power cable should be completely disconnected from the motor.

WARNING! While the power cable is detached from the motor, the trailing cable should not be reconnected to the miner. Damage to the machine or injury or death to personnel could result.

20. To prevent damage to the power cable lugs, stuffing box, and gland assembly, cover and secure the power cable to the miner in a safe location.

21. Replace the junction box o-ring and cover and secure with the hex head capscrews and lock washers to protect the motor’s electrical connections.

22. Tag, disconnect, and cap the two cooling water hoses (with elbow and adapter) from the two motor cooling water fittings on the gear case end of the motor.

23. Remove the two motor cooling water fittings from the motor and store in a clean place.

24. Plug the two motor cooling water ports to keep them clean.

WARNING! The next steps disconnect the gathering head drive motor from the adapter that links it to the gathering head gear case. The gathering head drive motor is extremely heavy. Be prepared to support this weight before performing the following steps.

25. Remove the socket head capscrews that secure the motor to the gear case adapter plate.

26. The gathering head drive motor should now be detached from the gear case and able to be removed from the gathering head assembly through the motor side cover opening.

______________________________________________________________ A6474X308 Rev. 0 5.237

Replacement of wear parts _________________________________________ Fig. 156: Upper deck cover

Upper deck cover

Lower deck cover

Fig. 157: Drive shaft and end plug removal

Drive shaft end plug

O-ring

Retainer ring Drive shaft

_________________________________________________________________ 5.238 Bucyrus – Model 25C Continuous Miner

________________________________________ Replacement of wear parts gathering head drive motor installation

When installing the gathering head drive motor, follow all Federal, State, and local safety regulations and observe the following: WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all lifting and blocking devices.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.

To install the gathering head drive motor: 1. Insert the gear case to motor seal between the adapter plate and the gear case (Fig. 158). When the motor is inserted, the seal should be located between the surfaces of the motor and the gear case.

2. Insert the gathering head motor through the slide cover opening, attachment bolt holes first. The junction box of the motor should be positioned toward the front of the gathering head.

Fig. 158: Gear case to motor seal installation

Gear case to motor seal

Gear case adapter plate

Motor

3. Position the motor against the gear case adapter plate and align the four attachment bolt holes on the gear case side of the motor with the four holes on the corners of the adapter plate.

4. Apply Loctite 242 (blue) to the four socket head capscrews.

5. Insert and tighten the socket head capscrews to secure the motor to the gear case adapter plate.

______________________________________________________________ A6474X308 Rev. 0 5.239

Replacement of wear parts _________________________________________

 6. Using an adjustable wrench, insert the two motor cooling water fittings into the gathering head drive motor’s cooling water ports, which are located on the gear case end of the motor.

7. Attach the two motor cooling water hoses (with elbow and adapter) to the fitting.

8. Remove the hex head capscrews and lock washers that secure the junction box cover.

9. Remove the cover and its o-ring.

10. Insert the three lugs of the power cable (with gland and stuffing box already installed) into the motor’s junction box.

11. Replace the stuffing box’s half-moon clamp in its channel to secure the stuffing box in the junction box.

12. Insert and tighten the two socket head capscrews and lock washers to secure clamp to the junction box.

13. Locate the motor’s lug connections inside the junction box and match the motor lug connections to the corresponding power cable lugs.

14. Attach the first motor lug to its corresponding power cable lug by inserting a hex head capscrew through the power cable lug, through the motor lug, through a flat washer, and through a lock washer. Secure the capscrew with a hex nut.

15. Repeat this step with the other two power cable and motor lugged connections.

16. When all three connections have been secured, wrap each of the three connections with a layer of rubber tape, then a layer of electrical (black) tape, and finally a layer of glass tape.

17. Replace the junction box o-ring and junction box cover and secure the cover with hex head capscrews and lock washers to secure the junction box cover.

18. Remove the pipe plug from the end of the motor (Fig. 159).

19. Slide the drive shaft through the gathering head motor and into the gathering head gear case (the drive shaft end without the threaded hole should be inserted first). The shaft may require some adjustment so that its end fits into the gear case.

20. Install the o-ring into the channel on the shaft end plug.

21. Insert the drive shaft end plug into position in the center of the motor.

_________________________________________________________________ 5.240 Bucyrus – Model 25C Continuous Miner

________________________________________ Replacement of wear parts 22. Insert the retaining ring to secure the shaft end plug inside the motor housing.

23. Replace the pipe plug into the end of the motor.

Fig. 159: Drive shaft installation

O-ring Retainer ring Pipe plug

Drive shaft

Drive shaft end plug

24. Replace the gathering head motor side access cover. Secure the cover to the gathering head by inserting and tightening the hex head capscrews.

25. Replace the upper deck cover and secure to the gathering head by inserting and tightening the hex head capscrews.

26. If removed, install the CLA over the motor (see CLA removal and installation procedure in this chapter).

______________________________________________________________ A6474X308 Rev. 0 5.241

Replacement of wear parts _________________________________________ Gathering head gear case removal and installation gathering head gear case removal

When removing the gathering head gear case, follow all Federal, State, and local safety regulations and observe the following: WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all lifting and blocking devices.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.

To remove the gathering head gear case: 1. Lower the conveyor tail section until it is level with the floor. Lower the gathering head until it touches the floor.

2. Raise the cutter head assembly to its highest position. Place blocking underneath the cutter head assembly. Lower the cutter head assembly onto the blocking.

3. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

4. Remove the gathering head motor’s side cover by removing the hex head capscrews and lock washers that secure the side cover to the gathering head assembly.

5. Remove the cover to expose the end of the motor.

6. Remove the square-headed pipe plug on the end of the gathering head motor.

7. Remove the retaining ring that secures the shaft end plug inside the motor housing (Fig. 159).

8. Using a slide hammer, pull out the drive shaft end plug.

9. Pull the drive shaft from the motor and store in a safe place.

10. Replace the pipe plug into the end of the motor.

11. Remove the CLA to expose the gathering head gear case (see CLA removal and installation procedure in this chapter).

12. Remove the hex head capscrews and lock washers that secure the upper deck cover (Fig. 160) to the gathering head assembly. Remove the upper deck cover to expose the gear case and the drive shaft end of the motor.

13. Remove the hex head capscrews and lock washers that secure the lower deck cover (Fig. 160) to the gathering head assembly and remove the lower deck.

_________________________________________________________________ 5.242 Bucyrus – Model 25C Continuous Miner

________________________________________ Replacement of wear parts Fig. 160: Deck covers

Upper deck cover

Lower deck cover

14. Loosen tension on the conveyor chain as much as possible (see Conveyor chain adjustment in the Adjustment procedures section of this chapter).

15. Separate the conveyor chain and remove the gathering head foot shaft (see the Foot shaft removal and installation procedure in this chapter).

16. Connect the trailing cable to energize the miner.

17. Raise the gathering head to its highest position. Place blocking underneath the gathering head and lower the gathering head onto the blocking.

18. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

19. Remove the drain plugs from the underside of the gathering head gear case and completely drain the gear case lubricant.

20. Replace the drain plugs into the underside of the gear case.

21. Connect the trailing cable to energize the miner.

22. Raise the gathering head off the blocking, remove the blocking, and lower the gathering head until it touches the floor.

______________________________________________________________ A6474X308 Rev. 0 5.243

Replacement of wear parts _________________________________________ 23. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

24. Disconnect, tag, and cap the four lubrication connections from the gathering head gear case.

25. Remove the socket head capscrews (Fig. 161) that secure the motor to the gear case adapter plate.

26. Remove the motor and clean out the cavity.

27. Remove the hex head capscrews that secure the gathering head gear case pot to the mounting plate.

28. The gathering head gear case is now unattached and can be removed from its position in the gathering head.

Fig. 161: Gear case removal Plugs

Socket head capscrews (gear case to adapter plate)

Adapter plate

Lubrication lines Hex head capscrews (gear case to mounting plate)

_________________________________________________________________ 5.244 Bucyrus – Model 25C Continuous Miner

________________________________________ Replacement of wear parts gathering head gear case removal

When installing the gathering head gear case, follow all Federal, State, and local safety regulations and observe the following: WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all lifting and blocking devices.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.

To install the gathering head gear case: 1. Insert a new gear case-to-motor seal between the adapter plate and the gear case (Fig. 162). When the gear case is inserted into the gathering head and the transfer case is positioned against the gathering head motor, the seal should be located between the surfaces of the motor and the gear case.

2. Carefully insert the gathering head gear case into position in the gathering head assembly.

3. Insert and tighten the hex head capscrews and lock washers to secure the gear case pot to its mounting plate.

Fig. 162: Gear case mounting Gear case adapter plate

Gear case-tomotor seal

Hex head capscrews

4. Install the motor and align the four holes on the corners of the adapter plate with the four attachment bolt holes on the gear case side of the motor.

5. Apply Loctite 242 (blue) to the four socket head capscrews.

6. Insert and tighten the four socket head capscrews to secure the gear case adapter plate to the motor.

7. Attach the four lubrication connections to the gathering head gear case.

______________________________________________________________ A6474X308 Rev. 0 5.245

Replacement of wear parts _________________________________________ 8. Attach the rose gun to the lower ports located adjacent to the gathering head side cover and fill the gathering head gear case to the proper level with lubricant. Check the gear case lubricant level at the sight glass adjacent to the gathering head side cover.

IMPORTANT! The bottom ports on the high speed input cases are the fill lines.

The top ports on the high speed input cases are the check lines.

9. Examine the gathering head gear case in various places for signs of leaking lubricant that identify improper installation or gear case damage.

10. Install the gathering head foot shaft and reconnect the conveyor chain (see Foot shaft installation procedure in this chapter).

11. Tighten the conveyor chain to the proper tension (see Conveyor chain adjustment in the Adjustment procedures section of this chapter).

IMPORTANT! Improper conveyor chain tension can lead to excessive wear, mechanical problems, and miner downtime. Always keep the conveyor chain at proper tension.

12. Replace the lower deck cover (Fig. 160) onto the gathering head assembly and secure to the gathering head assembly by inserting and tightening the hex head capscrews and washers.

13. Replace the upper deck cover (Fig. 160) onto the gathering head assembly and secure by inserting and tightening the hex head capscrews and washers.

14. Install the CLA onto the gathering head gear case turntable (see CLA removal and installation procedure in this chapter).

15. Remove the pipe plug from the end of the motor.

16. Slide the drive shaft through the gathering head motor and into the gathering head gear case (the drive shaft end without the threaded hole should be inserted first.) The shaft may require some adjustment so that its end fits into the gear case.

17. Install the o-ring into the channel on the shaft end plug (Fig. 163).

18. Insert the drive shaft end plug into position in the center of the motor.

19. Insert the retaining ring to secure the shaft end plug inside the motor housing.

20. Replace the pipe plug into the end of the motor.

_________________________________________________________________ 5.246 Bucyrus – Model 25C Continuous Miner

________________________________________ Replacement of wear parts 21. Replace the side cover onto the gathering head assembly.

22. Insert and tighten the hex head capscrews and lock washers to secure the side cover to the gathering head assembly.

Fig. 163: Drive shaft installation

O-ring Retainer ring Pipe plug

Drive shaft

Drive shaft end plug

______________________________________________________________ A6474X308 Rev. 0 5.247

Replacement of wear parts _________________________________________ Gathering head foot shaft removal and installation gathering head foot shaft removal

When removing the foot shaft, follow all Federal, State, and local safety regulations and observe the following: WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all lifting and blocking devices.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.

To remove the gathering head foot shaft (Fig. 164): 1. Lower the gathering head until it touches the floor.

2. Position the conveyor tail section directly behind the miner so that it is level with the floor.

3. Raise the cutter head assembly to its highest position. Place blocking underneath the cutter head assembly and lower the cutter head assembly onto the blocking.

4. Slowly advance the conveyor chain until a connecting link appears on the gathering head entrance pan.

5. Disconnect the trailing cable to de-energize the miner.

6. Loosen tension on the conveyor chain as much as possible (see Conveyor chain adjustment procedure in the Adjustment procedures section of this chapter).

7. With conveyor chain tension removed, remove the connecting link pins and the connecting link.

8. The conveyor chain should now be separated. Move the two pieces of the conveyor chain out of the way to allow for easier removal of the gathering head foot shaft.

9. Remove the hex head capscrews and lock washers that secure the foot shaft cover to the gathering head and remove the foot shaft cover.

10. Locate the two collars on the foot shaft and remove the hex head capscrews that secure each of the collars to the foot shaft. When the capscrews are removed, the flex lock nuts will fall free from the other side of the collar. Retrieve these nut and hand tighten them onto their capscrews for safe keeping. Remove both collars from the foot shaft.

_________________________________________________________________ 5.248 Bucyrus – Model 25C Continuous Miner

________________________________________ Replacement of wear parts 11. Slide the foot shaft couplings from the ends of the foot shaft toward the sprocket in the center. Once the couplings have been moved, the foot shaft is disconnected from the gear case bevel pinions.

12. The foot shaft can now be removed from the gathering head.

Fig. 164: Foot shaft removal Hex head capscrews

Foot shaft coupling

gathering head foot shaft installation

Foot shaft collar

When installing the foot shaft, follow all Federal, State, and local safety regulations and observe the following: WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all lifting and blocking devices.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.

To install the gathering head foot shaft (Fig. 164): 1. Slide a coupling onto each end of the foot shaft.

2. Insert the gathering head foot shaft into position between the two gathering head gear case bevel pinions.

IMPORTANT! Position the foot shaft so its sprocket will engage the conveyor chain links when the chain is reconnected.

3. Align the foot shaft splines with the bevel pinions’ splines.

4. Slide the right coupling over the foot shaft spline onto the bevel pinion splines until it touches the gear case seal carrier. Repeat with the left coupling.

______________________________________________________________ A6474X308 Rev. 0 5.249

Replacement of wear parts _________________________________________ 5. Place a collar onto each end of the foot shaft so that the collars keep the couplings secure against the gear case seal carriers, bridged between the foot shaft and bevel pinion.

6. Insert and tighten the hex head capscrews through both halves of each collar and into the flex lock nuts to secure the collars to the foot shaft.

7. Replace the foot shaft cover.

8. Insert and tighten the hex head capscrews and lock washers to secure the foot shaft cover to the gathering head.

9. Reattach the two ends of the conveyor chain by replacing the connecting link. Secure the link.

10. Tighten the conveyor chain to the proper tension (see Conveyor chain adjustment procedure in the Adjustment procedure section of this chapter).

IMPORTANT! Improper conveyor chain tension can lead to excessive wear, mechanical problems, and miner downtime. Always keep the conveyor chain at proper tension.

_________________________________________________________________ 5.250 Bucyrus – Model 25C Continuous Miner

________________________________________ Replacement of wear parts Gathering head lift cylinder removal and installation gathering head lift cylinder removal

When removing a lift cylinder, follow all Federal, State, and local safety regulations and observe the following: WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all lifting and blocking devices.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.

To remove a gathering head lift cylinder: 1. Lower the conveyor tail section so that it is level with the floor.

2. Completely raise the cutter head and gathering head assemblies.

3. Place blocking under the cutter head and gathering head assemblies and lower the assemblies onto the blocking.

4. Disconnect the trailing cable to de-energize the miner.

5. Remove the hex head capscrews and lock washers that secure the lift cylinder piston pin retaining bar to the gathering head side panel and then remove the retaining bar (Fig. 165).

Fig. 165: Gather head lift cylinder piston pin retaining bar Piston pin

Lock washer

Gathering head lift cylinder

Retaining bar

Hex head capscrew

______________________________________________________________ A6474X308 Rev. 0 5.251

Replacement of wear parts _________________________________________ 7. Use a slide hammer to pull the pin from the clevis bushings.

8. Connect the trailing cable to energize the miner.

WARNING! Stand clear of the blocked cutter head and gathering head assemblies during gathering head lift cylinder contraction.

9. Slowly contract the lift cylinder until the piston end comes free from its clevis.

10. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

11. Check the blocking that supports the cutter head and gathering head assemblies.

12. Move the gathering head lift cylinder control lever up and down to release any pressure from the gathering head lift cylinders.

13. Disconnect and plug the hydraulic hose from the gathering head lift cylinder’s hydraulic fitting.

14. Remove the hydraulic fitting from the gathering head lift cylinder and store it in a clean place.

15. Attach a lifting device to the gathering head lift cylinder. Take up any slack in the lift device so that the weight of the cylinder rests on the left device.

16. Remove the two hex head capscrews and lock washers that secure the pin retaining plate on the gathering head lift cylinder to the tractor frame and remove the retaining plate.

17. Using a slide hammer, remove the rod end pin from the frame clevis bushing. The cylinder should now be able to be removed from the miner.

_________________________________________________________________ 5.252 Bucyrus – Model 25C Continuous Miner

________________________________________ Replacement of wear parts gathering head lift cylinder installation

When installing a lift cylinder, follow all Federal, State, and local safety regulations and observe the following: WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all lifting and blocking devices.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.

To install the lift cylinder: 1. Insert the piston end bearing of the gathering head lift cylinder into the gathering head assembly clevis.

2. Insert the piston end through the aligned clevis bushings and piston end bearing.

WARNING! When aligning the cylinder end bearings within their clevises to allow for insertion of the retaining pins, do not test alignment with your fingers. Shifting parts could cause serious injury.

3. Place the pin retaining bar over the piston end pin and secure to the gathering head side panel with hex head capscrews and lock washers.

4. Insert the hydraulic fitting into the gathering head lift cylinder hydraulic port.

5. Attach the hydraulic hose to the gathering head cylinder hydraulic fitting.

6. Connect the trailing cable to energize the miner.

7. Slowly extend the cylinder so that its rod end bearing can be inserted into the gathering head cylinder frame clevis.

8. Disconnect the trailing cable to de-energize the miner.

9. Position the gathering head cylinder rod and bearing into the gathering head cylinder frame clevis.

10. Insert the rod end pin into the aligned clevis bushings and rod end of the cylinder.

IMPORTANT! Insert the pin so that its retaining channel remains outside of the bushing.

11. Insert the pin retaining plate in the pin’s channel to secure the pin in the clevis.

12. Insert and tighten the two hex head capscrews and lock washers that secure the pin retaining plate to the tractor frame.

______________________________________________________________ A6474X308 Rev. 0 5.253

Replacement of wear parts _________________________________________ Centrifugal loading apparatus (CLA) removal and installation CLA removal

When removing the boom pivot pin, follow all Federal, State, and local safety regulations and observe the following: WARNING! You can be seriously injured or killed by falling loads. Observe the safe working load limits of all blocking devices.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.

To remove a CLA:  1. Lower the conveyor tail section until it is level with the floor. Lower the gathering head until it touches the floor.

2. Raise the cutter head assembly to its highest position. Place blocking under the cutter head assembly. Lower the cutter head assembly onto the blocking.

3. Disconnect the trailing cable to de-energize the miner.

4. Use a screwdriver to pry out the hog rings (Fig. 166) from around each of the CLA’s socket head capscrews.

5. Remove the socket head capscrews located where the arms meet the CLA hub.

6. Remove the capscrews located in the center of the CLA hub. The CLA should now be free and able to be removed.

Fig. 166: Centrifugal loading apparatus (CLAs)

Hog rings

CLA tip

CLA

Socket head capscrews

_________________________________________________________________ 5.254 Bucyrus – Model 25C Continuous Miner

________________________________________ Replacement of wear parts

 7. Remove the four CLA alignment keys (Fig. 167) from the exposed gathering head gear case turntable and store the keys in a safe place.

Fig. 167: CLA alignment key removal Alignment key

Inner hub

CLA installation

When removing the boom pivot pin, follow all Federal, State, and local safety regulations and observe the following: WARNING! You can be seriously injured or killed by falling loads. Observe the safe working load limits of all blocking devices.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.

To install the CLA: 1. On the CLA exterior, mark the bolt hole (outer set of three holes) located directly adjacent to a key cut-out.

2. Place an alignment dowel (Fig. 168) in the gathering head gear case turntable bolt hole (outer set of three holes) that is directly adjacent to a key cut-out.

3. Place the four keys into their cutouts on the gathering head gear case turntable.

4. Place the CLA onto the gear case turntable so that the dowel extends through the marked CLA hole. Adjust the CLA as necessary to fit the turntable keys into the CLA cut-outs.

5. Insert two socket head capscrews into the CLA outer holes not blocked by the dowel.

6. Remove the alignment dowel and insert the last socket head capscrew into the CLA hole.

______________________________________________________________ A6474X308 Rev. 0 5.255

Replacement of wear parts _________________________________________

 7. Tighten the three capscrews to secure the CLA to the gear case turntable.

8. Use the hammer to install three hog rings into the counterbore around each of the three outer socket head capscrews of the CLA..

The rings should be tapped down until they are below the chamfer of the socket head capscrews.

IMPORTANT! Hog rings should be installed so that their sharp points are directed clockwise.

9. Insert the socket head capscrews into CLA hub bolt holes and tighten.

10 Use the hammer to install hog rings into the counterbore around each of the socket head capscrews of the CLA hub (Fig. 169). The rings should be tapped down until they are below the chamfer of the socket head capscrews.

Fig. 168: Alignment dowel placement Alignment dowel placement location Alignment key

Inner hub

Gear case turn table

Fig. 169: Hog ring installation

Capscrew chamfer

Hog ring

Hog ring

Bottom of hog ring counterbore

_________________________________________________________________ 5.256 Bucyrus – Model 25C Continuous Miner

________________________________________ Replacement of wear parts CLA tip replacement When replacing a CLA tip, follow all Federal, State, and local safety regulations and observe the following:  WARNING! You can be seriously injured or killed by falling loads. Observe the safe working load limits of all lifting and blocking devices.  WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.  1. Lower the conveyor tail section until it is level with the floor. Lower the gathering head until it touches the floor.

2. Raise the cutter head assembly to its highest position. Place blocking under the cutter head assembly, both on the floor and on the gathering head. Lower the cutter head assembly onto the blocking.

3. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

4. Locate the CLA tip which requires replacement.

5. Remove the hex head capscrews that secure the tip to the CLA. 6. Use force as necessary to remove the tip from the CLA..

7. Slide the new tip onto the CLA. 8. Insert and tighten the hex head capscrews through the tip and the CLA.

______________________________________________________________ A6474X308 Rev. 0 5.257

Replacement of wear parts _________________________________________ Tram motor removal and installation tram motor removal

When removing the tram motor, follow all Federal, State, and local safety regulations and observe the following: WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all lifting and blocking devices.

To remove the tram motor: 1. Lower the conveyor tail section until it is level with the floor.

2. Lower the gathering head and cutter head assemblies until they touch the floor.

3. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

4. Remove the rub rail pins that secure the tram rub rail to the rub rail section adjacent to it.

5. Swing the tram rub rail out to expose the tram gear case and locate the tram drive motor inside the gear case (Fig. 170).

6. Remove the hex head capscrews and hi-collar lock washers that secure the input shaft access cover to the motor housing.

7. Remove the input shaft access cover and its o-ring.

8. Remove the retaining ring that secures the shaft plug in position.

9. Remove the shaft plug with o-ring that secures the input shaft in the motor (Fig. 171).

10. Pull the input shaft from the motor and store in a safe place.

11. Replace the input shaft access cover on the motor housing and secure the cover with the hex head capscrews and hi-collar lock washers.

12. Tag, disconnect, and cap the cooling water hoses from the cooling water fittings located on the top left and right corners of the tram motor.

_________________________________________________________________ 5.258 Bucyrus – Model 25C Continuous Miner

________________________________________ Replacement of wear parts 13. Remove the cooling water fittings from the top left and right corners of the tram motor and store in a safe place.

14. Remove the hex head capscrews and disc lock washers that secure the tram motor bracket to the tram case.

15. Remove the socket head set screws that secure the tram motor bracket to the tram motor.

16. Remove the tram motor bracket from the tram motor.

17. Carefully slide the tram motor out from the tram case until the motor’s electrical connection and junction box cover are accessible.

18. Remove the socket head capscrews and hi-collar lockwashers that secure the junction box cover to the motor housing.

19. Remove the junction box cover and its o-ring from the motor housing.

20. Remove the socket head capscrews and lock washers that secure the stuffing box's half moon clamp to the junction box.

21. Tag and disconnect the power cable lugs and the communication connections.

22. Remove the clamps and slide the stuffing box out of the junction box. The power cable and communication cable should be completely disconnected from the motor.

WARNING! Do not reconnect the trailing cable to the miner while the power cable is detached from the motor. Serious injury or death or damage to the machine may result.

23. To prevent damage to the power cable lugs and gland assembly, cover the power cable and communication cable, and secure them to the miner in a safe location.

24. To protect the motor’s electrical connections, replace the motor junction box cover and o-ring and secure using the socket head capscrews and hi-collar lock washers.

25. Carefully remove the tram motor from the tram case and slide onto blocking.

______________________________________________________________ A6474X308 Rev. 0 5.259

Replacement of wear parts _________________________________________ Fig. 170: Tram drive motor location

Tram drive motor

Fig. 171: Shaft plug removal

Shaft plug

O-ring Retaining ring

_________________________________________________________________ 5.260 Bucyrus – Model 25C Continuous Miner

________________________________________ Replacement of wear parts tram motor installation

When removing the boom pivot pin, follow all Federal, State, and local safety regulations and observe the following: WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all lifting and blocking devices.

To install the tram motor: 1. Slide the tram motor into the tram case, leaving the motor’s junction box cover and stuffing box accessible outside the tram case.

Fig. 172: Tram motor installation Tram case

Tram motor

Motor-to-adapter seal

2. Remove the socket head capscrews and hi-collar lock washers that secure the junction box cover to the motor housing.

3. Remove the junction box cover and its o-ring.

4. Insert the three lugs of the power cable (with gland and stuffing box already installed) and communication cable into the tram motor’s junction box.

5. Replace the stuffing box’s half-moon clamp in its channel to secure the stuffing box in the junction box.

6. Tighten the socket head capscrews to secure the clamp to the junction box.

______________________________________________________________ A6474X308 Rev. 0 5.261

Replacement of wear parts _________________________________________

 7. Connect the motor so that it is phased correctly. Traction motor have to be phased such that one motor rotates clockwise and the other counterclockwise. At all times, the left and right motor connections should be made as below: Motor 1 - Left

2 - Right

Inverter Terminal

Color

Motor Terminal

Color

T1

Red

U/T1

Red

T2

White

V/T2

White

T3

Black

W/T3

Black

T1

Red

U/T1

Red

T2

White

V/T2

Black

T3

Black

W/T3

White

Note: The motor leads are phased at the MOTOR END. The electrician should only change the motor end connections to phase the motor correctly.

A new motor should come equipped with an encoder. The encoder connections should be made inside the traction enclosure and the traction case. See the Encoder removal and installation procedure in this section for more information.

8. Replace the motor junction box cover and o-ring, and secure it with socket head capscrews and hi-collar lockwashers.

9. Assemble the bracket to the motor.

10. Carefully slide the tram motor into position in the tram case. The end of the motor must be completely flush against the primary planetary adapter plate.

11. Insert and tighten the hex head capscrews and disc lock washers to secure the tram motor bracket to the tram case.

12. Insert the two cooling water fittings into the cooling water ports located on the top left and right corners of the tram motor.

13. Attach the cooling water hoses to the two cooling water fittings located on the top left and right corners of the tram motor.

14. Remove the input shaft access cover and its o-ring.

15. Slide the input shaft through the tram motor and into the tram planetary primary gear (the input shaft end without the threaded hole should be inserted first). The shaft may require some adjusting so that its splined end fits into the gear.

16. When the drive shaft is correctly positioned in the motor, install the o-ring onto the input shaft plug and then insert the plug into the motor.

_________________________________________________________________ 5.262 Bucyrus – Model 25C Continuous Miner

________________________________________ Replacement of wear parts

 17. Insert the retaining ring to secure the input shaft plug inside the tram motor.

18. Replace the input shaft access cover and its o-ring on the motor housing. Secure the cover with hex head capscrews and hi-collar lock washers.

19. Swing in the tram rub rail between the two adjacent rub rails and secure it with the rub rail pins.

______________________________________________________________ A6474X308 Rev. 0 5.263

Replacement of wear parts _________________________________________ Tram primary planetary gear removal and installation primary planetary gear removal

When removing the tram primary planetary gear, follow all Federal, State, and local safety regulations and observe the following: WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.

To remove the primary planetary gear (Fig. 173): 1. Lower the conveyor tail section until it is level with the floor.

2. Lower the gathering head and cutter head assemblies until they touch the floor.

3. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

4. Remove the two rub rail pins that secure the tram rub rail to the two rub rail sections adjacent to it and remove the tram rub rail to expose the tram gear case.

5. Remove the tram motor (see Tram motor removal and installation procedure in this chapter).

6. Remove the socket head capscrews that secure the motor adapter plate to the primary gear ring (and also secure the primary planetary carrier assembly to the tram case).

7. Remove the motor adapter plate from the tram case.

8. Carefully slide the primary planetary carrier assembly out of the primary gear ring and remove the assembly from the tram case.

9. Carefully slide the primary gear ring out of the tram case.

_________________________________________________________________ 5.264 Bucyrus – Model 25C Continuous Miner

________________________________________ Replacement of wear parts Fig. 173: Tram primary gear removal Tram case

Motor adapter plate Socket head capscrews

Primary planetary gear ring Primary planetary carrier assembly

Fig. 174: Alignment dowels and gear ring mounting Alignment dowels

Tram case

Primary planetary gear ring

Tram drive pinion gear

Mounting marks (match with alignment dowels)

______________________________________________________________ A6474X308 Rev. 0 5.265

Replacement of wear parts _________________________________________ primary planetary gear installation

To install the tram primary planetary gear: 1. Insert alignment dowels into four of the sixteen capscrew holes in the tram case (Fig. 174).

2. To facilitate gear ring insertion, mark the mounting holes of the primary planetary gear ring that corresponds to the holes in which dowels were placed.

3. Slide the primary planetary gear ring onto the alignment dowels so the dowels appear through the marked holes.

4. Carefully insert the primary planetary gear assembly into the gear ring, ensuring that the extension of the sun gear faces out from the centerline of the miner and that the internal gear teeth of the primary carrier are seated securely onto the tram drive pinion gear.

5. Place the two adapter plate dowels into two (2) 1 inch holes on the bottom left and right corners of the adapter plate.

6. Orient the adapter plate with the adapter dowels along the bottom edge.

7. Slide the adapter plate onto the four alignment dowels.

8. Insert and tighten twelve socket head capscrews into the holes in the adapter plate not blocked by the alignment dowels.

9. Remove the four alignment dowels and insert and tighten the final four socket head capscrews to secure the adapter plate and gear ring to the tram case.

10. Torque the sixteen socket head capscrews to the appropriate amount (see Torque tables in Chapter 6 of this manual).

11. Install the tram motor in the tram case (see Tram motor removal and installation procedure in this chapter).

12. Replace the tram rub rail between the two adjacent rub rails and secure it with the two rub rail pins.

13. Refill the tram gear case with oil.

_________________________________________________________________ 5.266 Bucyrus – Model 25C Continuous Miner

________________________________________ Replacement of wear parts

Tram secondary planetary gear removal/installation secondary planetary gear removal

When removing the tram secondary planetary gear, follow all Federal, State, and local safety regulations and observe the following: WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.

To remove the tram secondary planetary gear: 1. Lower the conveyor tail section until it is level with the floor.

2. Lower the gathering head and cutter head assemblies until they touch the floor.

3. Disconnect the trailing cable to de-energize the miner.

4. Remove the two rub rail pins that secure the tram rub rail to the two rub rail sections adjacent to it and remove the tram rub rail.

5. Remove the plug from the bottom of the tram secondary planetary gear cover and drain the lubricant from the gear case.

6. Replace the oil drain plug in the gear cover (Fig. 175).

7. Remove the sixteen socket head capscrews that secure the secondary planetary gear cover to the tram case and carefully remove the secondary planetary gear cover.

Fig. 175: Tram secondary planetary gear cover and drain plug

Tram secondary planetary gear cover

Socket head capscrews

Drain plug

______________________________________________________________ A6474X308 Rev. 0 5.267

Replacement of wear parts _________________________________________

 8. Remove the secondary planetary gear thrust washer (Fig. 176).

WARNING! The next step removes the secondary planetary gear ring from the secondary planetary gear assembly. The secondary planetary gear ring is extremely heavy. Be prepared to support its weight before removing it from the secondary planetary assembly.

9. Carefully slide the secondary planetary gear ring off the secondary planetary gear assembly.

10. Insert eight hex head capscrews into the sprocket bearing carrier to secure it to the tram case.

11. Carefully pull the secondary tram drive shaft from the gear and sprocket and store in a safe place.

12. Carefully slide the secondary planetary assembly out of the sprocket bearing carrier.

Fig. 176: Secondary planetary assembly removal Ring gear

Secondary planetary gear assembly

Thrust washer

Hex head capscrew

Secondary planetary gear assembly

Secondary tram drive shaft

Sprocket bearing carrier

Secondary planetary gear assembly

_________________________________________________________________ 5.268 Bucyrus – Model 25C Continuous Miner

________________________________________ Replacement of wear parts secondary planetary gear removal

To install the tram secondary planetary gear: 1. Carefully insert the secondary planetary gear assembly into the sprocket bearing carrier (Fig. 177), ensuring that the splined extension of the planetary carrier seats securely in the interior teeth of the sprocket.

Fig. 177: Planetary carrier installation Sprocket bearing carrier

Secondary planetary gear assembly Sprocket teeth

Splined extension

2. Slide the secondary tram drive shaft through the secondary planetary gear assembly and into the tram drive sprocket and reach gear set (the drive shaft end without the threaded hole should be inserted first). The shaft may require some adjustment so that the end fits into the reach gears.

3. Insert four alignment dowels into the holes in the sprocket bearing carrier not blocked by the eight hex head capscrews (Fig. 178).

4. To facilitate gear ring insertion, mark the mounting holes of the secondary planetary gear ring that corresponds to the holes in which the dowels were placed.

5. Remove the eight hex head capscrews that secure the sprocket bearing carrier to the tram.

Fig. 178: Gear ring installation Secondary planetary gear assembly

Sprocket bearing carrier

Gear ring

Thrust washer

Alignment marks

Alignment dowels

Hex head capscrews

______________________________________________________________ A6474X308 Rev. 0 5.269

________________________________________ Replacement of wear parts

 9. Apply silicon sealant to the ring gear.

10. Carefully slide the secondary planetary gear ring onto the four alignment dowels so that the dowels appear through the marked holes. The planetary gear teeth should slide smoothly and securely into the gear teeth should slide smoothly and securely into the gear ring teeth.

11. Place the thrust water into the secondary planetary carrier directly behind the secondary tram drive shaft. The side of the thrust washer with the inscribed circles should face away from the drive shaft.

12. Apply silicon sealant to the cover.

13. To facilitate gear cover replacement, mark the mounting holes of the secondary planetary gear cover that corresponds to the holes in which alignment dowels are placed.

14. Slide the secondary planetary gear case cover onto the alignment dowels so that the dowels appear through the marked holes.

IMPORTANT! The flat edge of the cover located adjacent to the lubrication fitting is the top of the cover. Orient the cover so that the lubricant level check plug is on the motor side of the cover and the drain plug is on the bottom.

15. Insert and tighten the twelve socket head capscrews into the holes in the gear case cover not blocked by the alignment dowels.

16. Remove the four alignment dowels.

17. Insert and tighten the remaining four socket head capscrews to secure the cover, the gear ring, and the sprocket bearing carrier to the tram case.

18. Using a torque wrench, torque all sixteen socket head capscrews to the proper torque (see Torque tables in Chapter 6 of this manual).

19. Using the lubrication fitting at the top of the gear cover, fill the secondary planetary gear case to the proper level with lubricant.

20. Examine the secondary planetary gear case in various places for signs of leaking lubricant that identify improper installation or gear case damage.

21. Replace the tram rub rail between the two adjacent rub rails and secure it with the two rub rail pins.

______________________________________________________________ A6474X308 Rev. 0 5.270

________________________________________ Replacement of wear parts Tram case removal and installation tram case removal

When removing the tram case, follow all Federal, State, and local safety regulations and observe the following: WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all lifting and blocking devices.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.

To remove the tram case: 1. Lower the conveyor tail section until it is level with the floor.

2. Raise the gathering head and cutter head and place a small stack of blocking under these two assemblies.

3. Lower the gathering head and cutter head onto the blocking so that the front end of the miner lifts off the floor.

4. Extend the stabilizer completely so that the rear end of the miner lifts off of the floor.

5. Place blocking in multiple locations under the miner tram track.

When the miner is lowered, the tram track should be secured between the blocking and the tractor frame.

6. Raise the stabilizer and the gathering head and cutter head assemblies so the weight of the miner rests on the blocking.

7. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

8. Remove the two rub rail pins that secure the tram rub rail to the two rub rail sections adjacent to it and remove the tram rub rail to expose the tram case.

9. Remove the hex head capscrew and lock washer that secure the front rub rail to the tractor frame and open the front rub rail cover.

10. Attach the grease gun to the front idler take-up cylinder fitting (Fig. 179) and pump grease into the take-up cylinder to extend the cylinder and remove pusher plate pressure on the idler shims.

______________________________________________________________ A6474X308 Rev. 0 5.271

Replacement of wear parts _________________________________________ 11. Remove all the idler adjustment shims and store the shims in a safe place.

12. Open the pressure release valve for the front idler take-up jack and allow the cylinder to contract.

Fig. 179: Idler take-up cylinder Idler take-up cylinder

Pressure release valve

Grease fitting

Idler adjustment shims

13. Locate a tram track link near the track entry opening at the bottom of the tram case (Fig. 180) and, using a hammer and punch, remove the two roll pins that secure the tram track pin between the links. Store the roll pins in a safe place.

14. Using the hammer and punch, remove the tram track pin to disconnect the links and separate the track. Store the track pin in a safe place.

Fig. 180: Tram track removal

Roll pins

Separate track here

Tram track pin

_________________________________________________________________ 5.272 Bucyrus – Model 25C Continuous Miner

________________________________________ Replacement of wear parts

 15. Attach guide wires to the end of the tram track that passes through the tram case.

16. Connect the trailing cable to energize the miner.

17. Use the tram motor to slowly rotate the sprocket so that the end of the tram track that passes through the case is pulled up through the case and rolls off the sprocket.

18. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

19. Pull on the tram track from the front of the miner (near the idler) so that the free end of the tram track is pulled clear of the tram case exit opening.

20. Remove the tram motor (see Tram motor removal and installation procedure in this chapter).

21. Remove the bolts and washers from the sprocket and motor sides of the tram case.

22. Place a stack of blocking in front of the tram case onto which the case can be removed.

WARNING! The next step removes the tram case from the tractor frame. The tram case (with sprocket and reach gears) is extremely heavy. Be prepared to support the tram case before removing it from the tractor frame.

WARNING! Ensure that the electrical cables and cooling water hoses for the tram motor are free from the tram cases before attempting to remove the tram case from the tractor frame.

23. Carefully slide the tram case out from the tractor frame and onto the blocking.

24. Pull the tram track guide wires out of the tram case exit opening and secure the wires to the tractor frame.

______________________________________________________________ A6474X308 Rev. 0 5.273

Replacement of wear parts _________________________________________ tram case installation

When installing the tram case, follow all Federal, State, and local safety regulations and observe the following: WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all lifting and blocking devices.

WARNING! You could be seriously injured or killed by falling loads. Follow mine procedure to remove blocking devices and use caution.

To install the tram case: 1. Block up the tram case adjacent to its tractor frame position at a level that makes it easy to slide the case into the tractor frame.

2. Thread the guide wires through the tram case exit opening, between the sprocket gears, and out the tram case entry opening.

3. Slide the tram case into position in the tractor frame.

IMPORTANT! The guide wires will be used to pull the tram track links onto the tram case sprocket after the tram case is installed.

WARNING! Before attempting to slide the tram case into the tractor frame, ensure that the tram motor electrical and water connections are out of the way. Failure to do so may result in damage to the electrical and water connections.

4. Slide the tram case into position in the tractor frame.

5. Install the bolts that secure the motor side of the tram case to the tractor frame.

6. Install the bolts that secure the sprocket side of the tram case to the tractor frame.

7. Replace the tram motor (see Tram motor removal and installation procedure in this chapter).

8. While feeding the tram track from the front of the miner (near the idler), pull on the tram track guide wires until a link of the tram track engages the sprocket.

9. Connect the trailing cable to energize the miner.

WARNING! Stand clear of the miner when using the motor to pull the tram track through the tram case.

_________________________________________________________________ 5.274 Bucyrus – Model 25C Continuous Miner

________________________________________ Replacement of wear parts 10. Use the tram motor to slowly rotate the sprocket and pull the tram track through the case until the end appears out the bottom.

WARNING! Double check that the links of the tram track are correctly seated onto the tram drive sprocket. Improper engagement of the tram track links onto the sprocket can cause serious mechanical damage.

11. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

12. Remove the guide wires from the tram track.

13. Connect the two ends of the tram track and using the hammer and punch, insert the track pin to secure the two track links together.

14. Using the hammer and punch, insert the two roll pins into the track pin to secure the pin in the links.

15. Adjust the tram track tension (see Tram track adjustment procedure in the Adjustment procedures section of this chapter).

16. Close the front rub rail cover and replace the hex head capscrews and lock washers that secure the front rub rail to the tractor frame.

17. Replace the tram rub rail between the two adjacent rub rails and secure it with the two rub rail pins.

18. Connect the trailing cable to energize the miner.

19. Remove blocking.

______________________________________________________________ A6474X308 Rev. 0 5.275

Replacement of wear parts _________________________________________ Tram reach gear set removal and installation tram case removal

When removing the tram reach gear set, follow all Federal, State, and local safety regulations and observe the following: WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all lifting and blocking devices.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.

To remove the tram reach gear set: 1. Lower the conveyor tail section until it is level with the floor.

2. Raise the gathering head and cutter head assemblies and place a small stack of blocking under each.

3. Lower the gathering head and cutter head onto the blocking so that the front end of the miner lifts off the floor.

4. Extend the stabilizer completely so that the rear end of the miner lifts off the floor.

5. Place blocking in multiple locations under the miner tram track to securely support the tractor frame off the floor.

6. Raise the stabilizer and the gathering head and cutter head assemblies so the weight of the miner rests on the blocking. When the tractor frame is lowered, the tram track should be secured between the blocking and the tractor frame.

7. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

8. Double-check the tractor frame support blocking now that the weight of the tractor frame is completely upon it.

9. Remove the two rub rail pins that secure the tram rub rail to the two rub rail sections adjacent to it and remove the tram rub rail to expose the tram case.

10. Remove the tram case (see Tram case removal and installation procedure in this chapter).

11. Remove the plug from the motor end of the reach gear case bottom and drain the lubricant from the gear case.

12. When the lubricant has been completely drained, replace the plug.

_________________________________________________________________ 5.276 Bucyrus – Model 25C Continuous Miner

________________________________________ Replacement of wear parts 13. Remove the hex head capscrews and lock washers (Fig. 181) that secure the reach gear case cover to the gear case and remove the cover.

Fig. 181: Reach gear case cover removal Hex head capscrews Lock washers Reach gear case cover

Reach gear case Rear side of tram case

Drain plug

14. Locate the cap bearing carrier that secures the tram drive pinion inside the reach gear case.

15. Using retaining ring pliers, remove the retaining ring located outside the cap bearing carrier on the tram drive pinion (Fig. 182).

16. Using the wire cutters, cut and remove the wire securing the cap bearing carrier capscrews in position.

17. Remove the four drilled head capscrews and lock washers that secure the cap bearing carrier to the tram case and remove the cap bearing carrier.

Fig. 182: Cap bearing carrier removal Drilled head capscrews

Cap bearing carrier

Retaining ring

Tram drive pinion

______________________________________________________________ A6474X308 Rev. 0 5.277

Replacement of wear parts _________________________________________

 18. Remove the three steel shims and the bearing found under the shims (Fig. 183).

19. Carefully pull the tram drive pinion out of the reach gear case through the cap bearing carrier opening.

Fig. 183: Tram drive pinion removal Bearing carrier opening Cap bearing carrier

Tram drive pinion Bearing cup and cone set

Shims

20. Cut and remove the wire securing the idler shaft capscrews in position.

21. Remove the drilled hex head capscrews that secure the idler shaft cap to the tram case and remove the idler shaft and three steel shims located under the cap.

22. Carefully slide the idler shaft out of the reach gear case through the idler shaft cap opening.

23. Remove the idler reach gear through the top opening of the reach gear case (Fig. 184).

24. Remove the bearing cup and cone sets from the center indentions of the idler reach gear.

_________________________________________________________________ 5.278 Bucyrus – Model 25C Continuous Miner

________________________________________ Replacement of wear parts Fig. 184: Idler reach gear and idler shaft removal Idler reach gear

Bearing cup and cone set Reach gear case

Rear side of tram case

Shims

Hex head capscrews

Idler shaft cap

25. Remove the hex head capscrews and lock washers that secure the sprocket reach gear bearing cap to the reach gear case (Fig. 185).

26. Remove the bearing cap and the three steel shims under the cap.

27. Remove the bearing cone and cup set from the end of the splined sleeve.

28. Carefully slide the splined sleeve out of the sprocket reach gear.

29. Remove the sprocket reach gear through the top opening of the reach gear case.

30. Remove the second splined sleeve bearing cone and cup set from the rear of the reach gear case, located behind the sprocket reach gear.

Fig. 185: Sprocket reach gear removal Sprocket reach gear Splined sleeve Shims

Bearing cup and cone set Reach gear case

Sprocket reach gear bearing cap

Hex head capscrews

______________________________________________________________ A6474X308 Rev. 0 5.279

Replacement of wear parts _________________________________________ tram reach gear set installation

To install the tram reach gear set: 1. Insert one of the bearing cup and cone sets (cone side facing out) into the cut-out inside the reach gear case adjacent to the tram case sprocket (Fig. 186).

Fig. 186: Bearing cup and cone set installation Bearing cup and cone set

2. Insert the sprocket reach gear into the top of the reach gear case and position it against the bearing cup and cone set adjacent to the tram case sprocket (Fig. 187).

Fig. 187: Sprocket reach gear installation

Sprocket reach gear set

3. Insert the splined sleeve into the reach gear case (Fig. 188), through the sprocket reach gear and through the bearing cup and cone set until it is positioned against the tram sprocket.

4. Slide the second bearing cup and cone set (cup side facing out) onto the end of the splined sleeve.

5. Replace the three steel shims over the bearing set.

6. Replace the sprocket reach bearing cap.

7. Insert and tighten the hex head capscrews and lock washers to secure the sprocket reach gear bearing cap to the reach gear case.

_________________________________________________________________ 5.280 Bucyrus – Model 25C Continuous Miner

________________________________________ Replacement of wear parts Fig. 188: Splined sleeve and bearing cap installation Sprocket reach gear Splined sleeve Shims

Bearing cup and cone set Reach gear case

Sprocket reach gear bearing cap

Hex head capscrews

8. Insert two cup and cone bearing sets into the central cut-outs on either side of the idler reach gear (Fig. 189). The cone side of the bearing sets should face out of the gear on both sides.

9. Insert the idler reach gear through the top opening of the reach gear case and position it against the sprocket reach gear, ensuring that the gear teeth securely mesh.

10. Insert the idler shaft through the bearing sets in the idler reach gear until it is positioned against the tractor frame.

11. Replace the three steel shims over the idler shaft.

12. Replace the idler shaft cap.

Fig. 189: Idler reach gear and idler shaft installation Idler reach gear

Rear side of tram case

Bearing cup and cone set Reach gear case

Shims

Hex head capscrews

Idler shaft cap

______________________________________________________________ A6474X308 Rev. 0 5.281

Replacement of wear parts _________________________________________

 13. Insert and tighten the ten drilled hex head capscrews to secure the idler shaft cap.

14. Insert the tram drive pinion through the cap bearing carrier opening (located on the inside of the tram case tram motor bay) into the reach gear case. Ensure that the teeth of the pinion securely mesh with the idler reach hear teeth.

15. Replace the pinion bearing.

16. Replace the three steel shims over the pinion bearing.

17. Replace the cap bearing carrier over the pinion end.

18. Insert and tighten the drilled hex head capscrews and lock washers to secure the cap bearing carrier to the tram case.

19. Install the retaining ring on the tram drive pinion.

20. Double check that the tram drive pinion, idler reach gear and sprocket reach gear teeth are properly meshed and the gears rotate smoothly.

21. Tighten the sprocket reach gear bearing cap capscrews to correct torque (see Torque tables in Chapter 6 of this manual).

22. Tighten the idler shaft cap capscrews to correct torque (see Torque tables in Chapter 6 of this manual).

23. Lock wire the idler shaft cap capscrews to secure their positions.

24. Tighten the tram drive pinion cap bearing carrier capscrews to correct torque (see Torque tables in Chapter 6 of this manual).

25. Lock wire the tram drive pinion cap bearing carrier capscrews to secure their positions.

26. Replace the reach gear case cover onto the top of the reach gear case.

27. Insert and tighten fourteen hex head capscrews and lock washers to secure the reach gear case cover to the gear case.

28. Remove the plug from the sprocket side of the reach gear case cover.

29. Fill the reach gear case to the proper level with lubricant (Spec.

100-14).

30. Replace the fill plug.

31. Replace the tram case into the tractor frame (see Tram case removal and installation procedure in this chapter).

_________________________________________________________________ 5.282 Bucyrus – Model 25C Continuous Miner

________________________________________ Replacement of wear parts IMPORTANT! The re-installation procedure for the tram case includes reinstallation of the primary and secondary planetary gears and the tram motor, and reconnection of the tram track.

32. Replace the tram rub rail between the two adjacent rub rails and secure it with the two rub rail pins.

33. Reconnect the trailing cable to energize the miner.

34. Raise the tractor frame by lowering the stabilizer and the gathering head and cutter head assemblies.

35. Carefully remove the support blocking from under the tractor frame.

36. Lower the tractor frame onto the floor by raising the stabilizer and the gathering head and cutter head assemblies.

______________________________________________________________ A6474X308 Rev. 0 5.283

Replacement of wear parts _________________________________________ Tram sprocket removal and installation tram sprocket removal

When removing the tram sprocket, follow all Federal, State, and local safety regulations and observe the following: WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all lifting and blocking devices.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.

To remove the tram sprocket: 1. Lower the conveyor tail section until it is level with the floor.

2. Raise the gathering head and cutter head and place a small stack of blocking under these two assemblies.

3. Lower the gathering head and cutter head onto the blocking so that the front end of the miner lifts off the floor.

4. Extend the stabilizer completely so that the rear end of the miner lifts off the floor.

5. Place blocking in multiple locations under the miner tram track.

When the miner is lowered, the tram track should be secured between the blocking and the tractor frame.

6. Raise the stabilizer and the gathering head and cutter head assemblies so the weight of the miner rests on the blocking.

7. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

8. Double check the tractor frame support blocking now that the weight of the tractor frame is completely upon it.

9. Remove the two rub rail pins that secure the tram rub rail to the two rub rail sections adjacent to it and remove the tram rub rail to expose the tram case.

10. Remove the hex head capscrew and lock washer that secures the front rub rail to the tractor frame and open the cover.

11. Attach the grease gun to the fitting on the grease take-up cylinder (Fig. 190) and pump grease to extend the cylinder and remove pusher plate pressure on the idler shims.

_________________________________________________________________ 5.284 Bucyrus – Model 25C Continuous Miner

________________________________________ Replacement of wear parts Fig. 190: Idler adjustment shim removal Idler take-up cylinder

Pressure release valve

Grease fitting

Idler adjustment shims

12. Remove all the idler adjustment shims and store the shims in a safe place.

13. Open the pressure release valve for the front idler take-up jack and allow the cylinder to contract.

14. Locate a tram track link near the track entry opening at the bottom of the tram case (Fig. 191) and, using the hammer and punch, remove the two roll pins that secure the tram track pin between the links. Store the roll pins in a safe place.

15. Using the hammer and punch, remove the tram track pin to disconnect the links and separate the track. Store the track pin in a safe place.

Fig. 191: Tram track removal

Roll pins

Separate track here

Tram track pin

______________________________________________________________ A6474X308 Rev. 0 5.285

Replacement of wear parts _________________________________________

 16. Attach guide wires to the end of the tram track that passes through the tram case.

17. Connect the trailing cable to energize the miner.

18. Use the tram motor to slowly rotate the sprocket so that the end of the tram track that passes through the case is pulled up through the case and rolls off the sprocket.

19. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

20. Pull on the tram track from the front of the miner (near the idler) so that the free end of the tram track is pulled clear of the tram case exit opening.

WARNING! Ensure that the end of the tram track is out of the tram case exit opening before attempting to remove the tram case from the tractor frame.

21. Remove the plug from the bottom of the cover and drain the lubricant from the gear case (Fig. 192).

22. Replace the oil drain plug in the gear cover.

23. Remove the Secondary planetary gear assembly (see Secondary planetary gear assembly removal and installation procedure in this chapter).

Fig. 192: Tram secondary planetary gear cover and drain plug

Tram secondary planetary gear cover

Socket head capscrews

Drain plug

_________________________________________________________________ 5.286 Bucyrus – Model 25C Continuous Miner

________________________________________ Replacement of wear parts

 24. Remove the bearing carrier (Fig. 193).

25. Remove the bearing/seal sleeve assembly from the end of the sprocket.

Fig. 193: Sprocket bearing carrier removal

Bearing/seal sleeve assembly

Sprocket Sprocket bearing carrier

WARNING! The next step removes the sprocket from the tram case. The sprocket is extremely heavy. Be prepared to support its weight before removing it from the tram case.

26. Remove the sprocket from the tram case (Fig. 194).

27. Remove the bearing/seal sleeve assembly from the rear of the sprocket bay of the tram case.

Fig. 194: Tram sprocket removal Bearing/seal sleeve assembly

Tram case Sprocket

______________________________________________________________ A6474X308 Rev. 0 5.287

Replacement of wear parts _________________________________________ tram sprocket installation

When installing the tram sprocket, follow all Federal, State, and local safety regulations and observe the following: WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.

WARNING! You could be seriously injured or killed by falling loads. Follow mine procedure to remove blocking devices and use caution.

To install the tram sprocket: 1. Install a spherical bearing into one of the bearing sleeves (Fig. 195).

2. Install the o-ring into the outside channel of the bearing sleeve (Fig. 195).

IMPORTANT! When the bearing sleeve is inserted into position, the o-ring forms a seal between the sleeve and the piece that holds it.

3. Install a Duo-Cone seal into the seal sleeve (Fig. 195) (see Duocone seal installation notes in this chapter). The rubber side of the seal should face toward the sleeve; the metal ring of the seal should face outward.

4. Insert the seal sleeve into the bearing sleeve.

Fig. 195: Bearing/seal sleeve assembly Spherical bearing Seal sleeve Duo-cone seal O-ring Bearing sleeve

Metal ring

Rubber seal

_________________________________________________________________ 5.288 Bucyrus – Model 25C Continuous Miner

________________________________________ Replacement of wear parts

 5. Insert and tighten the three set screw into the bearing sleeve to secure the seal sleeve in the bearing sleeve.

6. Insert the bearing/seal sleeve assembly into position at the rear of the sprocket bay of the tram case.

7. Install the two Duo-Cone seals into the channel in each end of the sprocket. The rubber side of the seals should face into the sprocket channel; the metal rings of the Duo-Cone seals should face outward.

8. Insert the end of the sprocket into the seal sleeve so that it seats into the spherical bearing. Push the sprocket until the metal rings of the Duo-Cone seals are securely against each other.

9. Install the other spherical bearing into the remaining bearing sleeve.

10. Install the o-ring into the outside channel of the bearing sleeve.  11. Install a Duo-Cone seal into the remaining seal sleeve. The rubber side of the seal should face toward the sleeve; the metal ring of the seal should be facing outward.

12. Insert the seal sleeve into the bearing sleeve.

13. Insert and tighten the three set screws into the bearing sleeve to secure the seal sleeve in position.

14. Slide the bearing/seal sleeve assembly onto the end of the sprocket. Push the sleeve assembly until the end of the sprocket seats into the spherical bearing and the metal rings of the DuoCone seals are securely against each other.

15. Replace the bearing carrier over the bearing sleeve and end of the bearing sleeve and end of the sprocket.

16. Install the Secondary planetary gear assembly (see the Secondary planetary gear assembly removal and installation procedure in this chapter).

17. While feeding the tram track from the front of the miner (near the idler), pull on the tram track guide wires until a link of the tram track engages the sprocket.

18. Connect the trailing cable to energize the miner.

WARNING! Stand clear of the miner when using the motor to pull the tram track through the tram case.

19. Use the tram motor to slowly rotate the sprocket and pull the tram track through the case until the end appears out the bottom.

______________________________________________________________ A6474X308 Rev. 0 5.289

Replacement of wear parts _________________________________________

 WARNING! Double check that the links of the tram track are correctly seated onto the tram drive sprocket. Improper engagement of the tram track links onto the sprocket can cause serious mechanical damage.

20. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

21. Remove the guide wires from the tram track.

22. Connect the two ends of the tram track and using the hammer and punch, insert the track pin to secure the two track links together.  23. Using the hammer and punch, insert the two roll pins into the track pin to secure the pin in the links.

24. Adjust the tram track tension (see Tram track adjustment procedure in the Adjustment procedures section of this chapter).

25. Close the front rub rail cover and replace the hex head capscrews and lock washers that secure the front rub rail to the tractor frame.

26. Replace the tram rub rail between the two adjacent rub rails and secure it with the two rub rail pins.

27. Connect the trailing cable to energize the miner.

28. Remove blocking.

_________________________________________________________________ 5.290 Bucyrus – Model 25C Continuous Miner

________________________________________ Replacement of wear parts Tram track front idler removal and installation tram track front idler removal

When removing the tram track front idler, follow all Federal, State, and local safety regulations and observe the following: WARNING! You can be seriously injured or killed by falling loads. Observe the safe working load limits of all lifting and blocking devices.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.

To remove the tram track front idler: 1. Raise the gathering head and cutter head assemblies to their highest points and place blocking underneath. Lower the assemblies onto the blocking. The gathering head and cutter head must be blocked high enough to allow the idler assembly to be removed from the tractor frame’s idler slide channel.

2. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

3. Remove the hex head capscrew and lock washer that secure the front rub rail to the tractor frame and open the front rub rail cover.

4. Attach the grease gun to the front idler take-up cylinder fitting (Fig. 196) and pump grease into the take-up cylinder to extend the cylinder and remove pusher plate pressure on the idler shims.

5. Remove all the idler adjustment shims and store the shims in a safe place.

6. Open the pressure release valve for the front idler take-up jack and allow the cylinder to contract.

Fig. 196: Idler take-up cylinder

Pressure release valve

Idler take-up cylinder

Grease fitting

Idler adjustment shims

______________________________________________________________ A6474X308 Rev. 0 5.291

Replacement of wear parts _________________________________________

 7. Locate a tram track link near the track entry opening at the bottom of the tram case (Fig. 197) and, using the hammer and punch, remove the two roll pins that secure the tram track pin between the links. Store the roll pins in a safe place.

8. Using the hammer and punch, remove the tram track pin to disconnect the links and separate the track. Store the track pin in a safe place.

Fig. 197: Tram track removal

Roll pins

Separate track here

Tram track pin

9. Attach guide wires to the end of the tram track that passes through the tram case.

10. Slide the front idler assembly out of the idler slide channel (Fig. 198).

Fig. 198: Front idler assembly removal

Take-up cylinder Pressure relief valve

Idler slide channel Front idler assembly

_________________________________________________________________ 5.292 Bucyrus – Model 25C Continuous Miner

________________________________________ Replacement of wear parts

 11. Slide the pusher plate and the spacer pusher out of the idler slide channel (Fig. 195).

Fig. 199: Pusher plate removal Take-up cylinder

Spacer pusher

Pressure relief valve Pusher plate

Idler slide channel

tram track front idler installation

To install the tram track front idler: 1. Insert the pusher spacer (Fig. 200) into the tractor frame’s idler slide channel so that it rests on the slide block support and is positioned against the take-up jack.

2. Ensuring that the channel guides face away from the take-up jack, insert the pusher plate into the idler slide channel until it touches the pusher spacer.

Fig. 200: Pusher plate installation Take-up cylinder

Pusher spacer

Pressure relief valve Pusher plate

Idler slide channel

______________________________________________________________ A6474X308 Rev. 0 5.293

Replacement of wear parts _________________________________________

 3. Insert the block slides of the front idler assembly (Fig. 197) into the idler slide channel. The relief valve of the slide blocks must be oriented toward the front of the miner.

4. Push the front idler assembly into the slide channel until the block slides are against the pusher plate channel guides.

Fig. 201: Front idler installation Take-up cylinder Front idler assembly

Pressure relief valve

Idler slide channel Pusher plate channel guide Block slide

Relief valve

5. Connect the two ends of the tram track and using the hammer and punch, insert the track pin to secure the two track links together.

6. Using the hammer and punch, insert the two roll pins into the track pin to secure the pin in the links.

7. Adjust the tram track tension (see Tram track adjustment procedure in the Adjustment procedures section of this chapter).

8. Close the front rub rail cover and replace the hex head capscrews and lock washers that secure the front rub rail to the tractor frame.

_________________________________________________________________ 5.294 Bucyrus – Model 25C Continuous Miner

________________________________________ Replacement of wear parts Front idler take-up cylinder removal and installation front idler cylinder removal

When removing the front idler cylinder, follow all Federal, State, and local safety regulations and observe the following: WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.

To remove the front idler take-up cylinder 1. Lower the conveyor tail section until it is level with the floor.

2. Lower the gathering head and cutter head until these two assemblies touch the floor.

3. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

4. Remove the hex head capscrew and lock washer that secures the front rub rail to the tractor frame and open the front rub rail cover.

5. Remove the hex head capscrews that secure the fill plate to the frame and remove the fill plate.

6. Locate the front idler take-up cylinder bracket assembly (Fig. 202) which is mounted to the rear of the idler shim channel.

Fig. 202: Front idler take-up cylinder bracket Bracket assembly

Idler shim channel

7. Pull the flip pin (Fig. 203) from the half link to release the take-up cylinder bracket from the tractor frame.

8. Lower the end of the bracket until it clears the half link and pull the bracket straight out to remove it from the tractor frame.

______________________________________________________________ A6474X308 Rev. 0 5.295

Replacement of wear parts _________________________________________ Fig. 203: Front idler take-up cylinder removal Idler take-up cylinder assembly

Bracket assembly

Flip pin

front idler cylinder installation

Flip pin

Tractor frame

To install the front idler take-up cylinder: 1. Replace the take-up cylinder bracket assembly into the tractor frame and secure it by inserting the flip pin through the half link.

2. Replace the fill plate and secure with capscrews.

3. Close the front rub rail cover and secure to the tractor frame with a hex head capscrew and lock washer to secure the front rub rail to the tractor frame.

_________________________________________________________________ 5.296 Bucyrus – Model 25C Continuous Miner

________________________________________ Replacement of wear parts Hydraulic pump removal and installation hydraulic pump removal

When removing the hydraulic pump, follow all Federal, State, and local safety regulations and observe the following: WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.

WARNING! You can be seriously injured or killed by falling loads. Observe the safe working load limits of all lifting and blocking devices.

To remove the hydraulic pump (Fig. 204):  1. Lower the conveyor tail section until it is level with the floor.

2. Lower the gathering head and cutter head assemblies until they rest on the floor.

3. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

4. Locate the rub rail directly behind the tram case on the operator’s side of the miner. Remove the two rub rail pins that secure the rub rail to the two rub rail sections adjacent to it and remove the rub rail.

5. Swing the operator’s case outward and locate the hydraulic pump and motor assembly.

6. Using the adjustable wrench, disconnect the inlet hose from the pump. Plug the hose end to keep it clean.

7. Using the adjustable wrench, disconnect the pilot and valve hoses from the pump fittings. Plug the hose ends to keep them clean.

______________________________________________________________ A6474X308 Rev. 0 5.297

Replacement of wear parts _________________________________________ Fig. 204: Hydraulic pump

Rub rail

Operator’s case

Fig. 205: Hydraulic pump installation

Motor

Hex head capscrew (2)

Pump

Lockwasher (2)

_________________________________________________________________ 5.298 Bucyrus – Model 25C Continuous Miner

________________________________________ Replacement of wear parts hydraulic pump installation

To install the hydraulic pump: 1. Slide the pump assembly into the pump motor (Fig. 205).

2. Insert and tighten, hex head capscrews and lockwashers to secure the pump assembly to the motor.

3. Insert the hydraulic hose fittings into the pump assembly and tighten.

4. Attach and tighten the exit pilot and valve hoses to the pump fittings.

5. Attach the inlet hose to the pump.

6. Replace the rub rail between the two adjacent rub rails and secure it with the two rub rail pins.

7. Check the hydraulic fluid level.

8. Jog pump motor on and off a few times to prime the pump before starting.

______________________________________________________________ A6474X308 Rev. 0 5.299

Replacement of wear parts _________________________________________ Hydraulic pump motor removal and installation hydraulic pump removal

When removing the hydraulic pump, follow all Federal, State, and local safety regulations and observe the following: WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.

To remove the hydraulic pump motor (Fig. 206): 1. Lower the conveyor tail section it is level with the floor.

2. Lower the gathering head and cutter head until they touch the floor.

3. Disconnect the trailing cable to de-energize the miner.

4. Remove the hydraulic pump (see Hydraulic pump removal procedure in this chapter).

5. Remove the two hex head capscrews that secures the motor to the pump stand.

6. Remove the two hex head capscrews and lockwashers that secure the pump stand to the tractor frame and remove the pump stand.

Fig. 206: Hydraulic pump stand removal Hex head capscrew (2)

Motor

Pump stand

Hex head capscrew (2)

_________________________________________________________________ 5.300 Bucyrus – Model 25C Continuous Miner

________________________________________ Replacement of wear parts

 7. Tag, disconnect, and cap the two cooling water hoses from the cooling water fittings on the pump motor.

8. Remove the cooling water fittings from the top left and right surface of the pump motor and store in a safe place.

9. Remove the cover and its o-ring from the motor’s junction box by removing four hex head capscrews and lockwashers.

10. Locate the three taped power connections inside the junction box.

11. Strip off the three layers of tape covering each of the three lug connections inside the junction box.

12. Tag the three lugs to facilitate reconnection during motor installation.

13. Remove the hex head capscrew, flat washer, lockwasher, and hex head nut that secures the three power cable lugs to the three motor lugs.

14. Remove the two socket head capscrews and lockwashers that secure the stuffing box’s half-moon clamp to the junction box.

15. Remove the clamp and slide the stuffing box out of the junction box.

The power cable should be completely disconnected from the motor.

16. To prevent damage to the power cable lugs and gland assembly, cover the power cable and secure it to the miner in a safe location.

17. To protect the motor’s electrical connections, replace the motor junction box cover and secure it using four hex head capscrews and lockwashers.

WARNING! The hydraulic pump motor is now detached from the tractor frame and can be removed. The hydraulic pump motor is extremely heavy. Prepare to support its weight before removing it from the tractor frame.

18. Carefully slide the hydraulic pump motor out of the tractor frame.

______________________________________________________________ A6474X308 Rev. 0 5.301

Replacement of wear parts _________________________________________

 hydraulic pump installation

To install the hydraulic pump motor (Fig. 202): 1. Slide the hydraulic pump motor into position in the tractor frame.

2. Remove the four hex head capscrews and lockwashers that secure the junction box cover and remove the cover and its o-ring.

3. Insert the three lugs of the power cable (with gland and stuffing box already installed) into the motor’s junction box.

4. Replace the stuffing box’s half-moon clamp in its channel to secure the stuffing box in the junction box.

5. Tighten the two socket head capscrews to secure the clamp to the junction box.

6. Inside the junction box, locate the motor’s lug connections. Match the motor lug connections to the corresponding power cable lugs (refer to the wiring diagram supplied in your Bucyrus America, Inc. parts manual).

7. Attach the first motor lug to its corresponding power cable lug by inserting a hex head capscrew through the motor lug, through the power cable lug, through a flat washer, and through a lockwasher.

Secure the capscrew with a hex nut. Repeat this step for the other two lugged connections.

8. When all three connections have been secured, wrap each of the three connections with a layer of rubber tape, then a layer of black tape and finally a layer of glass tape.

9. Replace the junction box o-ring and cover.

10. Insert the four hex head capscrews and lockwashers to secure the junction box cover and tighten.

11. Insert the two motor cooling water fittings into the pump motor cooling water ports.

12. Attach the two motor cooling water hoses to the fittings.

13. Position the pump stand against the motor and attach to the motor with two hex head capscrews.

14. Insert and tighten the two hex head capscrews and lockwashers to secure the pump stand to the tractor frame.

15. Install the hydraulic pump (see hydraulic pump installation procedure in this chapter).

16. Remove the hex head capscrew, flat washer, lockwasher, and hex head nut that secures the three power cable lugs to the three motor lugs.

_________________________________________________________________ 5.302 Bucyrus – Model 25C Continuous Miner

________________________________________ Replacement of wear parts 17. Remove the two socket head capscrews and lockwashers that secure the stuffing box’s half-moon clamp to the junction box.

18. Remove the clamp and slide the stuffing box out of the junction box.

The power cable should be completely disconnected from the motor.

19. To prevent damage to the power cable lugs and gland assembly, cover the power cable and secure it to the miner in a safe location.

20. To protect the motor’s electrical connections, replace the motor junction box cover and secure it using four hex head capscrews and lockwashers.

WARNING! The scrubber fan/motor is now detached from the tractor frame and can be removed. The motor is extremely heavy. Prepare to support its weight before removing it from the tractor frame.

21. Carefully slide the scrubber fan/motor out of the tractor frame.

______________________________________________________________ A6474X308 Rev. 0 5.303

Replacement of wear parts _________________________________________ Scrubber fan/motor removal and installation scrubber fan/motor removal

When removing the scrubber fan/motor, follow all Federal, State, and mine safety regulations and observe the following: WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.

To remove the scrubber fan/motor:  1. Lower the conveyor tail section until it is level with the floor.

2. Lower the gathering head and cutter head assemblies until they rest on the floor.

3. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

4. Locate the rub rail on the fan exhaust side at the rear of the miner (Fig. 207) and remove the pin that secures the rear rub rail to the rail adjacent to it. Open both rub rails.

Fig. 207: Scrubber fan/motor location

Scrubber fan/motor

5. Locate the scrubber fan motor junction box and remove the four hex head capscrews and lockwashers that secure the junction box cover. Remove the cover and o-ring.

6. Locate the three taped power connections inside the junction box.

7. Strip off the three layers of tape covering each of the three lug connections inside the junction box.

8. Tag the three lugs to facilitate reconnection during motor installation.

_________________________________________________________________ 5.304 Bucyrus – Model 25C Continuous Miner

________________________________________ Replacement of wear parts scrubber fan/motor installation

To install the scrubber fan/motor: 1. Carefully insert the scrubber fan/motor assembly into the tractor frame so the motor face is toward the scrubber’s mist eliminator box.

2. Orient the scrubber fan/motor so the motor drain is directly at the bottom of the assembly. Ensure that the scrubber fan/motor is positioned correctly for airflow out the rear vent of the miner.

3. Insert and tighten the twelve hex head capscrews and lockwashers to secure the scrubber fan/motor assembly to the tractor frame.

4. Remove the four hex head capscrews and lockwashers that secure the junction box cover and remove the cover and its o-ring.

5. Insert the three lugs of the power cable (with gland and stuffing box already installed) into the motor’s junction box.

6. Replace the stuffing box’s half-moon clamp in its channel to secure the stuffing box in the junction box.

7. Tighten the two socket head capscrews to secure the clamp to the junction box.

8. Inside the junction box, locate the motor’s lug connections. Match the motor lug connections to the corresponding power cable lugs (refer to the wiring diagram supplied in your Bucyrus America, Inc. parts manual).

9. Attach the first motor lug to its corresponding power cable lug by inserting a hex head capscrew through the motor lug, through the power cable lug, through a flat washer, and through a lockwasher.

Secure the capscrew with a hex nut. Repeat this step for the other two lugged connections.

10. When all three connections have been secured, wrap each of the three connections with a layer of rubber tape, then a layer of black tape and finally a layer of glass tape.

11. Replace the junction box o-ring and cover.

12. Insert the four hex head capscrews and lockwashers to secure the junction box cover and tighten.

13. Replace the rub rail hinge post.

14. Close both rub rails and secure with the rub rail pin.

______________________________________________________________ A6474X308 Rev. 0 5.305

Replacement of wear parts _________________________________________ Stabilizer cylinder removal stabilizer cylinder removal

When removing a stabilizer (foot) cylinder, observe all Federal, State, and mine safety regulations and observe the following: WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all lifting and blocking devices.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.

To remove a stabilizer cylinder: 1. Raise the conveyor tail assembly to its highest position.

2. Raise the cutter head and gathering head assemblies. Place appropriate blocking under the cutter head and gathering head assemblies.

3. Lower the cutter head and gathering head assemblies onto the blocking so that the front of the tractor frame lifts off the floor. Place blocking under the front of the tractor frame. Raise the cutter head and gathering head assemblies slightly so that the tractor frame lowers onto the blocking.

4. Completely extend the stabilizer so that the rear of the tractor frame lifts off the floor. Place blocking under the rear of the tractor frame. Raise the stabilizer slightly so that the tractor frame lowers onto the blocking.

5. Place blocking under the conveyor tail assembly and lower the tail assembly onto the blocking.

6. Extend the stabilizer so that it touches the floor. The stabilizer should not support any miner weight.

7. Double check that the tractor frame and the conveyor tail are securely blocked.

8. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

9. Locate the rod end bearing pin of the stabilizer cylinder (Fig. 208).

Remove the pin retaining bolts and then pull the pins.

10. Connect the trailing cable to energize the miner.

_________________________________________________________________ 5.306 Bucyrus – Model 25C Continuous Miner

________________________________________ Replacement of wear parts Fig. 208: Stabilizer cylinder bearings

Piston end pin

Pin retaining bolts Pin retaining bolts Rod end pin

11. Retract the stabilizer cylinder. The rod end bearing of the cylinder should remove itself from its stabilizer shoe clevis.

WARNING! Stand clear of the blocked tractor frame during contraction of the stabilizer cylinder.

12. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

13. Raise and lower the stabilizer cylinder lever to release any pressure from the conveyor lift cylinder.

WARNING! The next steps require crawling under the block supported conveyor tail section. Verify that this tail section is adequately secured before proceeding.

______________________________________________________________ A6474X308 Rev. 0 5.307

Replacement of wear parts _________________________________________ 14. Tag, disconnect, and cap the hydraulic hoses from the stabilizer cylinder’s fittings.

15. Remove the hydraulic fittings from the stabilizer cylinder and store in a clean place.

WARNING! Each stabilizer cylinder is extremely heavy. The next steps will remove the cylinder from its tractor frame mounting. Be prepared to support the weight from its tractor frame mounting. Be prepared to support the weight of the cylinder when it becomes free from the mounting.

16. Remove the bolts that hold the bearing pin retainer in place and remove the retainer.

17. Remove the pin.

_________________________________________________________________ 5.308 Bucyrus – Model 25C Continuous Miner

________________________________________ Replacement of wear parts Swivel pin assembly removal and installation swivel pin assembly removal

When removing the swivel pin, follow all Federal, State, and mine safety regulations and observe the following: WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all lifting and blocking devices.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.

To remove the swivel pin assembly (Fig. 209):  1. Lower the cutter head and gathering head assemblies until they touch the ground.

2. Position the conveyor tail section to the extreme right or left of the miner so that the chain is drawn to one side as far as possible and the conveyor swivel pin is exposed.

3. Lower the conveyor tail section until it is level with the floor.

4. Insert blocking between the conveyor tail section and the floor.

5. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

6. Remove the socket head capscrews from the upper swivel pin.

7. Remove the center setscrew from the center of the upper conveyor swivel pin.

8. Use a slide hammer to remove the upper conveyor swivel pin.

9. Remove the center setscrew from the center of the lower conveyor swivel pin.

10. Remove the socket head capscrews from the lower conveyor swivel pin.

11. Use a slide hammer to remove the lower conveyor swivel pin.

12. Reach into the conveyor chain return channel and retrieve both upper and lower swivel pin retainers

______________________________________________________________ A6474X308 Rev. 0 5.309

Replacement of wear parts _________________________________________ Fig. 209: Conveyor swivel pin

Dowel pin

Grease fitting

Set screw

Swivel pin

Socket head capscrews

Retainer

View A-A

_________________________________________________________________ 5.310 Bucyrus – Model 25C Continuous Miner

________________________________________ Replacement of wear parts

 swivel pin assembly installation

To install the swivel pin assembly (Fig. 209):  1. Working first on the upper swivel pin assembly, insert the dowel pin, center setscrew, and the grease fitting into the swivel pin.

2. Lower the swivel pin into the hole in the conveyor bed making sure the dowel pin is positioned in the notch and the top of the swivel pin is flush with the top surface of the conveyor bed.

3. Holding the swivel pin retainer with the flanged side downward, reach into the conveyor chain return channel and fit the swivel pin retainer into the hole.

4. Insert the socket head capscrews and tighten.

5. Working on the lower swivel pin assembly, insert the dowel pin, center setscrew and the grease fitting into the swivel pin.

6. Lift the swivel pin into the hole in the lower side of the conveyor making sure the dowel pin is positioned in the notch and the lower side of the swivel pin is flush with the lower surface.

7. Holding the swivel pin retainer with the flanged side upward, reach into the conveyor chain return channel and fit the swivel pin retainer into the hole.

8. Insert the socket head capscrews and tighten.

______________________________________________________________ A6474X308 Rev. 0 5.311

Replacement of wear parts _________________________________________ Tail roller removal and installation tail roller removal

When removing the tail roller, follow all Federal, State, and mine safety regulations and observe the following: WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all lifting and blocking devices.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.

To remove the tail roller (Fig. 210):  1. Lower the gathering head and cutter head assemblies until they rest on the floor.

2. Slowly advance the conveyor chain until a connecting link moves onto the conveyor tail section slide pan.

3. Loosen tension on the conveyor chain as much as possible (see Conveyor chain adjustment procedure I n this chapter).

4. Lower the conveyor tail section onto blocking so it is level with the floor.

5. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

6. With conveyor chain tension removed, remove the retaining rings from the connecting link.

7. Remove the connecting link and its strap. The conveyor chain should now be separated. Move the two pieces of the conveyor chain out of the way to allow for easier removal of the conveyor tail roller assembly.

8. Remove the socket head capscrews that secure the tail roller assembly to the slide pan.

9. Remove the tail roller assembly from its location in the slide pan.

_________________________________________________________________ 5.312 Bucyrus – Model 25C Continuous Miner

________________________________________ Replacement of wear parts Fig. 210: Tail roller

Tail roller Socket head capscrew

tail roller installation

To install the tail roller (Fig. 210): 1. Insert the tail roller assembly into the proper location in the slide pan.

2. Insert and tighten the socket head capscrews through the holes in the tail roller shaft and into the threaded holes in the slide pan.

3. Reattach the two ends of the conveyor chain by replacing the connecting link.

4. Secure the connecting link by replacing the side strap and the retaining rings onto the ends of its pins.

5. Tighten the conveyor chain to the proper tension (see Conveyor chain adjustment procedure in this chapter).

IMPORTANT! Improper conveyor chain tension can lead to excessive wear, mechanical problems and miner downtime. Always keep the conveyor chain at the proper tension.

______________________________________________________________ A6474X308 Rev. 0 5.313

Replacement of wear parts _________________________________________ Conveyor chain replacement When replacing the conveyor chain, observe all Federal, State, and mine safety regulations and observe the following: WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all lifting and blocking devices.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.

1. Lower the cutter head and gathering head assemblies until they touch the ground.

2. Position the conveyor tail section directly behind the miner and raise it. Insert the blocking under the tail section and lower the tail section onto the blocking.

3. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

4. Loosen the tension of the conveyor chain as much as possible (see Conveyor chain adjustment procedure in this chapter).

5. Remove the two retaining rings from a connecting link located near the rear of the conveyor bed.

6. Remove the connecting link. The chain is now separated.

7. Connect the come-along to the end of the chain on the conveyor bed.

8. Connect the new chain to the end of the lower chain and allow the new chain to extend behind the miner on the floor.

9. Use the come along to pull the old chain out of the miner. The new chain will follow the old through the conveyor return channel around the gathering head foot shaft and out onto the conveyor tail section.

10. When the entire length of old chain has been pulled through the miner and the replacement chain is in position, disconnect the old chain from the new and remove the come along.

11. Connect both ends of the new chain by replacing the connecting link, pins and retaining rings.

12. Tighten the conveyor chain (see Conveyor chain adjustment procedure in this chapter).

_________________________________________________________________ 5.314 Bucyrus – Model 25C Continuous Miner

________________________________________ Replacement of wear parts Duo-cone seals Duo-Cone seals consist of a pair of matched sets. Each set is made up of a metal seal ring and a rubber toric (see Fig. 211).

The special seal rings are precision lapped to ensure positive sealing at the mating surfaces. The torics position the seal rings and furnish the floating action that allows for shaft deflection and end play. They also provide a constant sealing face pressure, seal the back sides of the sealing rings to adjacent parts, and transmit the force needed to turn one metal ring, while holding the other stationary.

The faces of the mated sealing rings form a sealing band 0.8 mm (1/32") wide that retains the oil lubricant and keeps out dirt. As wear occurs, the contact band broadens, moving slowly inward until the inside diameter is reached. Thus, a simple visual check will show the amount of remaining life.

Fig. 211: Duo cone seal sets 1

2 3 4

6 7

9

5

1-Seal Ring 2-Rubber Toric 3-Housing Retainer Lip 4-Housing Ramp 5-Seal Ring Housing 6-Seal Ring Face 7-Seal Ring Ramp 8-Seal Ring Retaining Lip 9-Installation Tool

8

mating pairs

Duo-Cone seals must always be installed in mated pairs; two new seals together or two seals that have previously run together. Never assemble one new seal and one used seal together, or two used seals that have not previously run together.

handling

Proper handling and installation of these seals is vital to get maximum life and positive sealing protection given by these precision units. Special attention was given during shipping to ensure absolute For maximum service, keep seals clean during installation and with oil.

housing preparation

The housing components that contact the rubber toric rings (3 and 4 Fig. 211) must be free from foreign material (oil, grease, dirt, metal chips, dust or lint particles, etc.) before installing the seal. This should be done with a lint-free wipe and a non-petroleum based solvent. The solvent recommended is trichloroethane. Dry with a clean wipe.

______________________________________________________________ A6474X308 Rev. 0 5.315

Replacement of wear parts _________________________________________ IMPORTANT! To obtain maximum performance, the seals must be installed accurately to insure uniform loading at the mating faces and achieve a stable running position. Misalignment or cocking of seal rings during assembly can produce non-uniform loading and wobbling of the seals in their housings resulting in leakage due to scoring and/or pumping of debris past the toric rings. Improper installation can also result in breakage of the metal seal rings.

Put the torics (Item 1, Fig. 212) onto the metal seal rings. They should be positioned on the tail of the metal seal ring (2) and seat uniformly.

Be sure that the torics are not twisted and rest uniformly against the lip.

This can be done by checking the mold flash line on the toric outer diameter for even tracking around the seal. Remember that a twisted rubber ring will allow the face load to be uneven. If a toric is twisted, it can be straightened by gently pulling a section away from the metal ring and allowing it to snap back. Do this at several sections until the twist is corrected.

Fig. 212: Toric care 1

7

3

1 2

1

2

5

8

2

Check the retaining lip (Item 3, Fig. 212) and metal seal for rough tool marks or nicks. Smooth any nicks or scratches and re-clean. seal assembly

Install the toric so that it seals uniformly on the sealing ring. Be sure the toric is not twisted and rests uniformly against the lip that prevents it from falling off the metal seal ring. Press with fingers on the rubber ring only, seating the ring inside the lip.

Use when possible the special seal installer tools provided with the miner. DO NOT use a screwdriver or any sharp instrument to seat the ring. Always install new rubber torics on new or used metal rings. Both metal rings must be replaced if one is defective.

Special attention is given during manufacturing and shipping to ensure absolute cleanliness. To obtain maximum service, cleanliness during installation and while filling with oil must be the rule. Lack of care can cause premature seal failure.

Getting full performance also requires proper installation procedures be followed. This results in even loading on the faces and a stable running position. One seal cocked, or a ring out of alignment when reassembling may cause the load to be uneven. The seals may end up wobbling in their housings. This would produce leakage from scoring or debris pumped across the rings. Another result of incorrect installation could be the breakage of the metal rings themselves.

_________________________________________________________________ 5.316 Bucyrus – Model 25C Continuous Miner

________________________________________ Replacement of wear parts NOTICE! Improper care and installation can result in immediate leakage or reduced service life. seal preparation

Remove any foreign material from the rubber torics (Item 2 in Fig. 213) and the ramps (Item 7, Fig. 213) and lips (Item 8, Fig. 243) of both seal rings. This should also be done with a lint-free wipe and a nonpetroleum based solvent. Dry with a clean wipe.

Place the rubber torics on the metal seal ring at the bottom of the seal ring ramp and against the retaining ring (see Figure ). Make sure the rubber toric is straight on the seal ring and not twisted. Be careful not to nick or cut the torics during this assembly, as this can cause leaks.

Put the installation tool onto the metal seal ring and rubber toric (see Figure ). Lightly dampen the lower half of the rubber toric with the appropriate assembly lubricant. Techniques to dampen the toric include wiping with a lint-free towel, lubricating using a clean foam brush, or dipping in a container lined with towels saturated in the assembly lubricant (see Fig. 213).

Fig. 213: Seal Preparation 9

1

2

using installer tools

After the torics are on the seal rings, they can be put into the housing assembly. Simple installer tools are available that will facilitate installation while protecting the seals from damage. The tool is made to locate on the toric ring and slide it past the retaining lip on the housing. The lip on the installer tool permits uniform pressure to be exerted directly onto the toric and provides protection on the sealing surface.

A hinged installer tool is used for the smaller seals. This tool closes over the metal seal ring so that the lip of the tool will force the rubber toric into its seat.

The larger seals use a one piece installer tool which snaps around the seal ring. When the installer tool is in place on the metal seal ring, hand pressure is applied to push the toric into its seat. The toric must be seated uniformly relative to both seal ring and seat.

Dipping the seal assembly into a shallow pan of solvent is highly recommended. The solvent recommended is trichloroethane. This facilitates assembly by reducing friction between the toric and seat thus allowing the toric to slip easier past the remaining lip on the housing and sealing evenly in the housing nose radius. ______________________________________________________________ A6474X308

Rev. 0

5.317

Replacement of wear parts _________________________________________ After dipping the assembly in solvent, shake off the excess fluid and then promptly pop the seal into the housing with a push from the tool.

Remove the tool and check the standout height at several spots.

Make certain that the seal is straight in the bore and inside the lip on the ramp. The dimension must be uniform around the entire circumference of the seal. If the seal is at an improper height, check for twisting or bulging. The seal can be somewhat adjusted by gently pushing the toric into place by hand. If this does not result in proper placement, remove the seal and repeat installation.

IMPORTANT! The toric must lie uniformly in the seal with the sealing ring and parallel to the seat face. Be sure that the toric is not twisted and that it rests uniformly against the retaining lip or not deeper in one side of the seat than the other.

After proper height is obtained, allow the assembly to rest for a couple minutes to allow the solvent to dry. This is done so that when the housings are reassembled, the torics will roll rather than slide in the housing as the face load is increased. If the torics slide, they can result in an uneven load.

Insufficient lubrication can cause improper sealing. Again, the use of quick evaporating trichloroethane solvent will not leave an oil residue or cause corrosion of the metal parts. Other lubricants that leave a residue can allow the toric to slide, rather than roll in the seat. This will cause bad seal efficiency. reassembling housings

After reassembling the torics into the housings and just before assembling the housings, a thin film of light oil should be put onto the faces of the seals. A disposable tissue, cotton applicator or a clean finger can be used to spread the oil evenly.

IMPORTANT! Do not get any oil onto the rubber torics!

Check the seal faces one more time to ensure that there is no dust, dirt or other objects on either face. Be sure that all solvent has dried off of the housing.

IMPORTANT! Even a small piece of lint can hold the faces apart and cause leakage!

_________________________________________________________________ 5.318 Bucyrus – Model 25C Continuous Miner

________________________________________ Replacement of wear parts seal test

After the entire unit is reassembled, it may be a good practice to test the seals. A vacuum test is more sensitive than a pressure test and can be performed during a vacuum fill operation.  Carefully fill the compartment to the correct fluid level.  Slowly rotate the assembly several revolutions to seat the seals.  A vacuum test will catch severe seal damage such as broken seal rings or cut torics that may be damaged in the last phases of assembly. The torics are not designed to seal air. Some leakage can be expected using such a procedure.

Fig. 214: Installation issues

Toric sliding on retainer ramp.

Toric caught on housing retainer lip.

Toric sliding on seal ramp. installation process

With the lower half of the rubber toric seal still wet, use the installation tool to position the seal ring and the rubber toric squarely against the housing (Fig. 214). For smaller diameter seals, use sudden and even pressure to push the rubber toric under the retaining lip of the housing.

For larger diameter seals which will not press in with sudden and even pressure, it is acceptable to work the toric past the retaining lip by starting on one side and tapping the opposite side of the installation tool with a rubber mallet until it is engaged past the retaining lip of the housing.

Check the assembled height (height “A”, Fig. 215) in at least four places, 90° apart, using a caliper, tool makers' rule or any other calibrated measuring device. The difference in height around the ring must not be more than 1mm. If small adjustments are necessary, do not push or pull directly on the seal ring. Use the installation tool to push down and your fingers to pull up uniformly on the rubber toric and seal ring.

The rubber toric can twist if it is not wet all around during installation or if there are burrs or fins on the retaining lip of the housing. Twists, misalignment, and bulges of the toric will result in seal failure. If correct installation is not obvious, remove the seal from the housing and repeat the process.

The rubber torics must never slip on the ramps of either the seal ring or the housing. To prevent slippage, allow adequate evaporation time for the lubricant before proceeding with further assembly. Once correctly in place, the rubber toric must roll on the ramp only.

______________________________________________________________ A6474X308 Rev. 0 5.319

Replacement of wear parts _________________________________________ Wipe the face of each seal ring using a lint-free wipe. No particles of any kind are permissible on the sealing surfaces. (Even a hair can hold the seal surfaces apart and cause a leak.) Apply a thin film of oil on the entire seal face of one or both seals using a clean finger or a lint-free applicator. Oil must not contact surfaces other than the sealing faces.

Fig. 215: Installation process 9

1

2 11 9 5

3

final assembly

1

While completing the final assembly of the unit (Fig. 216), make sure that both housings are in correct alignment and are concentric. Slowly bring the two housings together. High impact can scratch or break the seal components.

If the rubber toric slips at any location, it will twist, causing the seal rings to cock. Cocked seals create uneven pressure on the seal faces, resulting in galling, scoring and leakage. Any wobbling action can cause dirt to enter by pumping mud past the torics.

Fig. 216: Final Assembly Max. Variation 0.04 in. (1.00 mm)

Seal Ring Locator Toric Ring Locator

_________________________________________________________________ 5.320 Bucyrus – Model 25C Continuous Miner

________________________________________ Replacement of wear parts Bearings handling of bearings

The most important single factor in obtaining good service and long life from bearings is to keep dirt and foreign particles out of the bearing.

■

Use only clean grease/oil from clean containers.

■

Keep the grease/oil containers closed.

■

Handle the grease/oil so as to keep it clean.

■

Clean all dirt from adjacent surfaces before opening a bearing housing.

■

Always protect an exposed bearing with a lint free protective cover.

cleanliness

Try to prevent chips or dirt from getting between the bearing face and the shaft or housing shoulder. Contamination keeps the bearing from seating properly. The dirt may then work out and cause the bearing to work back against the shoulder, resulting in the bearing adjustment being excessively loose. Chips or dirt on one side of the shoulder could cock the bearing on the shaft, causing a misaligned condition similar to an off square shoulder.

proper protection

Bearings are originally packed in cardboard cartons, tubes or spiral wrapping at the factory to give the proper protection against dirt and moisture. Leave bearings in these containers and store in a clean, dry place until ready to be used. Bearings should not be removed from cartons and left in open trays, pans or in open cabinets exposed to dirt, dust or moisture. Keep bearings clean and dry!

It is not necessary to wash new bearings to remove the slushing grease put on at the factory for rust protection. This grease has little lubricating value, but it will not harm to the lubricant used in the bearings.

In special cases, it is necessary to wash bearings before assembly because they become dirty. Use a clean solution; kerosene is recommended. Cover bearings with a lubricant as soon as possible after washing to prevent rust.

cleaning bearings

When bearings are removed, examine each one for wear. If the bearing is in good condition, it should be cleaned with a suitable cleaner and then dried. When drying a bearing that has just been cleaned, never rotate the bearing at high speed; there is no lubricant in the bearing to protect it. Id the bearing is being dried with an air hose, direct the airstream so that rotation does not occur. After the bearings have been cleaned and dried, they should be coated immediately with light oil and covered with a lint-free cloth.

IMPORTANT! A mixture of marking compound and spindle oil is good lube for the gears under light loads for 2-3 revolutions only. Check tooth patterns all round to make sure the pattern/markings are uniform.

______________________________________________________________ A6474X308 Rev. 0 5.321

Replacement of wear parts _________________________________________ bearing assembly

Bearing cones and cups can be assembled in many ways. Smaller bearings can be pressed onto shaft or into housings. Bearing cones can be heated and shrunk onto shafts. Cups can be frozen and contracted to slip into housings easier. Proper bearing operation hinges upon correct mounting. With any method used, a number of factors should be considered.

Mount in a relatively clean environment. Dirt and debris affect internal clearances and fits. Dust can keep two mating surfaces from being tight, causing out-of -round bores. Dirt on a shaft contact area can cause seal wear. Debris mixing with gear oil forms a lapping compound that wears the bearing. Keep the bearing in its container until ready to mount it.

■

Do not drop or roughly handle the bearings.

■

Do not subject bearings to sudden, large temperature changes.

This could cause condensation onto the bearing surfaces.

■

Do not handle the bearings more than necessary. Finger prints can be a starting point for rust.

■

When installing, be sure the cone or cup is solidly seated against its shoulder. After the part has been pressed, shrunk, or cooled on, check with a thickness gauge to make sure it is properly seated.

■

Be sure the bearing being installed is Original Equipment Manufacturer (OEM) . This ensures that an exact duplicate is put on. Bearings and shafts are designed for each other, and changes can cause failure, loss of warranty, and extended downtime.

■

Be sure the bearing fit is not too loose or too tight. A loose bearing will creep, slip and cause it to overheat and be subjected to abrasive wear on the bore or shaft.

■

On a tight bearing, the inner ring of the cup will be stretched to where there is no room for the rollers or balls to revolve freely.

■

The bearing should be supported properly and pressure should be applied to the correct ring of the bearing.

There are generally three basic methods to mounting bearings: cold mounting, temperature mounting, and hydraulic mounting.

Bearings up to 4 inches (102 mm) in diameter can be cold mounted, using a sleeve and a hammer or press. Soft-metal hammers, while less likely to cause damage, have a tendency to chip and send metal flying into the bearing.

The end faces of a driving sleeve should be flat, parallel, and free of burrs. The bearing seating on the shaft and in the housing should be lightly smeared with thin oil.

_________________________________________________________________ 5.322 Bucyrus – Model 25C Continuous Miner

________________________________________ Replacement of wear parts micronized graphite for bearing assembly

drivers for bearing cups and cones

Micronized graphite can be used on shafts, cone seats, and in the cone bores to facilitate the assembly and removal of bearing cones on the shaft. Considerably less pressure is needed to press on a cone if micronized graphite is used. Removal is easier too, since it reduces or eliminates oxidizing on the cone seat (fretting corrosion).

Drivers should be used wherever possible to assemble cups and cones. They save time, ease installation by driving/pressing cups onto cones straight, prevent damage to bearing cages and nicks in bearing parts, and in general assure better assembly.

Do not damage the cage of the bearing cone by pressing or driving against it. This will distort and loosen it. Distortion causes skewing of the rollers and early failure of the bearings. Loosening the cage will cause cage and rollers to fall off the cone.

Drivers can be hardened for longer life. If they are not available, mild steel bars can be used, although they are not preferred. Use mild steel, not hardened drifts or brass bars. Hardened bars damage the bearing.

Brass will chip easily and get into the bearing or behind the bearing face, preventing it from becoming seated against the shoulder.

When bars are used as drivers, take care to see that they are tapered to clear the bearing cage, and hit only against the bearing race. Drivers should be used wherever possible as they save time.

Heating bearings Temperature mounting is done by one of three ways: ■

heating one part

■

cooling one part

■

heating one and cooling another

Heating is recommended for larger bearings. Cooling is suitable for any size, straight or tapered, although if temperature mounting is to be done to smaller assemblies, cooling is preferred. Be absolutely sure that no bearings are ever heated over 135° - 150° C (275° - 300°F). If they are, they will begin to draw, or soften.

Heating bearings in oil is common. Before heating, the oil and the container should be clean. Quenching oils with a minimum flash point of 150° C (300 F) should be used. The oil quantity should be large in relationship to the bearing being heated. A smaller volume heats and cools too rapidly. Where oil is heated in a pan or metal container over an open flame, there should be a screen on which the bearings will rest. It should be raised an inch from the bottom of the pan.

The bearing must not rest on the bottom, since heat would be transferred directly from the flame through the pan to the bearing. This temperature will be very high and will draw the bearing. A wire rack can be installed about 3 inches from the bottom. This will keep the bearing away from the direct heat, and also out of contamination. Another method is to suspend the bearing in the bath.

______________________________________________________________ A6474X308 Rev. 0 5.323

Replacement of wear parts _________________________________________ Once the bearing is heated, wipe the bore clean, place the assembly immediately on the shaft, and lock it in place. If there is no locking device, use a mounting tool to hold the inner ring in place until it has cooled. Oil baths are not recommended for sealed bearings. induction heating

Induction heating is not recommended. Surface temperatures will get too high and will draw the bearings.

WARNING! When bearings are heated for assembly, the part heated should be checked after cooling to see that it is seated properly against the shoulder. Bearings have a tendency to pull away from the shoulder.

freezing/shrinking bearing cups

Where cups are to be assembled in housings with a press fit, they can be shrunk in a deep freeze unit or an alcohol bath cooled with dry ice.

In some cases, you must also heat the housing to get the cup to slip into place readily.

tapered roller bearing adjustment

The accurate location and mating of rotating parts depends on the internal running clearance and stability of the support bearings. Running clearance of tapered roller bearings can be readily adjusted to meet a variety of operation conditions. This is through the axial adjustment of either the cone (inner race) or cup (outer race).

Proper initial adjustment should compensate for thermal changes and/ or deflections produced by normal operation. Tapered roller bearings operate well over a relatively wide adjustment range. The optimum initial bearing adjustment results in an operating adjustment of almost "metal to metal", or no appreciable end play within the bearings.

WARNING! Check a heated bearing for assembly after cooling a proper shoulder seating.

adjustment for wear

Though the surface hardness of bearings resists abrasion, dirt in the lubricant accelerates wear. After extended periods of operation, this wear results in the loss of the original adjustment and increases running clearance or end play.

The adjustable feature of a tapered assembly allows readjustment to compensate for this condition. This readjustment increases life to bearings, seals, gears, and other rotating parts. These general recommendations for adjusting tapered roller bearings cover most applications.

thermal expansion

Thermal expansion reduces end play. As a bearing rotates, heat is generated, causing successive thermal expansions. Usually the cone and roller assembly expands first, followed by the cup. When the cup is in a rigid housing with a tight fit, it cannot expand until the housing itself heats and expands.

In a typical gear drive or transmission, the operating temperature of the cup is lower than the cone and roller assembly. This is due to the cooling effect of the housing, since normally it can more effectively dissipate heat than can the shaft on which the cone is mounted.

_________________________________________________________________ 5.324 Bucyrus – Model 25C Continuous Miner

________________________________________ Replacement of wear parts Under operating conditions, the component parts of the bearing do not expand uniformly. When a single-row tapered roller bearing is used at each end of a shaft, consider the axial expansion of the shaft and housing in determining the proper initial bearing adjustment.

Lubrication is important in the thermal characteristics. Bearings rotating at high speed partially or completely submerged in oil may cause a high degree of heat from their churning action of bearings in the lubricant.

Bearings usually are first adjusted with slight running clearance or end play. On applications such as gear cases, initial end play will be about 0.001 to 0.003 inches (0.025 -0.076 mm) on the small sizes and proportionately greater as the bearings size increases. Generally, running bearings at higher speeds and temperatures increases the amount of initial end play or running clearance required. torque for zero end play

The following recommended procedure for adjusting tapered roller bearings is used in most applications. Pull up on the end cap or bearing cup carrier, or end plate, without shims in place, until bearings bind slightly in rotation. Then the gap between the cap flange and housing or the end of the shaft, can be measured with a thickness gauge. The measured gap plus the end play desired will give the total shim pack required.

Another good way is to put a lead wire where the shims go and then pull up until all end play is taken up. The wire, which has to be larger than the original gap, is then flattened and can be measured with micrometers and the shim pack made up in the same manner as when thickness gauges are used. The shaft should then be tapped with a hammer so that the adjusted bearing member (cup or cone) is likewise backed off and seated against the adjusting device.

Where large tapered roller bearings are adjusted, it may be hard to manually feel when a "metal to metal" setting is reached. In such cases, a simple torque measuring device is commonly used. With this method, as the bearings are being adjusted, an increase in bearing torque can be detected which indicates that a close setting has been reached.

Do not confuse this torque with torque generated by gears and seals.

When bearings are being set for desired initial end play, check the axial movement of the shaft as the bearings rotate. Rotating bearings ensures that the rollers will align and seat against the cone rib, resulting in a true end play measurement.

______________________________________________________________ A6474X308 Rev. 0 5.325

Replacement of wear parts _________________________________________ bearing testing

After the bearings have been installed and the machine reassembled, it should be tested. Running the machine without a load or a short time will ensure that all components are installed correctly.

Check the bearings for noise, excessive heat and vibration. Any of these signs could indicate damage which may have occurred during the installation procedure (Fig. 217) . Interference or overload will produce a high-pitched whine. Bearing misalignment will cause a medium or low-pitched noise and poor shaft finish or out-of-round housings will create a rumbling noise. Excessive heat is frequently caused by the presence of too much lubricant.

bearing removal

If the bearing is designed to be installed with an arbor press, then use an arbor press to remove the bearing. If the bearing or shaft is too long to fit in a press, use a bearing puller.

If the bearing does not come off the shaft easily, a different approach must be tried. One possible method is to heat the bearing with a torch, thereby increasing the clearance between the shaft and the bearing.

CAUTION! Be careful not to set fire to any grease or lubricant while using a torch.

Make sure the heating torch is the proper type and that it is set for heating, not cutting or burning.

IMPORTANT! Observe all applicable fire and safety regulations.

Remember to provide proper support for the bearing and shaft during disassembly.

Fig. 217: Wear patterns in failed bearings Wide worn area

Wavy wear pattern

_________________________________________________________________ 5.326 Bucyrus – Model 25C Continuous Miner

________________________________________ Replacement of wear parts Bevel gear adjustment Straight bevel gears connect shafts having perpendicular axes. The alignment of bevel gears is more critical than that of spur gears or helical gears. An adjustment on all bevel gear sets corrects any tooth contact errors.

Straight bevel gears are produced to run with a localized tooth contact.

Since the area of contact does not cover the whole tooth, slight tolerance in positioning the gears in assembly and some displacement under operating loads is possible without concentration of the loads on the ends of the teeth.

Regarding tooth contact pattern, the contact length is usually about half the tooth length and toward the inner end of the tooth (small end). Under a heavy load, the tooth contact will spread out and shift toward the heel (large end of the tooth). The resulting contact is called “central toe contact”.

To check the tooth pattern, paint the gear teeth with gear marking compound and run the gears briefly under a light load two or three revolutions.

IMPORTANT! A mixture of marking compound and spindle oil is suitable for lubricating the gears under light loads for two or three revolutions only. Check tooth pattern all around gear to make sure that the pattern is uniform.

Fig. 218 shows examples of recommended tooth contact patterns for straight bevel gears. Also shown are typical examples of incorrect contact patterns due to errors in gear assembly and the changes necessary to correct them. To check tooth pattern, paint gear teeth with a gear marking compound, and run gears briefly under light load two or three revolutions.

Fig. 218: Tooth contact patterns

Low Contact: To correct, move out on pinion cone ERROR

High Contact: To correct, move in on pinion cone

Preferred contact pattern on a completed gear run on a test machine under a light load with a control gear.

ERROR

______________________________________________________________ A6474X308 Rev. 0 5.327

Replacement of wear parts _________________________________________ Gears and gear failure The three most common gear failures are tooth breakage, pitting and scoring.

Breakage happens because an unexpectedly high load is applied to a gear or because of bending fatigue that occurs through repetition of loading as the gear rotates. A gear tooth will frequently break at its base.

Pitting is fatigue at the surface occurring when the stress exceeds the endurance limit of the surface material. After sufficient repetitions, bits of surface metal will drop off. Insufficient lubricant usually causes pitting to start.

Scoring occurs under heavy loads with insufficient lubrication. The oil film breaks down, resulting in metal to metal contact and high temperatures. The high spots on the two metal surfaces weld together, but the weld breaks at once. This action causes the gear teeth to wear very rapidly.

Gear maintenance tips Lubrication is the first line of defense against gear failure. Be sure all gear cases are filled to the proper level with the specified lubricant.

Check the lubricant level regularly and be on the alert for unusual noises or excessive heating in the gear cases.

After some gears have been running for several years, hairline cracks may develop in the body or teeth. The teeth may also become chipped or broken. These minor maintenance problems should not be ignored, but should be corrected as soon as possible after they are discovered.

Some of the ways to correct such problems include welding, drilling and tapping and tooth resurfacing or metal spraying.

CAUTION! Because these maintenance techniques are specialized, they should be performed only by qualified personnel.

When a gear case is rebuilt, all gears should be replaced with a new set. The old set should be tested with magnaflux equipment or dye penetrant to detect any gears with hidden flaws or cracks. The old set can then be used as a spare after any bad gears are replaced. Sometimes magnafluxing is not possible, but it remains a desirable goal since it finds flaws that are sometimes invisible to the human eye.

The wear pattern on gear teeth can show how the gears are meshing.

Abnormal wear patterns will appear on gear teeth (Fig. 219). Shimming can sometimes be used to adjust the meshing of gears to prevent premature gear failure.

_________________________________________________________________ 5.328 Bucyrus – Model 25C Continuous Miner

________________________________________ Replacement of wear parts Fig. 219: Examples of worn gear teeth

Shock loading

Improper type of lubricant

Bent or broken teeth

Contaminated lubricant

______________________________________________________________ A6474X308 Rev. 0 5.329

Replacement of wear parts _________________________________________ Lock wiring fasteners single wire

Insert the wire through the fastener from inside the bolt circuit toward outside the bolt circle, advancing in clockwise direction (Fig. 216).

wired in pairs

Establish the left and right hand fasteners as viewed from center of the bolt circle. Insert left hand fastener from inside to outside of the bolt circle. Insert the right end of the wire through right hand fastener from outside of the bolt circle (Fig. 220).

Fig. 220: Lock wiring fasteners

Special fasteners Various types of self- locking bolt and nut fasteners are in use. They are to be used in the same manner as standard fasteners with regard to tensile strength and torque; but they provide better locking qualities and reduce the number of parts used in fastening. Most special fasteners, once used, should not be re-used because of the locking material retention limitations.

Self-locking screws This socket head screw has a number of threads with wide, offset sections, which produce the self-locking effect by causing a high friction bind against the matting threads. This type fastener is identified by a triangle at the base of the socket. Because of this self- locking feature, the use of washers is usually not necessary. It is suitable in assemblies subjected to high vibration. installation

The self- locking screw (Fig. 221) is generally used where measured torque is required. When this is specified, hand wrench only - do not power wrench. This is to obtain an accurate reading and not due to structural limitations of the screw.

The top performance of this screw is reduced with each use. Re-use of this fastener should be limited to twice. For assemblies that require shims with self- locking screws, establish the shim set using standard fasteners. For final assembly, remove the standard fasteners and install the self- locking type, then torque down as required.

_________________________________________________________________ 5.330 Bucyrus – Model 25C Continuous Miner

________________________________________ Replacement of wear parts Fig. 221: Self-locking screws 2 to 4 pitches

4 pitches min.

Screw locking feature 6 thread pitches max.

See Detail A

Wider Thread Sections

Triangle at bottom of socket identifies self-locking screw

DETAIL A

Locknuts Locknuts reduce use of (but do not replace) cotter pins, jam nuts, lock tabs and safety wire. These latter methods are usually more suitable for certain applications where permanent fastening is required, or in areas inaccessible or hidden after final assembly.

Locknuts with nylon or fiber inserts should not be re-used. A locknut with unlimited reuse contains a spring steel lock ring in the head. The locking feature is an elliptical insert, which is permanently bonded to the nut. installation

Be sure bolt or stud has a 35° - 45° chamfer on threaded end and the end is flat. The flat diameter should be 1/32 inches below root diameter of thread on bolt or stud. These features are necessary to allow the lock ring to thread on for maximum grip without damage.

CAUTION! Do not power wrench the lead thread of the lock ring insert until it is engaged by hand turning. Then tighten normally.

Make sure the bolt or stud threads extend at least 2-1/2 threads beyond the top of the insert.

______________________________________________________________ A6474X308 Rev. 0 5.331

Replacement of wear parts _________________________________________ Component substitution IMPORTANT! Anti-seizing compounds may be used with this type of locknut.

Washers are not normally required here, but if assembly does, include them as they are needed due to high stress torque.

When parts need changed, OEM equipment is recommended.

This includes less obvious components such as hydraulic hoses, couplings, and valves, as well as the more obvious ones such as relays, gears, and torque shafts.

WARNING! Components not meeting specifications can fail, cause serious injury, and damage equipment.

WARNING! Do not substitute materials or compounds not complying with OEM. Use of non-OEM supplies may void warranties.

IMPORTANT! When performing maintenance on the machine, remember that fabrication, installation, modifications or adjustments must be according to OEM specifications.

_________________________________________________________________ 5.332 Bucyrus – Model 25C Continuous Miner

_________________________________________________ Troubleshooting Troubleshooting procedures The following section lists possible problems encountered when servicing the Continuous Miner and can aid in locating and correcting these problems.

This section covers basic components, with each listed in a troublecause-remedy format.

WARNING! Some procedures must be carried out with the cover of the electrical controller removed and some procedures require the controller to be energized during the tests. It is extremely important that you take all necessary precautions to prevent accidental electrical shock while working within the controller. An MSHA-certified electrician must supervise and inspect all work performed.

For maintenance procedures and tests that DO NOT require the controller to be energized, these precautions include: ■

Before removing the controller cover, remove power from the system by unplugging the battery.

■

Use insulated gloves and tools where possible.

■

All connections must be tight and care must be taken to pre vent bolts, nuts, washers and other small metal fasteners from being dropped or lost inside the controller. These lost fasteners could cause electrical shorts inside the controller.

For procedures that DO require that the controller be energized while the cover is off: ■

At no time should you reach inside the controller while it is energized. If it becomes necessary to make adjustments or to replace parts inside the controller, the machine circuit breaker must be turned to the “OFF” position and the capacitor bank discharged (see above). Once the circuit breaker is in the “OFF” position and the capacitor bank discharged, adjustments or parts replacements can be made.

■

Use insulated gloves and tools where possible.

■

All connections must be tight and care must be taken to prevent bolts, nuts, washers and other small metal fasteners from being dropped or lost inside the controller. These lost fasteners could cause electrical shorts inside the controller.

_____________________________________________________________ A6474X308 Rev. 0 5.333

Troubleshooting _________________________________________________ WARNING! Never disconnect a hydraulic hose if the circuit is pressurized or there is a load on the circuit. If a hose is disconnected while the cylinder is supporting a load, the load will fall.

Typical hydraulic problems The most common causes for improper function are: ■

contaminated oil or poor oil quality

■

low or insufficient oil in the system

■

using the wrong type of oil or wrong viscosity grade

■

air in the hydraulic system

■

internal or external leakage of the hydraulic system

■

improper mechanical adjustments, such as reliefs

■

mechanical or structural damage leading to component failure

■

components by-passing (internal leaking or inability to hold pressure) which leads to erosion of bushings, valve spools, and other costly, critical components

The greatest aid to troubleshooting a hydraulic system is the confidence that comes with knowing the intended operation of the system, along with a fundamental understanding of basic hydraulic principles. Every component in the system has an intended purpose. The construction and operating characteristics of each of these components should be clearly understood before attempting to troubleshoot the machine. For example, understanding that a solenoid controlled directional valve can be manually actuated will save considerable time in isolating a defective solenoid. Please familiarize yourself with the operational descriptions of the hydraulic circuits given in the Hydraulics section of this chapter.

It is also important to know the capabilities of the system. Each component in the system has a maximum rated speed, flow, torque, or pressure. If the system is loaded beyond the specifications, the possibility of failure is greatly increased. The correct operating pressures of a system must be known and must always be checked and set with a pressure gauge. Refer to the hydraulic schematic in the Bucyrus America, Inc. parts manual supplied with your machine for the correct operating parameters. When in doubt, always assume that the correct pressure is the lowest pressure that will allow adequate performance of the system function(s) while remaining below the maximum rating of the machine’s components.

_________________________________________________________________ 5.334 Bucyrus – Model 25C Continuous Miner

_________________________________________________ Troubleshooting The ability to recognize trouble indicators in a specific system is usually acquired with experience. the gaining of this experience can be greatly enhanced by developing a logical sequence for determining the cause of a hydraulic problem and implementing the proper remedy.

Refer to the general troubleshooting charts in this section that illustrate the logical sequence for shutdown, troubleshooting, and restarting the machine. The charts cover: ■

general safety procedure for shutting down the machine

■

troubleshooting excessive noise

■

troubleshooting excessive heat

■

troubleshooting incorrect flow

■

troubleshooting incorrect pressure

■

troubleshooting faulty movement/operation

■

general restart checklist and procedure

This general information is intended to enhance the understanding of basic hydraulic principles which will lead to the development of a logical troubleshooting procedure. Specific troubleshooting checklists for each hydraulic circuit are given directly after the very important section entitled “Contaminants in hydraulic systems”.

Contaminants in hydraulic systems SYSTEM CONTAMINATION is the primary cause of hydraulic component failure! Cleanliness must be a high priority when servicing the hydraulic system. Even very small particles can damage system components by scoring valves, clogging orifices, and wearing seals prematurely. It is not the intent of this operation manual to outline a contamination control program but some of the most effective steps that have been identified in successful programs are given below: 1. Ensure that bulk oils are at acceptable cleanliness levels.

Areas where Bucyrus America, Inc. customers have made improvements in the past include: –

implement ISO Cleanliness Code standards for bulk hydraulic oils

–

evaluate bulk oil shipments for cleanliness by conducting particle counts and maintain records

–

minimize drum usage by utilizing tote tanks and five gallon pails

–

utilize plastic versus steel storage tanks, if possible

_____________________________________________________________ A6474X308 Rev. 0 5.335

Troubleshooting _________________________________________________ –

install desiccant breathers on all bulk tanks

–

use sealed plastic containers for adding oil to small sumps

–

locate bulk tanks near equipment and pump directly to reservoirs

–

utilize filter carts to maintain oil cleanliness standards

–

properly train personnel on the importance of clean oil and best practices for storage and handling

–

monitor your program closely and look for continuous improvement

2. Eliminate contamination source through “clean” maintenance practices.

This is best achieved by understanding the primary sources of contamination during maintenance and troubleshooting which are given below: –

always clean the area around the component that is to be removed and inspected

–

store components in a plastic bag after inspection and prior to replacement on machine

–

cap off all open hoses/fittings

–

never touch a filter with bare hands when installing it back onto the machine

–

pay close attention to the filler/breather cap and replace it when damaged or in the recommended time frame

Contact your Bucyrus America, Inc. representative for more information on implementing an effective program to ensure that your oil and maintenance practices are not contributing to your equipment failure.

Specific hydraulic circuit troubleshooting Multi-function failure If more than one function fails to operate on the machine, check the output of the pumps. Since this is an “open center” circuit, the normal pressure (with all directional control valves in the center position) should be less than 100 psi. This pressure reading illustrates the necessary pressure to circulate the oil through the system. If the pressure reading under these conditions is significantly greater than 100 psi, it is likely that one of the control valves is trying to direct oil to one (or more) of the circuits on the machine.

_________________________________________________________________ 5.336 Bucyrus – Model 25C Continuous Miner

_________________________________________________ Troubleshooting The next step in troubleshooting a multi-function failure is to check the pilot pressure on the main control valve manifold. This pressure should be between 400 - 500 psi. If the pilot pressure is significantly below 350 psi, start with the General Troubleshooting Flow Chart IV - Incorrect Pressure.

Another step to resolve multi-function failure is to have an electrician check for power to the solenoid circuits.

Individual hydraulic circuit failures Perform the following checks on the individual circuits in conjunction with the general troubleshooting: Oil tank fill  Check to see that the oil fill strainer is clean.  Check the venturi ejector for blockage.  Check for low oil in the new oil supply.

Cutter head raise Check the directional control valve for proper operation.  Check to see that piping has not been crossed, especially if the problem occurs after maintenance or repair work.  Check that the "in-line" counterbalance holding valve is piloted and shifting to direct retract port cylinder oil flow back to tank.  Check to see that there is no mechanical bind.  Check cylinders for bypassing.  Check for pilot pressure on the cutter head cylinder’s holding valves. Also check that the valves are shifting to send (extend port) oil back to the tank. Note: Cylinder removal will be required to safely achieve this).

Cutter head lower  Check the direction control valve for proper operation.  Check to see that piping has not been crossed, especially if the problem occurs after maintenance or repair work.  Check to see that there is no mechanical bind or hydraulic block.  Check flow control valve cartridge.  Check cylinders for bypassing.  Check for pilot pressure on the cutter head cylinder's holding valves. Also check that the valves are shifting to send (extend port) oil back to the tank. Note: Cylinder removal will be required to safely achieve this.

_____________________________________________________________ A6474X308 Rev. 0 5.337

Troubleshooting _________________________________________________ Gathering head raise  Check the directional control valve for proper operation.  Check to see that piping has not been crossed, especially if the problem occurs after maintenance or repair work.  Check pressure at the LH pressure gauge on snubber.  Check to see that there is no mechanical bind.  Check cylinders for bypassing.  Check accumulator for 500 psi pre-charge, and that the bladder is functioning properly.  Check needle valve on pilot circuit to verify that it is not open or leaking off.  Check in-line counterbalance valve for proper operation or blockage.

Gathering head float  Check the control valve for proper operation.  Check to see that piping has not been crossed, especially if the problem occurs after maintenance or repair work.  Check to see that there is no mechanical bind.  Check accumulator for 500 psi pre-charge, and that the bladder is functioning properly.  Check cylinders for bypassing (they will leak out the top).  Check needle valve on pilot circuit to verify that it is not open or leaking off.  Check counterbalance valve for proper operation (See the schematic in the Bucyrus America, Inc. parts book supplied with your machine for the proper setting).

Conveyor raise  Check the directional control valve for proper operation.  Check to see that piping has not been crossed, especially if the problem occurs after maintenance or repair work.  Be sure that the built-in atmospheric-vented reliefs on the cylinders are not dumping oil.  Check to see that there is no mechanical bind.  Verify that cylinders are not bypassing.

_________________________________________________________________ 5.338 Bucyrus – Model 25C Continuous Miner

_________________________________________________ Troubleshooting Conveyor lower  Check the directional control valve for proper operation.  Check to see that piping has not been crossed, especially if the problem occurs after maintenance or repair work.  Verify that pilot pressure is being applied to open the piloted builtin checks.  Verify that cylinders are not bypassing.

Conveyor swing  Check the directional control valve for proper operation.  Check for any mechanical bind or any obstruction blocking movement, either to the cylinder itself, the main pivot area, or to some point along or under the discharge conveyor itself. Also check to ensure that the pivot bushings have not frozen up from lack of lubrication.  Verify that the cylinder is not bypassing.

Stabilizer raise  Check the directional control valve for proper operation.  Check to see that piping has not been crossed, especially if the problem occurs after maintenance or repair work.  Check the lubrication network for bound bushings.  Check for any mechanical bind or any obstruction blocking movement.  Check cylinder for bypassing.

Stabilizer lower  Check the control valve for proper operation.  Check to see that piping has not been crossed, especially if the problem occurs after maintenance or repair work.  Check the lubrication network for bound bushings.  Check for any mechanical bind or any obstruction blocking movement.  Check cylinder for bypassing.

_____________________________________________________________ A6474X308 Rev. 0 5.339

Troubleshooting _________________________________________________ General safety procedure for shutting down machine When shutting down the machine fore maintenance:  lower or mechanically secure (block) all suspended loads  exhaust any pressure locked in the system  drain down all accumulators  isolate the electrical control system  isolate the electrical power supply Follow all procedures listed in the Shutdown procedure in this chapter.

_________________________________________________________________ 5.340 Bucyrus – Model 25C Continuous Miner

_________________________________________________ Troubleshooting Table 7: Flow chart I for troubleshooting excessive noise Pump Noisy Cause

Motor Noisy Remedy

Cause

Cavitation

A

Coupling misaligned

Air in fluid

B

Motor or coupling worn or damaged

Coupling misaligned

C

Pump worn or damaged

E

Relief/Counterbalance Valve Noisy Remedy

Cause

Remedy

C

Setting too low or too close to another valve setting

D

Worn poppet and seat

E

Remedies A. Any or all of the following:  replace dirty filters  wash strainers in solvent compatible with system fluid  clean clogged inlet line  clean reservoir breather vent  change system fluid  change to proper pump drive motor speed  check fluid temperature B. Any or all of the following:  tighten leaky inlet connections  fill reservoir to proper levels: with few exceptions, all return lines should be below fluid level in the reservoir  bleed air from system  replace pump shaft seal; also replace shaft if worn at seal journal C. All of the following:  align unit  check condition of seals, bearings, and coupling D.  install and/or adjust pressure gauge E.  overhaul or replace defective parts

_____________________________________________________________ A6474X308 Rev. 0 5.341

Troubleshooting _________________________________________________ Table 8: Flow chart II for troubleshooting excessive heat Pump Heated

Motor Heated Cause

Fluid Heated

Cause

Remedy

Cause

Remedy

See Fluid Heated

System pressure too high

D

Cause

Remedy

Fluid heated

See Fluid Heated

Cavitation

A

Relief or unloading valve set too high

D

Valve setting incorrect

D

Unloading valve set too high

D

Air in fluid

B

Excessive load

C

Worn or damaged valve

E

Fluid dirty or low supply

F

Relief or unloading valve set too high

D

Worn or damaged motor

E

Incorrect fluid viscosity

F

Excessive load

C

Faulty fluid cooling system

G

Worn or damaged pump

E

Worn pump, valve motor, cylinder, or other component

E

Fluid heated

Remedy

Relief Valve Heated

See Fluid Heated

Fluid heated

Remedies  locate and correct mechanical binding A. Any or all of the following:  check for workload in excess of circuit design  replace dirty filters  clean clogged inlet line

D.  install and/or adjust pressure gauge; keep at least 125 psi difference between valve settings

 clean reservoir breather vent

E.  overhaul or replace defective parts

 change system fluid

F.  change filters

 change to proper pump drive motor speed

 check system fluid viscosity; change if necessary

 overhaul or replace supercharge pump  fill reservoir to proper level B. Any or all of the following: G.  clean cooler and/or strainer  tighten leaky inlet connections  replace cooler control valve  fill reservoir to proper levels: with few exceptions, all return lines should be below fluid level in the reservoir

 repair or replace cooler

 bleed air from system  replace pump shaft seal; also replace shaft if worn at seal journal C. All of the following:  align unit  check condition of seals, bearings, and coupling

_________________________________________________________________ 5.342 Bucyrus – Model 25C Continuous Miner

_________________________________________________ Troubleshooting Table 9: Flow chart III for troubleshooting incorrect flow No Flow Cause

Low Flow Remedy

Excessive Flow

Cause

Remedy

Cause

Remedy

Pump not receiving fluid

A

Flow control set too low

D

Flow control set too high

D

Pump drive motor not operating

E

Relief or unloading valve set too low

D

RPM of pump drive motor incorrect

H

Pump to drive coupling sheared

C

Flow by-passing thru partially open valve

E of F

Improper size pump used for replacement

H

Pump drive motor turning in wrong direction

G

External leak in system

B

Directional control set in wrong position

F

RPM of pump drive motor incorrect

H

Entire flow passing over relief valve

D

Worn pump, valve, motor, cylinder, or other component

E

Damaged pump

C

Pilot filter clogged

A

Improperly assembled pump

E

Pilot filter clogged

A

Remedies A. Any or all of the following:  replace dirty filters  clean clogged inlet line

F. Any or all of the following   check position of manually operated controls  check electrical circuit on solenoid operated controls

 clean reservoir breather vent  repair or replace pilot pressure pump  fill reservoir to proper level G.  reverse rotation  overhaul or replace supercharge pump H.  replace with correct unit B. Any or all of the following:  tighten leaky inlet connections  bleed air from system C. All of the following:  check for damaged pump or pump drive  replace and align coupling D.  adjust setting on valve E.  overhaul or replace part

_____________________________________________________________ A6474X308 Rev. 0 5.343

Troubleshooting _________________________________________________ Table 10: Flow chart IV for troubleshooting incorrect pressure No Pressure

Low Pressure

Cause

Remedy

Cause

No flow

See Table 5 Pressure relief path exists

Erratic Pressure

Remedy See Table 5

Cause

Excessive Pressure

Remedy

Cause

Remedy

Air in fluid

B

Pressure reducing, relief, or unloading valve misadjusted

D

Pressure recuing, relief, or unloading valve worn or damaged

E

Pressure reducing valve set too low

D

Worn relief valve

E

Pressure reducing valve damaged

E

Contamination in fluid

A

Damaged pump, motor, or cylinder

E

Accumulator defective or has lost charge

C

Worn pump, motor, or cylinder

E

Remedies A.  replace dirty filters and system fluid B.  tighten leaky connections  fill reservoir to proper level and bleed air from system C.  gas valve for leakage  charge to correct pressure  overhaul if defective D.  adjust valve E.  overhaul or replace part

_________________________________________________________________ 5.344 Bucyrus – Model 25C Continuous Miner

_________________________________________________ Troubleshooting Table 11: Flow chart V for troubleshooting faulty operation No Movement Cause No flow or pressure

Slow Movement

Remedy

Cause

See Table Low flow 5

Erratic Movement Remedy

Excessive Speed or Movement

Remedy

Cause

Cause

Remedy

See Table 5

Erratic pressure

See Table Excessive flow 6

See Table 5

Air in fluid

See Table Feedback 3 transducer malfunctioning

E

Limit or sequence device (mechanical, electrical, or hydraulic) inoperative or misadjusted

E

Fluid viscosity too high

A

Mechanical bind

B

Insufficient control pressure for valves

See Table 6

No lubrication of machine ways or linkage

G

Misadjusted or malfunctioning valve amplifier

C

No command signal to valve or amplifier

F

No lubrication of machine ways or linkage

G

Erratic command signal

F

Overriding work load

H

Inoperative or misadjusted valve amplifier

C

Misadjusted or malfunctioning valve amplifier

C

Misadjusted or malfunctioning valve amplifier

C

Inoperative solenoid or proportional valve

E

Sticking valve

D

Malfunctioning feedback transducer

E

worn or damaged cylinder or motor

E

Worn or damaged cylinder or motor

E

Sticking valve

D

Pilot filter clogged

See Table 5

Worn or damaged cylinder or motor

E

Remedies A.  check fluid temperature  check system fluid viscosity; change if necessary B.  locate bind and repair C.  adjust, repair, or replace part D.  clean and adjust or replace part  check condition of system fluid and filters E.  overhaul or replace part F.  repair command console or interconnecting wires G.  lubricated H.  adjust, repair, or replace counterbalance valve

_____________________________________________________________ A6474X308 Rev. 0 5.345

Troubleshooting _________________________________________________ Table 12: Restarting checklist Has the cause of the failure been remedied?

No

Carry out further investigation.

Yes

Clean or flush the system as required.

Yes Can dirt have entered the system by the unit failure or during replacement?

No Is the unit the correct one?

No

Modify or replace with correct unit.

No

Remedy installation.

No

Remedy installation.

Yes

Is the unit adjusted to a safe condition for start up?

Yes Are all hydraulic connections correct?

Yes Are all electrical connections correct?

Yes Is the unit adjustable?

No

Adjust to a safe condition.

Yes No Have the cases of pumps and motors been filled?

No

Fill case.

Yes

Bleed or prime as necessary.

No

Remove safety interlocks.

No

Sound alarm or inform personnel.

Yes Will the system require bleeding or priming?

No Have all safety interlocks been removed

Yes Are all personnel aware the machine is restarting?

Yes Start machine (see Startup procedure in this chapter).

_________________________________________________________________ 5.346 Bucyrus – Model 25C Continuous Miner

_________________________________________________ Troubleshooting Water System including Circuits Table 12: Water system troubleshooting including circuits Trouble, symptom or cause

Probable cause

recommended water volume (gpm)  Dynamic water pressure (psi) is not being supplied to the recommended cannot be maintained psi.

Test, check and/or remedy  Change setting to the recommended psi.

 Water supply hose is not the minimum diameter

   Change hose to the recommended diameter size.

 Incoming supply of water has a problem.

 Check the water supply itself to see if there is an issue & fix.

damaged or clogged filter, contaminates  Dirt in the system. in the water system

 Remove the filter and clean it thoroughly; flush the system as necessary.  Change water filter frequently.

plugged water nozzles are restricting  Dirt in the system. the flow of water or pressure fluctuates

 Remove the nozzles and clean thoroughly; flush the system as necessary.  Change water filter frequently.

pressure fluctuates and there is ex-  Air in the system. treme noise in the system  Pressure too high. excessive water blowing from scrubber  Excessive pressures on scrubber screen sprays. exhaust

 Check for leaks.  Adjust the pressure.  Adjust psi setting.

Pressure setting on jet pump too low.

 Adjust psi setting.

Damaged screen or mist eliminator.

Replace.

Mist eliminator not sealing.

Replace seal.

Sump needs cleaned.

Remove mist eliminator and clean sump.  Remove mist eliminator and clean.

Mist eliminator baffles dirty. water function will not shut “OFF” with Hydraulic pilot operated water valve stuck closed. radio remote Faulty solenoid. Radio remote toggle switch faulty.

Clean or replace.   Replace.  Replace toggle switch.

no water pressure on the  pressure gauge 

Water filter plugged.



Replace or clean.

Main water ball valve “OFF”.



Close valve.



No incoming water.



Fix water supply issue.

Contaminated water supply



Clean or filter the incoming water supply to the miner.

Faulty solenoid plug connection.



Check the connection.

Faulty solenoid.



Replace.

No hydraulic pilot pressure to water valve.



Check for pinched hose and check the hydraulic pilot valve.

water filter stopping up  frequently scrubber water will not turn “ON” when  scrubber motor is running  

_____________________________________________________________ A6474X308 Rev. 0 5.347

Troubleshooting _________________________________________________ Table 12 (continued): Water system troubleshooting including circuits Trouble, symptom or cause

Probable cause

scrubber water will not shut “OFF”  after scrubber motor stops 

Test, check and/or remedy

Hydraulic pilot operated water valve stuck open.



Clean or replaced valve.

Faulty solenoid



Replace.



Adjust psi.



Check water volume gpm.

jet pump not removing  Incorrect pressure reducing valve setting. water from sump Low water volume to scrubber circuit. Pressure reducing valve internal strainer dirty.

Remove strainer and clean. 

Jet pump nozzle plugged with dirt.

Backflush pump, remove nozzle and clean.

Excessive pressure setting on scrubber screen sprays.  Suction hose from sump to jet pump plugged with sludge or hose has a loose connection.  Incorrect hose size from jet pump to manifold.  Manifold plugged.

Adjust psi.

scrubber screen dirty Incorrect pressure reducing valve setting. Low water volume to scrubber circuit. Pressure reducing valve internal strainer dirty. Spray nozzles clogged or incorrect nozzle size.

 Remove restriction or tighten hose connection. Check for correct hose size.   Clean. Adjust psi.  Check water volume gpm.  Remove strainer and clean.   Clean nozzles and check nozzle part size.

_________________________________________________________________ 5.348 Bucyrus – Model 25C Continuous Miner

_________________________________________________ Troubleshooting Bearings Table 13: Bearing troubleshooting Trouble, symptom or cause

Probable cause

overheating bearing 

Test, check and/or remedy

Wrong type of grease or oil.



Consult the lubrication chart for the proper lubricant.



Low oil level; loss of lubricant through seal; excessive grease.



Oil level should normally be at the center of lowest ball or roller in bearing; check seals for signs of leaking.



Insufficient clearance in bearing.



Replacement bearing should be identical to original equipment to ensure proper internal clearance.



Housing bore out of round; housing warped; excessive distortion of housing; undersized housing bore.



Check and scrape housing bore to relieve pinching of bearing; be sure pedestal surface is flat and shims cover entire area of pillow block base when applicable.



Shaft out of line.



Correct alignment and be sure shafts are coupled in a straight line.

Insufficient clearance in bearing.



Replacement bearing should be identical to original equipment to ensure proper internal clearance.



Foreign matter acting as abrasive.



Clean bearing housing and replace worn seals.



Housing bore out of round; housing warped; excessive distortion of housing; undersized housing bore.



Check and scrape housing bore to relieve pinching of bearing; be sure pedestal surface is flat and shims cover entire area of pillow block base when applicable.



Shaft and other parts of bearing assembly distorted.



Replace bearing, shaft and other parts as needed.

Enlarged housing bore causing spinning of outer ring in housing.



Re-bore housing and press steel bushing in bore, then machine bore to correct size.



Foreign matter acting as abrasive.



Clean bearing housing and replace worn seals.



Unbalanced loading.



Check balance of rotating parts and rebalance as needed.

Chip in bearing housing; insufficient clearance in bearing; Ball or roller dented from extreme loading.



Replace with OEM bearing; do not hammer on any part of bearing; clean housing and use fresh lube.

noisy bearing 

vibrating bearing 

unsatisfactory  performance

_____________________________________________________________ A6474X308 Rev. 0 5.349

Troubleshooting _________________________________________________ Electrical System Table 14: Electrical system troubleshooting Trouble, symptom or cause

Probable cause

motor contact chatter 

Test, check and/or remedy

Low voltage



Check supply voltage, especially during starting. Check coil voltage rating. Increase voltage or change coil rating as required.



Poor contact in control circuit.



Replace the contact or use holdingcircuit interlock.

(3-wire control)



Broken shading coil.



Replace magnet and armature assemblies.

Abnormal in rush current.



Use the next larger size contactor or check for grounds, shorts or excessive motor current.



Rapid jogging.



Install larger device rated for jogging service.



Insufficient contact pressure.



Replace contacts and springs, check for contacts for abnormal wear or damage.



Low voltage preventing magnet from sealing.



Check supply voltage to coil, especially for momentary voltage dip during starting.



Foreign matter preventing contacts from closing.



Clean contacts with Freon. Contacts used at low current and voltage levels should be cleaned with Freon.



Vibration in starter mounting.



Insulate starter from shock and vibration.



Short circuit.



Remove fault and check to be sure fuse or breaker size is correct.

Filing or dressing.



Do not file silver contacts. Rough spots or discoloration will not harm contacts or impair their efficiency.

welding of motor contactor tips 

chart contact life or  overheating of motor contactor 

Interrupting excessively high currents. 



Excessive jogging.



Install larger unit rated for jogging service.



Weak contact pressure.



Replace contacts and springs. Check contacts for abnormal wear or damage.



Foreign matter on contact surface.



Clean contacts with Freon. Take steps to reduce entry of foreign matter into enclosure.



Short circuit or ground fault.



Remove fault and check to be sure fuse or breaker size is correct.



Loose connections in power circuit.



Clean and tighten.



Sustained overload.



Check for excessive motor load current or install larger unit.

Install larger unit. Check for grounds, shorts or excessive motor currents.

_________________________________________________________________ 5.350 Bucyrus – Model 25C Continuous Miner

_________________________________________________ Troubleshooting Table 14 (continued): Electrical system troubleshooting Trouble, symptom or cause

Probable cause

failure to pick-up and seal 

Test, check and/or remedy

Low voltage.



Check system voltage and voltage dips during starting.



Wrong coil or wrong connection.



Check coil marking and wiring.



Mechanical obstruction.



With power off, check for free movement of armature and contacts.



Coil open or overheated.



Replace.

Sticky substance on pole faces.



Clean pole faces with Toluol and seal with a drop of DC200 silicone fluid.



Voltage not removed.



Check coil circuit or length of leads from supply voltage to coil. May be excessive.



Worn or rusted parts causing binding.

Replace unit.



Contacts welded.



See welding under contacts section.

Mechanical damage.



Handle and store coils carefully.

Three phase power not present at contactors.

Contactor tips damaged.

Check three phase input to contactors.   Check contactor tips.



Pump not running.



Start pump.



Low hydraulic level.



Check oil level and level indicator light.



Failed control relay contacts.



Check contacts

Cutter head motor start and stop switches, conveyor start switch, or pump start switch not working properly.



Check for faulty switches.

Control relay malfunction.



Check coil and contacts.



Overload relay.



Check overload relays.



Failed left cutter head motor contactor.



Check contactor coil. Verify that contacts are free to move.

failure to drop out 

open circuit  both cutter head motors do not start 

left cutter head motor starts but Auxillary contacts not closing. right cutter head motor does not   Time delay malfunction.   Load current relay problem.    Failed contactor.   Overload relay problem.

Check contactor auxillary contacts and wiring.  Check coil and timed closed contacts and wiring.  Verify that normally closed load current relays are NOT open.and check wiring.  Check contactor coil and contact tips and wiring.  Check overload relays and wiring.

both cutter head motors start but Problem with auxillary contacts. stop when pump start and cutter head start switches are released

Check right cutter head motor contactor auxillary contacts and associated wiring.  Check overcurrent relays.

Overcurrent relays. _____________________________________________________________ A6474X308 Rev. 0 5.351

Troubleshooting _________________________________________________ Table 14 (continued): Electrical system troubleshooting Trouble, symptom or cause

Probable cause

Test, check and/or remedy

conveyor starts forward operation but  stops when conveyor stop switch is released

Problem in holding circuit.



Check normally open conveyor forward auxiliary contact and associated wiring.

conveyor will not start in forward or re-  verse. Contactor IS NOT pulling in contacts 

Pump not running.



Start pump.

Failed control relay contacts.



Check contacts.



Conveyor start and stop switches or conveyor forward/reverse not working properly



Check for faulty switches.



Overload relay tripped/faulty/



Check overload relays.



Over current relay tripped/faulty.



Check over current relay.



Conveyor forward/reverse contactor failure.



Check contactor coils. Verify that contacts are free to move.

conveyor will not start in forward or re-  verse. Contactor IS pulling in contacts

Three phase power is not present at contactors.



Check three phase power input to the contactors.

Contactor tips are damaged.



Check contactor tips.

Forward/Reverse selector switch.



Check that the Forward/Reverse selector switch is completing the circuit.

Conveyor Forward auxiliary contacts.



Verify that the conveyor forward auxiliary normally closed contacts have not failed to open.

Forward/Reverse selector switch.



Check that the Forward/Reverse selector switch is completing the circuit.

Conveyor Reverse auxiliary contacts.



Verify that the conveyor reverse auxiliary normally closed contacts have not failed to open.

 conveyor operates in forward only  

conveyor operates in reverse only  

_________________________________________________________________ 5.352 Bucyrus – Model 25C Continuous Miner

_________________________________________________ Troubleshooting AC Traction System Table 15: Inverter fault and warning codes

Alarm Code

Description

Device Action

System Fault (if detected when pump on / traction idle)

System Error (if detected when pump off)

System Fault (if detected when pump on / traction active)

Control Control Control System System System Message Reaction Message Reaction Message Reaction Possible Cause Possible Solution 0

No Fault

N/A

N/A

None

N/A

None

N/A

None

N/A

N/A

1

Current limit reduced below 150% by IGBT thermal protection

Warning N/A

None

N/A

None

N/A

None

1. High heat sink temperature.

1. Improve coolant flow.

2. Sustained operation at high output current.

2. Reduce load.

Under voltage

Latched Left VFD None Fault Under voltage

2

Left VFD Pump Under shutvoltage down / inhibit

Left VFD Pump Under shutvoltage down / inhibit

3. Allow one minute to cool.

1. Supply voltage 1. Improve supply falls below quality or reduce 750V while total machine drive enabled. load.

2. Rectifier output 2. Replace rectifier. voltage too low.

4

5

Heatsink Trip

IGBT Short Circuit

Latched Left VFD None Fault Temp Trip

Latched Left VFD None Fault Short Circuit

Left VFD Pump Temp Trip shutdown / inhibit

Left VFD Pump Temp Trip shutdown / inhibit

Left VFD Pump Short shutCircuit down / inhibit

Left VFD Pump Short shutCircuit down / inhibit

3. Drive has faulty 3. Replace drive.

DC bus voltage measurement circuit.

1. Insufficient 1 Restore coolant coolant flow. flow.

2 Remove and re2. Poor thermal install with reccontact beommended tween drive thickness layer base and encloof heat sink sure surface, paste. too much or too little heat sink paste.

1. Operation in 1. Reset fault, alstall condition low drive one for more than minute to cool, one minute. remove cause of stall condition.

2. Motor winding fault or terminal- 2. Remove fault. to-terminal fault.

3. Reset fault and 3. Sudden incontinue. crease in me4. Replace drive. chanical load if running in open- 5. Replace drive. loop mode.

If fault always occurs at the instant the drive is enabled: 4. IGBT failure 5. Current transducer failure.

Note: _____________________________________________________________ Left side drive - for right drive, replace “left” with “right” A6474X308

Rev. 0

5.353

Troubleshooting _________________________________________________ Table 15 (continued): Inverter fault and warning codes Alarm Code

Description

Device Action

System Error (if detected when pump off)

System Fault (if detected when pump on / traction idle)

System Fault (if detected when pump on / traction active)

Control Control Control System System System Message Reaction Message Reaction Message Reaction Possible Cause Possible Solution 6

13

Overvoltage

Warning Left VFD None Over voltage

Left VFD Pump Over shutvoltage down / inhibit

Left VFD Pump Over shutvoltage down / inhibit

Motor Overload Latched Left Tract None Fault Motor Overload

Left Tract Pump Motor shutOverload down / inhibit

Left Tract Pump Motor shutOverload down / inhibit

1. Supply voltage 1. Reduce supply exceeds 1200V. voltage.

2. Dynamic brake 2. Wait for dyresistor thermal namic brake cut-out has resistor to cool. occurred while 3. Put machine in braking. air and check 3. The dynamic braking operabrake unit is not tion. Replace operating. rectifier/brake module if no braking observed..

1. Traction motor 1. Wait for cool load too high. down period and resume operation at lower speed.

2. Incorrect motor 2. Check motor parameter setsetup in menu tings C. 3. Motor stalled.

20

Left Motor Instantaneous Overload

Latched Left Tract None Fault Motor Inst Overload

Left Tract Pump Motor Inst shutOverload down / inhibit

Left Tract Pump Motor Inst shutOverload down / inhibit

1. Operation in stall condition for more than one minute.

2. Motor winding fault or terminalto-terminal fault.

27

Overvoltage Trip Latched Left VFD None Fault Overvoltage Trip

Left VFD Pump Overvolt- shutage Trip down / inhibit

Left VFD Pump Overvolt- shutage Trip down / inhibit

3. Remove cause of stalled motor.

1. Remove machine from stall condition.

2. Check motor windings and replace motor if necessary.

3. Sudden in3. Check compocrease in menent configurachanical load if tion with drive running in open- programmer and loop mode. examine conditions around If fault always machine. occurs at the inIf fault always stant the drive is occurs at the inenabled. stant the drive is enabled.

4. IGBT failure 4. Replace unit.

5. Current transducer failure.

5. Replace unit.

1. Supply voltage 1. Reduce supply exceeds 1200V. voltage 2. Dynamic brake 2. Wait for dyresistor thermal namic brake cut-out has resistor to cool. occurred while 3. Replace rectibraking. fier/brake mod3. The dynamic ule. brake unit is not operating.

Note: Left side drive - for right drive, replace “left” with “right” _________________________________________________________________ 5.354 Bucyrus – Model 25C Continuous Miner

_________________________________________________ Troubleshooting Table 13 (continued): Inverter fault and warning codes Alarm Code

Description

Device Action

System Fault (if detected when pump on / traction idle)

System Error (if detected when pump off)

System Fault (if detected when pump on / traction active)

Control Control Control System System System Message Reaction Message Reaction Message Reaction Possible Cause Possible Solution 34

35

38

43

44

60

Motor RTD Trip Latched Motor None Fault RTD Trip

Motor TSAT Trip Latched Motor None Fault TSAT Trip

Overspeed 10% Latched Left Tract None Fault Motor Overspeed

Output Phase Loss

Latched N/A Fault

None

Lost CAN comm Latched Left VFD None Fault Comms Fail

Encoder Loss (Position Error)

Latched Left Motor None Fault Encoder Fault

Motor Pump RTD Trip shutdown / inhibit

Motor TSAT Trip

Pump shutdown / inhibit

Left Tract Pump Motor shutOverdown / speed inhibit

Left VFD Pump Phase shutLoss down / inhibit

Left VFD Pump Comms shutFail down / inhibit

Left Motor Encoder Fault

Pump shutdown / inhibit

Motor Pump RTD Trip shutdown / inhibit

Motor Pump TSAT Trip shutdown / inhibit

Left Tract Pump Motor shutOverdown / speed inhibit

Left VFD Pump Phase shutLoss down / inhibit

Left VFD Pump Comms shutFail down / inhibit

Left Motor Pump Encoder shutFault down / inhibit

1. Traction motor load too high.

2. Insufficient motor cooling water flow

1. Traction motor load too high.

2. Insufficient motor cooling water flow

1. Wait for cool down period and resume operation at lower speed.

2. Restore cooling water flow 1. Wait for cool down period and resume operation at lower speed.

2. Restore cooling water flow 1. Severe electri- 1. Check conneccal noise on tions and shieldencoder signal. ing.

2. Incorrect setting 2. Check motor of encoder setup in C pulse number or menu. motor pole 3. Remove cause. number.

3. Machine running downhill or dragged by external cause.

1. Output phase 1. Check motor disconnected. connection.

2. Output current very low.

2. Reset and resume operation.

3. Inverter output 3. Replace inverter phase not working.

1. CAN link dis1. Reconnect CAN connected. link.

2. Severe electrical noise on CAN link.

2. Check connections and shielding.

3. Drive has no control power

3. Restore control power.

4. Drive has hard- 4. Replace inverter ware fault.

1. Encoder failure. 1. Check encoder wiring 2. Encoder power supply lost.

2. Replace encoder 3. Encoder signal disconnected.

Note: Left side drive - for right drive, replace “left” with “right” _____________________________________________________________ A6474X308

Rev. 0

5.355

Troubleshooting _________________________________________________ Table 13 (continued): Inverter fault and warning codes Alarm Code

Description

Device Action

System Error (if detected when pump off)

System Fault (if detected when pump on / traction idle)

System Fault (if detected when pump on / traction active)

Control Control Control System System System Message Reaction Message Reaction Message Reaction Possible Cause Possible Solution 61

Error 61

Latched Left VFD None Fault Undefined Fault Code

Left VFD Pump Left VFD Pump 1. Instantaneous 1. Reset fault and Undeshutdown/ Undefined shutdown/ overload has resume operafined Inhibited Fault Inhibited occurred but tion.

Fault Code duration not Code long enough to determine source of indication.

67

Encoder Ride Thru

Latched Left VFD None Fault in Encoder Ride Thru

Left VFD None in Encoder Ride Thru

Left VFD None in Encoder Ride Thru

68

Stall Fault

Warning Left Motor None Stalled

Left Mo- None tor Stalled

Left Motor None Stalled

69

Auto Encoderless Operation

Warning Left VFD None in Encoderless Mode

Left VFD Limit in EnTram to coderless First Mode Speed

Left VFD Limit in EnTram to coderless First Mode Speed

Unde- Undefined Fault N/A fined Code

Left VFD None Undefined Fault Code

1. Temporary loss 1. Continue to of encoder operate the signal. miner until secondary fault occurs.

1. Machine stuck. 1. Remove machine from stall 2. Loss of encoder position signal.

2. Continue to operate the miner until secondary fault occurs.

1. Machine run1. Check encoder ning in encoder- wiring and cycle less until power power. cycle and en2. Replace encoder fixed. coder and cycle power.

Left VFD Pump Left VFD Pump 1. Internal unUndeshutdown/ Undefined shutdown/ known fault to fined inhibit Fault inhibit component.

Fault Code 2. Fault occurred Code faster than component could register.

1. Restart system and operate normally.

2. Replace component if error persists.

NOTE: Fault and Error messages are given for the Left-side drive. The set of messages for the right drive will be identical, except for message numbers and the replacement of the text "Left" with the text "Right".

_________________________________________________________________ 5.356 Bucyrus – Model 25C Continuous Miner

_________________________________________________ Troubleshooting Table 16: Rectifier fault and warning codes Alarm Code

Description

Device Action

System Error (if detected when pump off)

System Fault (if detected when pump on / traction idle)

System Fault (if detected when pump on / traction active)

Control Control Control System System System Message Reaction Message Reaction Message Reaction Possible Cause Possible Solution 0

No Fault

None

N/A

1

Heatsink Alarm Warning Rectifier Temp Warning

None

Rectifier None Temp Warning

Under voltage

None

2

4

5

Heatsink Trip

IGBT Short Circuit

N/A

N/A

Latched None Fault until Healthy

None

N/A

None

Rectifier Temp Warning

None

Rectifier If present Rectifier Under for >1 sec Under voltage after first voltage 5 sec of pump start, inhibit drive function

1. Restore coolant flow.

2. Poor thermal 2. Remove and recontact beinstall with rectween drive ommended base and enclothickness layer sure surface, of heat sink too much or too paste. little heat sink paste.

If present 1. Supply voltage 1. Restore supply, for >1 sec below 460V or improve supply after first disconnected. quality or reduce 5 sec of total machine 2. CAN control pump load. board is applystart, ing precharge 2. Replace rectiinhibit inhibit signal. fier. drive function 3. SCR control 3. Replace recticircuit failure. fier.

Latched Rectifier None Fault Temp Trip until Healthy

Rectifier Pump Temp shutTrip down / inhibit

Rectifier Pump Temp Trip shutdown / inhibit

Latched Rectifier Fault Short until Circuit Healthy

Rectifier Pump Short shutCircuit down / inhibit

Rectifier Short Circuit

None

1. Insufficient coolant flow.

Pump shutdown / inhibit

4. Drive has faulty 4. Replace rectiDC bus voltage fier. measurement circuit.

1. Insufficient 1. Restore coolant coolant flow. flow 2. Poor thermal 2. Remove and recontact beinstall with rectween drive ommended base and enclothickness layer sure surface, of heat sink too much or too paste. little heat sink paste.

1. Damaged brake 1. Check braking resistor. by placing machine in air, run 2. Dynamic brake in second speed IGBT failure. and then return to neutral. If tracks coast excessively, replace brake resistor.

2. If brakes do not coast excessively, replace rectifier.

_____________________________________________________________ A6474X308 Rev. 0 5.357

Troubleshooting _________________________________________________ Table 16 (continued): Rectifier fault and warning codes Alarm Code

Description

Device Action

System Error (if detected when pump off)

System Fault (if detected when pump on / traction idle)

System Fault (if detected when pump on / traction active)

Control Control Control System System System Message Reaction Message Reaction Message Reaction Possible Cause Possible Solution 15

17

19

Rectifier IGBT Over Temp

Brake Resistor Thermal Trip

Rectifier Input Instantaneous Overload

Latched Rectifier Fault IGBT until Over Healthy Temp

None

Latched Brake Fault Resistor until Thermal Healthy Trip

None

Latched None Fault until Healthy

None

Rectifier IGBT Over Temp

Pump shutdown / inhibit

Brake Inhibit Resistor Drive Thermal Function Trip

Rectifier IGBT Over Temp

Pump shutdown / inhibit

Brake Resistor Thermal Trip

Inhibit Drive Function

Rectifier If present Rectifier Input Inst >1 sec, Input Inst Overload Pump Overload shutdown / inhibit

1. Insufficient coolant flow.

1. Restore coolant flow.

2. Poor thermal 2. Remove and recontact beinstall with rectween drive ommended base and enclothickness layer sure surface, of heat sink too much or too paste. little heat sink paste.

1. Braking resis- 1. Allow the systors overheated. tem to cool and/ or set second 2. Thermal switch speed to above malfunction.

66% to remove braking action.

2. Replace thermal switch.

1. Restore all input phases.

If present 1. No supply or >1 sec, missing input Pump phase during shutstartup. down / 2. DC bus connec- 2. Eliminate incorinhibit tion reversed on rect polarity. rectifier or inverter.

3. Short-circuit on 3. Remove shortDC bus. circuit.

4. Two failed 4. Replace faulty IGBTs in an inverter module. inverter module.

5. Dynamic brake 5. Replace rectifier IGBT failure. module.

42

Rectifier Phase Warning None Sync Loss Fault

Unde- Undefined Fault N/A fined Code

None

Rectifier None Undefined Fault Code

Rectifier Phase Sync Loss

If present Rectifier If present 1. No supply or for >10 Phase for >10 missing input sec after Sync Loss sec after phase after first 5 sec first 5 sec startup of pump of pump 2. Fault in synstart, start, chronization inhibit inhibit circuit. drive drive function function Rectifier Pump Rectifier Pump 1. Internal unUndeshutdown/ Undefined shutdown/ known fault to fined inhibit Fault inhibit component.

Fault Code 2. Fault occurred Code faster than component could register.

1. Restore all input phases.

2. Replace rectifier.

1. Restart system and operate normally.

2. Replace component if error persists.

_________________________________________________________________ 5.358 Bucyrus – Model 25C Continuous Miner

_________________________________________________ Troubleshooting AC Traction System Interfacing Connectors and Cabling Table 17: Inverter control connector (CN2) Cable 15C + SHIELD

6C + SHIELD

3C + SHIELD

Cable Marker CONTROL

ENCODER

AUXREF

Pin S

Description RTD RED (2 or 3 wire)

Wire Marker RTD1

Color BLK

P

RTD WHITE (3 wire only)

RTD2A

WHT

R

RTD WHITE (2 or 3 wire)

RTD2B

RED

M

TSTAT+

TSTAT+

GRN

N

TSTAT-

TSTAT-

ORG

A

LOGIC COM (+24V)

24V

BLU

B

MASTER ENABLE

ENABLE

WHT/BLK

f

CAN ADDRESS LSB

CANLSB

RED/BLK

g

CAN ADDRESS MSB

CANMSB

GRN/BLK

C

MANUAL TRAM FWD

EFWD

ORG/BLK

D

MANUAL TRAM REV

EREV

BLU/BLK

T

SPARE

SPARE

BLK/WHT

E

RELAY NO

RLYNO

RED/WHT

Y

RELAY NC

RLYNC

GRN/WHT

L

RELAY COM

RLYCOM

BLU/WHT

b

DIGITAL SHIELD

SHD

SHIELD

Z

ENCODER SUPPLY+

ENCV+

BLK

G

ENCODER A

ENCA

WHT

H

ENCODER A\

ENCA\

RED

J

ENCODER B

ENCB

GRN

K A F

ENCODER B\ ENCODER SUPPLYENCODER SHIELD

ENCB\ ENCVSHD

ORG BLU SHIELD

U

TRAM REF SUPPLY (+5V)

5V

BLK

V

MANUAL TRAM REF

REF

WHT

W

ANALOG COMMON

0V

RED

X

ANALOG SHIELD

SHD

SHIELD

Fig. 222: Inverter control connector (CN2) NOTE: Colors indicated follow primary/secondary where the secondary color is a stripe.

R

A

T

S

U e

g

j c

N M

a K

J

C W

D E

X

h b

L

V

f

d

P

B

Y Z

F

G H

_____________________________________________________________ A6474X308 Rev. 0 5.359

Troubleshooting _________________________________________________ Fig. 223: Inverter/rectifier power connector (CN1)

A

B

D

C NOTE: Colors indicated follow primary/secondary where the secondary color is a stripe.

Table 18: Inverter/rectifier power connector (CN1)

Cable 4C

Cable Marker POWER

Pin

Description

A

120VAC

Wire Marker L

B

NEUTRAL

N

BLK

C

EMERGENCY TRAM

ETRAM

WHT

D

GROUND

GND

BLU

Color RED

Table 19: CAN Connectors (Rectifier CN2/3 Inverter CN3/4) Cable 2C+S HIELD

Cable Marker CAN

Pin

Description

A

CAN H

Wire Marker CANH

B

CAN L

CANL

BLU/WHT

C

0V

0V

SHIELD

Color WHT/BLU

NOTE: Colors indicated follow primary/secondary where the secondary color is a stripe.

Fig. 220: CAN Connectors (Rectifier CN2/3 Inverter CN3/4) A

B

C

_________________________________________________________________ 5.360 Bucyrus – Model 25C Continuous Miner

_________________________________________________ Troubleshooting Table 20: Control system pin outs Super Simpson machine control unit Connector X1 - 35 Burndy Female Pin No. Signal Name X1-A Output Relay 1 - Spare X1-B Output Relay 2 - Spare X1-C Output Relay 3 - AUX #1 Relay Output X1-D Relay 4 -MMR Status X1-E Relays Input (1 - 8) X1-F Output Relay 5 - AUX #2 Relay Output X1-G Output Relay 6 - Spare X1-H Output Relay 7 - Head Lights Output X1-J Output Relay 8 - Pump Run X1-L Output Relay 9 - Left Cutter Run X1-M Output Relay 10 - Scrubber Run Output X1-N Output Relay 11 - Conveyor Forward Run Output X1-P Output Relay 12 - conveyor Reverse Run Output X1-R Relays Input (9 - 16) X1-S Output Relay 13 - Right Cutter Run X1-T Digital Input 15 - CB2 Status X1-U Digital Input 16 - Cutter Breaker Feedback X1-V Digital Input 17 - Right E-Stop Feedback X1-W Neutral X1-X Digital Input 18 - Pump Feedback X1-Y Digital Input 19 - Pump External Overload X1-Z Output Relay 19 - L/R E-Stop Feedback X1-a Output Relay 20 - Main Supply Status X1-b Used as MOR Output Only X1-c Output Relay 21 - R Traction External Overload X1-d Input Relay - Ext Circuit Monitoring X1-e Input Relay - Ext Circuit Monitoring X1-f Input Relay - Ext Circuit Monitoring X1-g E-Stop Neutral X1-h E-Stop Input X1-l E-Stop Output

Signal Type 110 VAC Output 110 VAC Output 110 VAC Output 110 VAC Input 110 VAC Input 110 VAC Output 110 VAC Output 110 VAC Output 110 VAC Output 110 VAC Output 110 VAC Output 110 VAC Output 110 VAC Output 110 VAC Input 110 VAC Output 100 VAC Digital Input 100 VAC Digital Input 100 VAC Digital Input Neutral 110 VAC 100 VAC Digital Input 100 VAC Digital Input 110 VAC Input 110 VAC Input 110 VAC Output 110 VAC Output 110 VAC Input 110 VAC Input 110 VAC Input 110 VAC Neutral 110 VAC Input 110 VAC Output

_____________________________________________________________ A6474X308 Rev. 0 5.361

Troubleshooting _________________________________________________ Table 20: Control system pin outs, continued Super Simpson machine control unit Connector X2 - 19 Burndy Female Pin No. Signal Name X2-A Aux. Supply Output 24V+ X2-B Aux. Supply Output 0V X2-C Supply Input 24V+ X2-D Supply Input 0V X2-E Data Logging (Methane) RS485-A X2-F Data Logging (Methane) RS485-B X2-G Data Logging (Methane) RS485-Reference X2-H External Slaves RS485-A X2-J External Slaves RS485-B X2-K External Slaves RS485-Reference X2-L RS422 TX-P X2-M RS422 TX-N X2-N RS422 RX-P X2-P Frequency Selection #1 X2-R Frequency Selection #2 X2-S Frequency Selection #3 X2-T 24V Input - Spare X2-U RS422 RX-N X2-V Supply Output

Signal Type 24V Output 0V Output 24V Input 0V Input Ext. Communication Ext. Communication Ext. Communication Ext. Communication Ext. Communication Ext. Communication Ext. Communication Ext. Communication Ext. Communication 24V Digital Input 24V Digital Input 24V Digital Input 24V Digital Input Ext. Communication 24VDC Output

_________________________________________________________________ 5.362 Bucyrus – Model 25C Continuous Miner

_________________________________________________ Troubleshooting Table 20: Control system pin outs, continued Super Simpson machine control unit Connector X3 - V35 Burndy (34 Pin Female) Pin No. X3-A X3-B X3-C X3-D X3-E X3-F X3-H X3-J X3-K X3-L X3-M X3-N X3-P X3-R X3-S X3-T X3-U X3-V X3-W X3-X X3-Y X3-Z X3-AA X3-BB X3-CC X3-DD X3-EE X3-FF X3-HH X3-JJ X3-KK X3-LL X3-MM X3-NN

Signal Name Solenoid 1 - Gathering Head Up Solenoid 3 - Shear Up 100+ VDC for Solenoid Drivers Solenoid 4- Shear Down Solenoid 2 - Gathering Head Down Solenoid 5 - Conveyor Up 0V for 110 VDC Solenoid Drivers Solenoid 6 - Conveyor Down 0V for 110 VDC Solenoid Drivers Solenoid 7 - Conveyor Left Digital Input 1 - Spare Solenoid 8 - Conveyor Right Digital Input 2 - Spare Solenoid 9 - Stabilizer Up Digital Input 3 - Spare Solenoid 10 - Stabilizer Down Digital Input 4 - LH Traction External Overload Solenoid 11 - Fire Suppression Digital Input 5 - Tram Breaker Solenoid 12 - Breaker OFF Digital Input 6 - Low Oil Level Solenoid 13 - Breaker ON Digital Input 7 - Reserved Solenoid 14 - Cutter Water Spray Digital Input 8 - Reserved Solenoid 15 - Scrubber Water Digital Input 9 - Spare Solenoid 16 - Methane Override Enable Digital Input 10 - Spare Digital Input 11 - Miner Model Select Digital Input Digital Input 12 - Miner Model Select Digital Input 13 - Miner Model Select Digital Input 14 - Miner Model Select

Signal Type Solenoid 0VDC O/P Solenoid 0VDC O/P 100 VDC + Input Solenoid 0VDC O/P Solenoid 0VDC O/P Solenoid 0VDC O/P 0V - Input Solenoid 0VDC O/P 0V - Input Solenoid 0VDC O/P 100VAC Digital Input Solenoid 0VDC O/P 100VAC Digital Input Solenoid 0VDC O/P 100VAC Digital Input Solenoid 0VDC O/P 100VAC Digital Input Solenoid 0VDC O/P 100VAC Digital Input Solenoid 0VDC O/P 100VAC Digital Input Solenoid 0VDC O/P 100VAC Digital Input Solenoid 0VDC O/P 100VAC Digital Input Solenoid 0VDC O/P 100VAC Digital Input Solenoid 0VDC O/P 100VAC Digital Input 100VAC Digital Input Neutral 100VAC I/P 100VAC Digital Input 100VAC Digital Input 100VAC Digital Input

_____________________________________________________________ A6474X308 Rev. 0 5.363

Troubleshooting _________________________________________________ Table 20: Control system pin outs, continued Super Simpson machine control unit Connector X4 - GAPL26 26 Pin Female Pin No. X4-A X4-B X4-C X4-D X4-E X4-F X4-H X4-J X4-K X4-L X4-M X4-N X4-P X4-R X4-S X4-T X4-U X4-V X4-W X4-X X4-Y X4-Z X4-AA X4-BB X4-CC X4-DD

Signal Name Right Conveyor Motor Phase A Right Conveyor Motor Phase B Right Conveyor Motor Phase C Scrubber Motor Phase A Scrubber Motor Phase B Scrubber Motor Phase C Left Conveyor Motor Phase A Left Conveyor Motor Phase B Left Conveyor Motor Phase C Left Cutter Motor Phase A Left Cutter Motor Phase B Left Cutter Motor Phase C Right Cutter Motor Phase A Right Cutter Motor Phase B Right Cutter Motor Phase C Pump Motor Phase A Pump Motor Phase B Pump Motor Phase C Left Tram Motor Phase A Left Tram Motor Phase B Left Tram Motor Phase C Right Tram Motor Phase A Right Tram Motor Phase B Right Tram Motor Phase C +24 VDC Active 0VDC Neutral

Signal Type 4-20mA 4-20mA 4-20mA 4-20mA 4-20mA 4-20mA 4-20mA 4-20mA 4-20mA 4-20mA 4-20mA 4-20mA 4-20mA 4-20mA 4-20mA 4-20mA 4-20mA 4-20mA 4-20mA 4-20mA 4-20mA 4-20mA 4-20mA 4-20mA +24VDC 0VDC

Super Simpson Battery Backup Power Supply Connector X5 - 8 Pin Burndy Female Pin No. X5-A X5-B X5-C X5-D X5-E X5-F X5-G X5-H

Signal Name Door Switch Input Door Switch Output Main Supply O/P 24V+ Main Supply O/P 0V N/C RS458 - A RS458 - B RS458 - Reference

Signal Type Link Link 24V+ Output 0V Output Communication Communication Communication

_________________________________________________________________ 5.364 Bucyrus – Model 25C Continuous Miner

_________________________________________________ Troubleshooting Table 20: Control system pin outs, continued Super Simpson Battery Backup Power Supply Connector X6 - 8 Pin Burndy Male Pin No. X6-A X6-B X6-C X6-D X6-E X6-F X6-G X6-H

Signal Name 100VAC Neutral Earth 100VAC Line N/C 0VDC 100VDC + N/C N/C

Signal Type Supply Input Supply Earth Connection Supply Input Output 110VDC Output 110VDC

Super Simpson Machine Control Unit Connector X7 - RS-422 Graphics Display Pin No. X7-A X7-B X7-C X7-D

Signal Name RS-422 RS-422 RS-422 RS-422

Signal Type RxRx+ TxTx+

Super Simpson Machine Control Unit Connector X8 - RS-422 Data Logger Pin No. X8-A X8-B X8-C X8-D X8-E X8-F

Signal Name +24VDC Active 0VDC Neutral RS-422 RS-422 RS-422 RS-422

Signal Type +24VDC Output 0VDC RS-422 RxRx+ TxTx+

Super Simpson Display Unit (4X20 “Lil’ Blue”) Terminal Connections J3, J4 Pin No. 24V+ 0V A B COM

Signal Name Auxiliary Supply I/P 24V+ Auxiliary Supply I/P 0V Display RS485 - A Display RS485 - B Display RS485 - Reference

Signal Type 24V Input 0V Input External Communications External Communications External Communications

_____________________________________________________________ A6474X308 Rev. 0 5.365

Troubleshooting _________________________________________________ Table 20: Control system pin outs, continued Super Simpson Programming A1 Pin No. X1-A X1-B X1-C X1-D

Signal Name Rx Tx 0V -

Signal Type Rx Tx 0V -

Super Simpson Thermistor Module A2 CAN Pin No. X2-A +24VDC Active X2-B 0VDC X2-C CAN H X2-D CAN H X2-E CAN L X2-F CAN L X2-G Thermistor T1 X2-H Thermistor T2

Signal Name

Signal Type 24VDC 0VDC CAN H CAN H CAN L CAN L T1 T2

Super Simpson Traction Unit Connector X10 - GAPL26 26 Pin Male Pin No.

Signal Name

Signal Type

X10-A X10-B X10-C X10-D X10-E X10-F X10-H X10-J X10-K

External Supply (GND) External Supply (GND) Spare Left Hand Forward (LHFWD) External Supply (GND) External Supply (GND) Deadman Right Hand Reverse (RHREV) External Supply (GND)

+13V GND (Ext.) +13V GND (Ext.)

X10-L X10-M X10-N X10-R X10-T X10-U X10-V X10-X X10-Y X10-Z X10-AA X10-BB X10-CC X10-DD

External Supply (GND) Left Hand Reverse (LH REV) Right Hand Forward (RHFWD) External Supply (13VDC) External Supply (13VDC) Data A 0V FP 0V FP Data B Right Hand Proportional Output System Supply (+24VDC Active) Left Hand Proportional Output System Supply (24VDC GND) Data Communications

+13V GND (Ext.) +13V ON/OFF Output +13V ON/OFF Output +13V Supply +13V Supply RS-485 Signal A 12V GND 12V GND RS-485 Signal B 0-10V Prop. Output +24V Supply (System) 0-10V Prop. Output +24V GND (System) RS-485 Reference

+13V ON/OFF Output +13V GND (Ext.) +13V GND (Ext.) +13V ON/OFF Output +13V ON/OFF Output +13V GND (Ext.)

_________________________________________________________________ 5.366 Bucyrus – Model 25C Continuous Miner

_________________________________________________ Troubleshooting Table 21: Solenoid fault and warning codes

Alarm Code

Description

Device Action

System Error (if detected when pump off)

System Fault (if detected when pump on / traction idle)

System Fault (if detected when pump on / traction active)

Control Control Control System System System Message Reaction Message Reaction Message Reaction Possible Cause Possible Solution 0

ADC Fault

Latched Solenoid Fault ADC Fault

None

None

Inhibit valve

Solenoid Inhibit 1. Analog to digital 1. Cycle power to ADC Fault pump converter maldevice. then infunctioning.

2. Replace elechibit valve 2. Internal ADC tronics. only readings are cross-checked against a known value.

1

Safety Power Switch Fault

Latched Solenoid Fault Power Switch Fault

None

None

Inhibit valve

Solenoid Power Switch Fault

2

Spool Position Sensor Faulty

Latched Solenoid Fault Spool Position Faulty

None

None

Inhibit valve

4

Solenoid A Resistance Too Low

Latched Solenoid Fault A Resistance Low

None

Solenoid Inhibit A Resis- valve tance Low

Inhibit 1. Fail-safe power 1. Cycle power to Pump switch dysdevice. then Infunctional.

2. Replace elechibit Valve 2. Power switch tronics. only and watchdog is unable to shutdown power to the solenoid driver circuitry for failsafe functionality.

Solenoid Inhibit 1. Spool position 1. Cycle power to Spool Pump sensor is dysdevice.

Position then Infunctional.

2. Replace elecFaulty hibit Valve 2. Output of the tronics. only internal hall3. Check that effect sensor is spool position outside the magnet on expected valve is corrange or when rectly installed. solenoids are not energized, the reading from this sensor is not as expected for spool at center.

Solenoid Inhibit 1. Solenoid resis- 1. Cycle power to A Resis- valve tance below 14 device. tance Low ohms.

2. Check coil con2. Internal coil nection inside short circuit. solenoid hous3. Internal soil ing. earth fault.

3. Check moisture ingress.

4. Replace electronics.

_____________________________________________________________ A6474X308 Rev. 0 5.367

Troubleshooting _________________________________________________ Table 21, continued: Solenoid fault and warning codes Alarm Code

Description

Device Action

System Error (if detected when pump off)

System Fault (if detected when pump on / traction idle)

System Fault (if detected when pump on / traction active)

Control Control Control System System System Message Reaction Message Reaction Message Reaction Possible Cause Possible Solution 5

Solenoid A Resistance Too High

Latched Solenoid Fault A Resistance High

None

Solenoid Inhibit A Resis- valve tance High

Solenoid A Resistance High

Inhibit valve

6

Solenoid B Resistance Too Low

Latched Solenoid Fault B Resistance Low

None

Solenoid Inhibit B Resis- valve tance Low

Solenoid Inhibit B Resis- valve tance Low

7

Solenoid B Resistance Too High

Latched Solenoid Fault B Resistance High

None

Solenoid Inhibit B Resis- valve tance High

Solenoid B Resistance High

8

Supply Undervoltage

ReSolenoid settable Supply Fault Undervoltage

None

Solenoid Inhibit Supply valve Undervoltage

Solenoid Inhibit Supply valve Undervoltage

9

Supply Overvoltage

ReSolenoid settable Supply Fault Overvoltage

None

Solenoid Inhibit Supply valve Overvoltage

Solenoid Inhibit Supply valve Overvoltage

Inhibit valve

1. Solenoid resis- 1. Cycle power to tance above device.

37 ohms.

2. Check coil con2. Internal coil nection inside open circuit. solenoid housing.

3. Check moisture ingress.

4. Replace electronics.

1. Solenoid resis- 1. Cycle power to tance below 14 device. ohms.

2. Check coil con2. Internal coil nection inside short circuit. solenoid hous3. Internal coil ing. earth fault.

3. Check moisture ingress.

4. Replace electronics.

1. Solenoid resis- 1. Cycle power to tance above device.

37 ohms.

2. Check coil con2. Internal open nection inside circuit. solenoid housing.

3. Check moisture ingress.

4. Replace electronics.

1. Supply voltage 1. Cycle power to below 10V. device.

2. Solenoid board 2. Check power power circuitry supply voltage. faulty.

3. Check supply to 3. Earth fault on ground resisthe 24VDC tance is open. supply line.

4. Replace electronics.

1. Supply voltage 1. Cycle power to above 35V. device.

2. Solenoid board 2. Check power power circuit supply voltage. faulty.

3. Check supply to 3. High voltage ground resisfault on the tance is open.

24VDC supply 4. Replace elecline. tronics.

_________________________________________________________________ 5.368 Bucyrus – Model 25C Continuous Miner

_________________________________________________ Troubleshooting Table 21, continued: Solenoid fault and warning codes Alarm Code

Description

Device Action

System Error (if detected when pump off)

System Fault (if detected when pump on / traction idle)

System Fault (if detected when pump on / traction active)

Control Control Control System System System Message Reaction Message Reaction Message Reaction Possible Cause Possible Solution 10

Under Temperature Fault

ReSolenoid settable Under Fault Temp Fault

None

Solenoid Inhibit Under valve Temp Fault

11

Over Temperature Fault

ReSolenoid settable Over Fault Temp Fault

None

Solenoid Inhibit Over valve Temp Fault

12

Communication ReSolenoid Timeout settable CommuniFault cations Timeout

None

Solenoid Inhibit Commu- valve nications Timeout

Solenoid Under Temp Fault

Inhibit valve

1. temperature 1. Cycle power to below -40° C (device.

40° F).

2. Assure slice is 2. Solenoid board not operating temperature at temperature. circuit faulty. 3. Replace electronics.

Solenoid Inhibit 1. Temperature 1. Cycle power to Over valve voltage above device.

Temp 85° C (185° F). 2. Assure slice is Fault 2. Solenoid board not operating temperature at temperature. circuit faulty. 3. Replace electronics.

Solenoid Inhibit 1. No command 1. Cycle power to Communi- Pump received device. cations then In250ms while 2. Check CAN Timeout hibit Valve active. connection to only 2. CAN bus condevice. nection bro3. Check display ken. for network 3. CAN bus fault layout. other than solenoid.

_____________________________________________________________ A6474X308 Rev. 0 5.369

Troubleshooting _________________________________________________ Table 22: RTD Corresponding Temperature Values Resistance (Ohms)

Temperature (°C)

Resistance (Ohms)

Temperature (°C)

Resistance (Ohms)

Temperature (°C)

100

0.0

135

89.3

170

178.6

101

2.6

136

91.8

171

181.1

102

5.1

137

94.4

172

183.7

103

7.7

138

96.9

173

186.2

104

10.2

139

99.5

174

188.8

105

12.8

140

102.0

175

191.3

106

15.3

141

104.6

176

193.9

107

17.9

142

107.1

177

196.4

108

20.4

143

109.7

178

199.0

109

23.0

144

112.2

178.4

200.0

110

25.5

145

114.8

179

201.5

111

28.1

146

117.3

112

30.96

147

119.9

113

33.2

148

122.4

114

35.7

149

125.0

115

38.3

150

127.6

116

40.8

151

130.1

117

43.4

152

132.7

118

45.9

153

135.2

119

48.5

154

137.8

120

51.0

155

140.3

121

53.6

156

142.9

122

56.1

157

145.4

123

58.7

158

148.0

124

61.2

159

150.5

125

63.8

160

153.1

126

66.3

161

155.6

127

68.9

162

158.2

128

71.4

163

160.7

129

74.0

164

163.3

130

76.5

165

165.8

131

79.1

166

168.4

132

81.6

167

170.9

133

84.2

168

173.5

134

86.7

169

176.0

_________________________________________________________________ 5.370 Bucyrus – Model 25C Continuous Miner

_______________________________________________________________

Technical data

________________________________________________________________

________________________________________________________________

_________________________________________________________________

__________________________________________________ Technical data

Technical data This chapter contains the most important technical data on the 25C Continuous Miner ®. Further data can be found in the spare parts lists.

At the end of this chapter you will find information on the bolt tightening torques, HFA fluids, greases, etc. Read this chapter through carefully and pay particular attention in particular to the safety instructions.

IMPORTANT! The technical data listed in this chapter is for stock machines only. Customer specials may not be listed.

Components of the 25C Continuous Miner Technical data sheet Note: All dimensions and rates are for a Miner with a 36” diameter cutter drum and 12” ground clearance. operating dimensions

Recommended mining range............................... approx. 48 - 96 in (1,219 - 2,438 mm) Minimum height over cutter head assembly ........ approx. 34 in (864 mm) Maximum reach ................................................... approx. 128.25 in (3,258.8 mm) Ground clearance ................................................ approx. 9 in (229 mm) Length (rear bumper to bit tip) ......................... approx. 26 ft 9 in (8.15 m)

transport dimensions

Frame width (including rub rails) ......................... approx. 10ft 8.75 in (3.26 m) Overall length....................................................... approx. 36 ft 3 in (11.05 m) Height over scrubber duct.................................... approx. 36 in (914 mm) Weight (total)........................................................ approx. 135,000 lbs (61.2 metric tons)

cutter unit

Cutter drum diameter ........................................... approx. 34 - 40 in (864 - 1,016 mm) Cutter drum bit speed .......................................... approx. 62 rpm/584fpm (178 m/min) Cutter drum width................................................. approx. 11 ft 9 in (3.58 m)

______________________________________________________________ A6474X308 Rev. 0 6.3

Technical data ___________________________________________________ loading unit

Loading method ..........................................................3 - 6 finger CLA Conveyor width ...........................................................approx. 38 in (965 mm) Conveyor speed..........................................................approx. 475 fpm (145 m/min) Conveyor depth...........................................................approx. 6 in (152 mm) Loading capacity .........................................................25 - 20 tpm

traction unit

Crawler chain width.....................................................20 in (508 mm) Crawler assembly length.............................................9 ft 5-1/4 in (2.88 m) Ground pressure .........................................................29.8 psi (205 kPa) Crawler speed.............................................................0 - 90 fpm (0 - 27 m/min)

_________________________________________________________________ 6.4 Bucyrus – Model 25C Continuous Miner

______________________________________________ Tightening torques Tightening torques IMPORTANT! Due to the application of fasteners being subject to great stresses and heavy or extreme vibration, it is imperative that all bolts be applied with an adequate amount of torque. For this reason this list of recommended torque settings for different types and sizes of fasteners used has been compiled. The tightening torques stated in the spare parts lists have to be observed, as well, for installation and maintenance.

IMPORTANT! Use a calibrated torque wrench for accuracy!

Table 23: Grade 8 bolt torque specifications (calculated at 75% proof load) Bolt size

Recommended torque setting (ft-lbs) (dry)

Recommended torque setting (ft-lbs) (wet)

1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1 1-1/8 1-1/4 1-3/8 1-1/2 1-3/4 2 2-1/4 2-1/2 2-3/4 3 3-1/4 3-1/2 3-3/4 4

12 25 44 70 107 154 212 376 606 909 1287 1875 2382 3161 4988 7500 10969 15000 17794 23507 30286 38266 47545 58100

6 12 22 35 53 77 106 188 303 454 644 938 1191 1581 2494 3750 5484 7500 8897 11753 15143 19133 23773 29085

______________________________________________________________ A6474X308 Rev. 0 6.5

Tightening torques _______________________________________________ Table 24: Metric bolt torque specifications (calculated at 75% proof load) Property Class

8.8

10.9

12.9

M6 - M16: 800 M20 - M30: 830

1040

1220

Minimum Tensile Strength (MPa) Nominal Size and Thread Pitch

Dry ft-lbs (in-lbs)

Lubricated ft-lbs (in-lbs)

Dry ft-lbs (in-lbs)

Lubricated ft-lbs (in-lbs)

Dry ft-lbs (in-lbs)

Lubricated ft-lbs (in-lbs)

M5 X 0.80 M6 X 1.00 M7 X 1.00 M8 X 1.25 M10 X 1.50 M12 X 1.75 M14 X 2.00 M16 X 2.00 M18 X 2.50 M20 X 2.50 M22 X 2.50 M24 X 3.00 M27 X 3.00 M30 X 3.50 M33 X 3.50 M36 X 4.00

(54) (92) (156) (2250 37 65 104 161 222 314 428 543 796 1079 1468 1886

(41) (69) (116) (169) 28 49 78 121 167 235 321 407 597 809 1101 1415

(78) (133) (222) (333) 53 93 148 230 318 449 613 776 1139 1543 2101 2699

(59) (99) (167) (242) 40 69 111 172 238 337 460 582 854 1158 1576 2024

(91) (156) (260) (377) 62 108 173 269 372 525 716 908 1331 1804 2455 3154

(68) (116) (195) (284) 47 81 130 202 279 394 537 681 998 1353 1842 2366

_________________________________________________________________ 6.6 Bucyrus – Model 25C Continuous Miner

_______________________________________________ Permissible media Permissible media Lubrication fluids and greases NOTICE! Use only lubrication fluids and greases approved by Bucyrus America, Inc. ! These fluids and greases have been tested at Bucyrus America, Inc. and guarantee reliable operation of the mechanical and hydraulic functions of the machine.

IMPORTANT! The lubrication fluids and greases listed in the same table can be mixed. Other products may only be used if the supplier can guarantee that they are equivalent.

Differently composed fluids and greases must not be mixed as this may change the consistency, i.e. the mixture can become thinner so that the lubrication effect is not sufficient. It may also be dangerous to use lubricating greases and fluids having the same specification base but different origins.

In case of doubt, the manufacturer of the lubrication to be used should be contacted as to the compatibility of the lubrication in question.

IMPORTANT! Bucyrus America, Inc. expressly point out that the approval of the listed products relates only to the pure technical use in our mechanical and hydraulic systems. The responsibility for the constituents used in the hydraulic concentrates lies solely with the respective manufacturer.

IMPORTANT! Be sure to use the manufacturer’s instructions for use.

NOTICE! When performing maintenance on the machine, all used oil and lubricants should be stored and disposed of per your local EPA standards.

______________________________________________________________ A6474X308 Rev. 0 6.7

Permissible media ________________________________________________ Approved suppliers: Table 25: Anti-wear hydraulic oil (Spec 100-1) 1 2 3 4 5 6 7 8 9 10 11 12 13

14 15 16 17 18

Supplier Amoco Oil Company Gulf Oil Mobil Oil Corporation Chevron U.S.A. Sun Oil Company Unocal 76 Shell Oil Company Century Lubricating Oils, Inc. Atlantic Richfield Company Texaco Lubricants Company Exxon Pennzoil Standard Oil Company Standard Oil Co. of Ohio Boron Oil Company BP Oil Inc. Lubricating Engineers Conoco Inc. Hydrotex Phillips Miners Oil

Brand name Amoco AW Oil No.68 Harmony 68 AW Mobil DTE-16 Chevron Hydraulic Oil AW ISO 68 Sunvis 868 Unax AW 68 Shell Hydraulic Oil #33 Hydraulic AW 68 Duro AW S-315 Oil Texaco Rando Oil HD 68 Nuto 68 Pennzbell AW 68 Hydraulic Oil Industron 54 Industron 53 Energol HLP-C68 6120 Monolec Hydraulic Oil Super Hydraulic oil 68 Systems 5K 68 Maginus A Oils 81350 Hydraulic Oil 68AW

Table 26: Extreme pressure gear oils (Spec. 100-2) 1 2 3

Supplier Amoco Oil Company Gulf Oil Mobil Oil Corporation

4

Chevron U.S.A.

5 6

Sun Oil Company Unocal 76

7 8

Shell Oil Company Century Lubricating Oils, Inc.

9

Texaco Lubricants Company Exxon Pennzoil

10 11

Brand name Amoco Permagear EP 460 EP Lubricant HD 460 Mobil Gear 634 Mobil Gear 636 Chevron Gear Compound EP ISO 460 Sunep 460 Extra Duty NL Gear Lube 7 EP Extra Duty NL Gear Lube 8 EP Shell Omala 680 Hulbest EP-7 Powergear 460 Meropa 680

Spartan EP 460 Super Maxol EP 460 Gear Lube Super Maxol EP 460 Gear Lube 12 Lubricating Engineers 608 Almosal Vari-Purpose Gear Lubricant 13 Conoco Inc. Gear Oil 460 14 Hydrotex 933 Industrial Gear Lubricant 15 Phillips All Purpose Gear Oil 85W-90 5EP 16 Miners Oil Gear Oil EP460 _________________________________________________________________

6.8

Bucyrus – Model 25C Continuous Miner

_______________________________________________ Permissible media Table 27: Extreme pressure motor bearing grease (Spec. 100-3)

1

Supplier Amoco Oil Company

2 3 4

Gulf Oil Mobil Oil Corporation Chevron U.S.A.

5 6 7 8

Sun Oil Company Unocal 76 Shell Oil Company Century Lubricating Oils, Inc.

9 10 11 12

Texaco Lubricants Company Exxon Pennzoil Lubricating Engineers

13

Conoco Inc.

14 15 16

Hydrotex Phillips Atlantic Richfield

Brand name Amolith Grease 2 EP Rykon Premium Grease 2 EP Gulfcrown grease EP#2 Mobilux EP-2 Chevron Dura-Lith Grease EP-2 NLGI 2 Sun Prestige 742EP Multiplex EP2 Alvania EP-2 Hullith EP2 Multipurpose Grease or Replex2 or Uniwrl 2 or Uniwrl EMB or Hullith GP 2 or Hullith EP 2 Texaco Multifak EP 2 Lidok EP 2 Pennlith EP 712 Grease 3752 Almagard Vari-Purpose Lubricant EP Conolith grease No. 2 or Super Sta Grease No. 2 LC-65 Hyplex Philube EP Grease Litholine H EP-2 Grease

Table 28: Semi-fluid grease (Spec. 100-4)

1 2 3 4 5 6

Supplier

Brand name

Texaco Lubricants Company Century Oils Limited Hydrotex Pennzoil Unocal Exxon

Novatex EP 000 Joy Loader Semi-Fluid grease MPD-60 Ultra E.P. 000 Semi-Fluid 760 Grease MM Grease Lidok E.P. 000

______________________________________________________________ A6474X308 Rev. 0 6.9

Permissible media ________________________________________________ Table 29: Invert emulsion hydraulic fluid (Spec. 100-5)

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

Supplier Unocal 76 Conoco Inc. Atlantic Richfield Company Brooks Oil Company Cincinnati – Vulcon Company Cities Service Oil company Century Oils Limited Fiske Bros. Refining Company Getty Oil Company (Veedol, Tidewater) Gulf Oil Company E.F. Houghton Century Lubricating Oils Imperial Oil and Grease Mobil Oil Corporation National Oil and Chemical Co. Pennzoil Quaker Chemical Company Henery E. Sanson and Sons MFGE Company Southwest Grease and Oil Company, Inc. Southwest Petroleum Corp.

22 23 24 25

Standard Oil Company of Ohio (Boron Sohio) Sun Oil Company Tower Oil Company Wynn Oil Company Lubrication Engineers

26

Hydrotex

Brand name FR Fluid FR Hydraulic Fluid Duro FR-HD Brooks Fire Resistant Hydraulic Fluid B Vulcon FR Fluid #1 Citgo Pacemaker Invert FR Fluid Aquacent Light Lubriplate HO-Retard Veedol Auburn FRH FR Fluid Houghto-Safe 5046 Houghto-Safe 5046W Hulsafe 600 Astrol 587 Pyrogard D Erifon 1, 2, and 3 Maxmul FRP/G Quintolubric 958 Series Quintolubric 958 Series Hydra-Mul Premium Emulsion Fluid Invert Emulsion Fire Resistant Hydraulic Fluid Swepco Fire Resistant Hydraulic oil #718 Staysol FR Sunsafe F Safoil Anti-Wear Hydraulic Fluid Hydra-Safe Heavy Medium 6455 Monolec Fire Resistant Hydraulic Fluid HY-Guard

_________________________________________________________________ 6.10 Bucyrus – Model 25C Continuous Miner

_______________________________________________ Permissible media Table 30: Extreme pressure gear oil, SAE 90 (Spec. 100-6)

1 2 3 4

Supplier Amoco Oil Company Gulf Oil Mobil Oil Corporation Chevron U.S.A.

5 6 7 8 9 10 11 12

Sun Oil Company Unocal 76 Shell Oil Company Century Lubricating Oils, Inc. Texaco Lubricants Company Exxon Pennzoil Lubricating Engineers

13 14 15

Conoco Inc. Hydrotex Phillips

16 17 18 19 20

Atlantic Richfield Cities Service Pennzoil Miner Oil Texaco, Lubricants Company

Brand name Amoco Premagear EP 320 EP Lubricant HD 320 Mobil Gear 632 Chevron Gear Compound EP ISO 320 Sunep 320 Extra Duty NL Gear Lube 6EP Omala 75 Hulbest EP-6 Meropa 320 Spartan EP 320 Super Maxol EP 220 Gear Lube 605 Almasol Vari-Purpose Gear Lubricant Gear Oil 320 932 Industrial Gear Lube Philube All Purpose Gear Oil 85W90 Pennant NL S-1000 Citgo EP Compound 110 Pen Gear #320 Gear Oil EP220 Texaco Multigear EP 80W-90

Table 31: Hydraulic and general purpose oil medium-heavy/R&O inhibited (Spec. 100-7) 1 2 3 4

Supplier Amoco Oil Company Gulf Oil Mobil Oil Corporation Chevron U.S.A.

5 6

Sun Oil Company Unocal 76

7 8 9 10 11 12 13

Shell Oil Company Century Lubricating Oils, Inc. Texaco Lubricants Company Exxon Pennzoil Lubricating Engineers Conoco Inc.

14 15 16 17 18

Hydrotex Atlantic Richfield Cities Service Miner Oil Texaco, Lubricants Company

Brand name American Industrial Oil No. 68 Harmony 68 DTE Heavy – Medium Chevron Turbine Oil ISO 68 or Chevron Machine Oil R&O ISO 68 Sunvis 754 Unax RX68 or Turbine Oil 68 Turbo 68 Centraulic R&O 68 Regal Oil R&O N-68 Tresstic 68 Pennzbell RO 68 6120 Monolec Turbine Oil Detol R&O 68 or Turbine Oil 68 Systems 1, System 5K 68 Duro 5.315 Citgo Pacemaker A/W68 Hydraulic Oil AW68 TDH 1893

______________________________________________________________ A6474X308 Rev. 0 6.11

Permissible media ________________________________________________ Table 32: Hydraulic and general purpose oil heavy/R&O inhibited (Spec. 100-8) 1 2 3 4

Supplier Amoco Oil Company Gulf Oil Mobil Oil Corporation Chevron U.S.A.

5 6

Sun Oil Company Unocal 76

7 8 9

Shell Oil Company Century Lubricating Oils, Inc. Atlantic Richfield Company

10 11 12 13 14 15 16 17 18

Texaco Lubricants Company Exxon Pennzoil Cities Service Lubrication Engineers Conoco Inc. Hydrotex Phillips Miner Oil

Brand name American Industrial Oil No. 150 Harmony 150 DTE Oil EX. Heavy Chevron Machine Oil AW ISO 150M or Chevron Machine Oil R&O ISO 150 Sunvis 961 Unax RX 700 or Turbine Oil 700 Turbo 150 Centraulic R&O 150 Duro 600 or S-700 Regal Oil R&O 150 Teresstic 150 Pennzbell RO 150 Citgo Pacemaker 150 6405 Monolec Turbine Oil Dectol R&O 76 System 1 150, System 5k 150 Magnus Oils 700 ISO 150

Table 33: Worm gear lubricant, compounded cylinder oil (Spec. 100-9) 1 2 3

Supplier Amoco Oil Company Mobil Oil Corporation Chevron U.S.A.

4 5

Sun Oil Company Unocal 76

6 7 8 9 10 11

Century Lubricating Oils, Inc. Atlantic Richfield Company Texaco Lubricants Company Exxon Pennzoil Conoco Inc.

Brand name Cylinder Oil No. 1000 Extra Hecla Super Cylinder Oil Chevron Cylinder Oil W ISO 1000 Sun Steam Cylinder Oil Worm Gear Lube 250 or Stevalc Garwal 680 Modoc 195 650 T Cylinder Oil 1000 Cylesstic TK-1000 Cylinder Oil #1000 Inca Oil 1000

_________________________________________________________________ 6.12 Bucyrus – Model 25C Continuous Miner

_______________________________________________ Permissible media Table 34: Light gear oil, SAE 40 motor oil (Spec. 100-10)

1 2 3 4

Supplier Amoco Oil Company Gulf Oil Mobil Oil Corporation Chevron U.S.A.

5 6 7

Sun Oil Company Unocal 76 Shell Oil company

8 9 10

Century Texaco Lubricants Company Exxon

11 12 13

Pennzoil Lubricating Engineers Conoco Inc.

14 15

Hydrotex Phillips

Brand name Amoco 300 SAE 40 Super Duty 40 Delvac 1340 Chevron RPM Heavy Duty Motor Oil 15W-40 Sunoco Super C 40 Guardol Motor Oil SAE 40 Rotella Oil 40 (Automotive) Turbo Oil 150 (Industrial) Rimula CT40 (Foreign) Rotela SX40 (Foreign) Flexe SAE 40 Ursa Super plus SAE 40 XD-3 Extra SAE 40 or XD-3 SAE 40 Long Life SAE 40 Motor Oil 8440 Monolex GFS Engine Oil Fleet Heavy Duty Motor Oil SAE 40 Hyfilm SAE 40 Super HD II Motor Oil SAE 15W-40

Table 35: Synthetic EP gear lubricants (Spec. 100-11)

1

Supplier Century Lubricants Company

Brand name Synthetic EP Gear Lubricants

Table 36: Multi-purpose tractor hydraulic fluid (Spec. 100-12)

1 2 3 4 5 6 7

Supplier Exxon / Mobil Century / Fuchs Shell Chevron BP Lubricants Quaker State Conoco

Brand name Mobilfluid 424 Multitran Donax TD Tractor Hydraulic Fluid Tractran UTH Quaker State FCI HD Powertran Fluid

______________________________________________________________ A6474X308 Rev. 0 6.13

Permissible media ________________________________________________ Table 37: Extreme pressure gear oil (Spec. 100-13)

1

Supplier Century Lubricants

Brand name Powergear H680

Table 38: High temperature lithium complex motor bearing grease (Spec. 100-14) 1 2 3

Supplier Mobil Conoco Phillips Shell

Brand name Mobilith SHC 100 Triton 100 Albida EMS 2

Table 39: High demulsibility EP gear oil gear oil (Spec. 100-15)

1

Supplier Conoco

Brand name GLW Gear Oil 220

_________________________________________________________________ 6.14 Bucyrus – Model 25C Continuous Miner

_______________________________________________________________

For your information

________________________________________________________________

________________________________________________________________

_________________________________________________________________

_____________________________________________________ Our service

For your information Our service If you need to order spare parts or if technical problems occur, please contact our after-sales service personnel or contact us direct.

Service address Beckley, WV 351 Ragland Road Beckley, WV 25801 Phone: (304) 256-5927 Fax: (304) 256-5928

Craig, CO 400 Mack Lane Craig, CO 81625 Phone: (970) 824-3249 Fax: (970) 824-8851

Pulaski, VA 4041 Wurno Road Pulaski, VA 24301 Phone: 540-980-4530 Fax: 540-980-6211

Washington, PA 255 Berry Road Washington, PA 15301 Phone: (724) 743-1200 Fax: (724) 228-2177

Duffield, VA P.O. Box 847 6808 Fraley Avenue Duffield, VA 24244 Phone: (276) 431-7000 Fax: (276) 431-2464

Houston, PA 2045 West Pike Street Houston, PA 15342 Phone: (724) 743-1200 Fax: (724) 743-1201

Carrier Mills, IL 9580 State Route 13 West Carrier Mills, IL 62917 Phone: (618) 982-9000 Fax: (618) 982-9912

Oak Hill, WV P.O. Box 60 843 Lochgelly Road Oak Hill, WV 25901 Phone: (304) 469-3302 Fax: (304) 465-0450

Paonia, CO P.O. Box 566 719 Second Street Paonia, CO 81428 Phone: (970) 527-3151 Fax: (970) 527-6846

______________________________________________________________ A6474X308 Rev. 0 7.3

Our service______________________________________________________ Rebuild facility address Huntington, UT P.O. Box 1190 Route 10, 1Mile North Huntington, UT 84528 Phone: (435) 687-9831 Fax: (435) 687-2522

Norris City, IL 635 Illinois Highway 1 Norris City, IL 62869 Phone: (618) 378-3441 Fax: (618) 378-3106

Pearisburg, VA P.O. Box 463 222 Industrial Park Drive Pearisburg, VA 24134 Phone: (540) 921-2111 Fax: (540) 921-2711

_________________________________________________________________ 7.4 Bucyrus – Model 25C Continuous Miner

Forced Potato TITO Remote Console (Bucyrus 25M Miner Version)

Operator’s Manual Issue: KN5602.C

Forced Potato Mining Electronics

Contents Contents ............................................................................................... 2 Preface ................................................................................................. 3 Introduction ........................................................................................... 4 Notice ............................................................................................ 4 Safety Notice ........................................................................................ 5 What’s New........................................................................................... 6 Remote Control Battery Charger .......................................................... 8 Remote Control Diagnostics ............................................................... 11 Notice .......................................................................................... 12 User Setup .......................................................................................... 13 Password Entry ........................................................................... 13 Options ........................................................................................ 14 1. Radio Channel ....................................................................... 15 2. Radio Timeout ....................................................................... 15 3. Tilt Switch .............................................................................. 16 4. ID Number ............................................................................. 16 5. Saving Changes .................................................................... 17 Maintenance ....................................................................................... 18 Inspection Frequency .................................................................. 18 Factory Service Frequency ......................................................... 18 Tools ............................................................................................ 19 Disassembly ................................................................................ 20 Cleaning ...................................................................................... 21 Reassembly ................................................................................. 22

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Preface This document is intended to provide reference to the Type KN Remote Console. This version of the TITO remote console has been developed for operation of Bucyrus continuous miners.

Forced Potato Inc. 640 Bizzell Drive Lexington, KY 40510 Telephone: +859 252 4439 Fax: +859 252 4641 Web: www.forcedpotato.com © Forced Potato Inc. Other than is permitted by law, no part of this document may be reproduced, stored in a retrieval system or transmitted in any form or process without prior written consent of Forced Potato Inc. Every effort has been made to ensure the accuracy and correctness of the information presented within this document. However, Forced Potato does not provide guarantee of its correctness or accuracy.

Other than is required by law, no warranty of any kind is expressed or implied.

Copies of this manual, and other documentation pertaining to Forced Potato control system products, may be obtained by contacting Forced Potato directly.

For all matters involving servicing or purchase of Forced Potato control system components used with machinery manufactured by Bucyrus, please contact your Bucyrus representative or local Bucyrus service center.

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Introduction The Type L0KN Remote Console (RC) is a self-contained battery powered remote control that has been specifically designed to provide a safer, more efficient means of operating mining machinery.

Notice This manual includes information specific to the following part: Part# L0KN5602

Description Bucyrus UHF

If this manual does not correspond to your equipment’s part number, please contact Forced Potato Inc. immediately to obtain a copy of the correct publication.

To obtain service of your TITO L0KN56 model remote control handset please contact your local Bucyrus representative or service center.

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Forced Potato Mining Electronics

Safety Notice The advent of remote control has afforded the operator a notable improvement in personal safety. However, the potential for injury or fatality still exists when operating heavy machinery remotely.

Thus, it is expressly important that the operator observe safe work practice when operating a remote control mining machine. This will be defined by mine management and should encompass MSHA recommendations where applicable.

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What’s New The Type KN Remote Console has been designed to meet the requirements of AS4240 / MDG5001. These requirements compel a number of design variations over existing equipment manufactured by Forced Potato Inc.

•

Size Whilst a similar physical layout has been retained to support transparent integration, the overall size has grown to support control spacing standards as specified by AS4240.

•

Visual Diagnostics A highly efficient LED display has been integrated to facilitate operating diagnostics. Information such as operating frequency, power and general operating status is available at all times.

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Forced Potato Mining Electronics •

Battery To improve operational readiness, a larger battery pack has been incorporated which affords a minimum 20 hours of continuous remote control operation.

•

Tilt Monitoring Dual tilt switches have been installed to allow detection of the angle of inclination relative to the horizontal plane. This feature can be enabled or disabled via the User Setup Options on the Remote Control Battery Charger. By default, this option is disabled.

•

Safety The most important design addition is single electrical fault tolerance. By incorporating dual-pole switch architecture and a new approach to switch sampling, a high level of fault tolerance has been achieved.

The KN56 TITO remote console also features a push-button stop button. This push-button makes the device compliant with MSHA P03-3 recommendations.

•

Ergonomics In an effort to improve operator comfort, stylish comfort knobs have been added to the most commonly used functions – traction and shear. These are entirely optional and can be removed if required.

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Forced Potato Mining Electronics

Remote Control Battery Charger Connect the Remote Control Battery Charger to your mains power outlet. During initial power-up, the firmware release information is displayed for 10 seconds.

After this period, the charger will then display the main screen which details the charge status.

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Forced Potato Mining Electronics Diagnostics The Remote Control Battery Charger permits the operator to verify that all switches are operating as expected. Similarly, it provides a secondary means of determining the operating frequency.

Power Up Turn the RC on by asserting and holding the ON [SHIFT] key for twoseconds. This startup requirement has been introduced to reduce the likelihood of incidental activation.

After the two-second period has expired, the RC will show the operating frequency via the LED display. The available operating frequencies for the L0KN5602 (Bucyrus UHF) are as follows: Indicated Frequency UHF1 UHF2 UHF3 UHF4 UHF5 UHF6 UHF7 UHF8

Actual Frequency 458.500MHz 458.525MHz 458.550MHz 458.575MHz 458.600MHz 458.625MHz 458.650MHz 458.675MHz

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Forced Potato Mining Electronics The Remote Control Battery Charger continually scans all 8 channels in an attempt to recognize a supported RC. On average, the Remote Control Battery Charger requires approximately 4 seconds to acquire a signal.

Upon detecting a valid signal, an identification screen is displayed for three seconds to allow classification of the type and frequency of the operating RC.

After this period has expired, the diagnostic screen is displayed.

Operators should be satisfied that all key functions operate as expected prior to taking the equipment underground. Similarly, operators should verify that the operating frequency corresponds to that displayed on the RC – See the Frequency Table on the previous page.

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Forced Potato Mining Electronics

Remote Control Diagnostics The RC supports a number of inbuilt diagnostics to aid operation. The following table details each of these messages and their implication.

Message UHF1, UHF2, UHF3, UHF4, UHF5, UHF6, UHF7, UHF8 ON

Meaning Operating on Frequency 1, 2, 3, 4, 5, 6, 7 or 8

ON

Power is ON and a command is being sent to the machine.

(Flashing)

Power is ON

OFF

Powering down whilst issuing PUMP OFF command.

STOP

Radio Stop Activated

TILT

The RC’s angle of inclination is beyond 45° relative to horizontal. The STOP command is issued continuously until the unit is righted.

The internal battery is low with and expected remaining operating time of approximately 30 minutes.

Indicating possible service requirements, a fault condition has been detected.

LOW (Flashing) SERV

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Forced Potato Mining Electronics

Notice The SERV message is displayed when a fault condition has been detected. There are a number of problems that can generate this fault and most of these would typically require the unit to be submitted for factory service.

However, this condition can be triggered if the operator asserts switches prior to turning the unit ON. If switches other than those allocated to User Setup are asserted prior to power up, it is assumed that these switches are faulty, consequently resulting in automatic power down.

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Forced Potato Mining Electronics

User Setup The RC supports a number of user programmable options that can be adjusted via the Remote Control Battery Charger. To engage User Setup and with the RC turned off, assert the following keys, in sequence, for two seconds: Assert Assert Assert

CONVEYOR ► SHEAR UP ON [SHIFT]

The RC will display SET on its LED display to indicate that User Setup has been selected.

Password Entry When the Remote Control Battery Charger has acquired the signal, the following password entry screen is displayed:

The password FORCED must be entered before access to User Setup is granted.

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Forced Potato Mining Electronics To enter characters, use the following keys: To change a character: Assert CONVEYOR UP or CONVEYOR DOWN To change cursor position: Assert CONVEYOR ► or CONVEYOR ◄ To check the password: Assert ON [SHIFT] After entering the password, assert ON [SHIFT] to gain access to the System Menu.

Options There are five menu options available to the end user. To navigate the system menu, see the following:

To change the menu option: Assert CONVEYOR ► or CONVEYOR◄ To engage or leave the menu option: Assert ON [SHIFT] To change the option value: Assert CONVEYOR UP or CONVEYOR DOWN

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Forced Potato Mining Electronics

1. Radio Channel

There are 8 selectable channels available to the end-user. This allows the mine to support multiple machines.

2. Radio Timeout

The RC supports a timeout that automatically powers the unit down if there is no switch activity after a defined period of time. A selectable range of between 2 and 60 minutes can be chosen.

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Forced Potato Mining Electronics

3. Tilt Switch

To support AS4240 requirements, dual tilt switches which detect the angle of inclination have been installed. If this option is enabled, the RC will automatically issue the Radio Stop command until the unit is righted upon detecting tilt motion beyond 45° relative to horizontal. (The LED display will show TILT as a diagnostic response.) After being righted, power is automatically removed.

Importantly, a 250ms timer acts to filter our mild impacts to compensate for the effects of inertia. This is an essential requirement when Tilt Monitoring is enabled.

4. ID Number

Each Remote Console is programmed with its respective serial number upon leaving the factory. This feature is not accessible to the end user and is password protected.

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Forced Potato Mining Electronics

5. Saving Changes

To save changes to the setup, you must select the EXIT & SAVE option and assert ON [SHIFT]. To abort changes to the setup, you can simply turn the RC OFF.

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Forced Potato Mining Electronics

Maintenance The maintenance required for Remote Consoles is basically limited to assembly, cleaning & inspection. Coal dust and other particulate deposits foul switch operation and can eventually lead to premature seal failure if not regularly expunged.

Inspection Frequency The following routines should be undertaken daily.

•

Determine if cleaning and disassembly is necessary. Onsite conditions should be used to determine the regularity of this procedure. If cleaning is required, see the following pages.

Typically, cleaning on a weekly basis is sufficient.

•

Perform a functional test on the Remote Control Battery Charger.

Factory Service Frequency Factory Service of this equipment is required 12-months from the date of dispatch with an allowance of 1-month for logistics.

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Forced Potato Mining Electronics

Tools Forced Potato Inc. recommends that the Maintenance Accessory Kit be acquired (or similar) to aid systematic maintenance. A maintenance kit is available which includes the following parts: Allen Hex Set

Allen ⅝″ Socket

Multi-Bit Precision Torque Driver

Field Part Replacements

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Forced Potato Mining Electronics

Disassembly • • • • •

Remove the M3 bolts.

Remove the switch guard.

Remove the switch caps.

Remove the comfort knobs by loosening the grub screw.

Remove the engraved plate.

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Cleaning • • •

•

Expunge heavy debris from the switch assembly with a Soft Bristle Cleaning Brush.

Wash the transmitter with warm soapy water.

Inspect the switch seals for signs of deterioration. Seals exhibiting wear require the equipment to be scheduled for factory service.

Note: these seals are the primary seal, a secondary seal within the switch itself and an internal neoprene seal operate as a barrier to moisture ingress.

Dry the transmitter with light compressed air or cloth.

Important Do not use caustic solvents or displacement solutions as this may cause premature seal failure.

Do not use metal implements to dig out coal, mud or soapstone that may be found in the charge receptacle.

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Forced Potato Mining Electronics

Reassembly • •

• • • •

Ensure all switch seals are tight. If a seal appears loose, tighten the seal to the recommended torque of 2.5Nm. Ensure all switch plate M2 bolts are tight. If an M2 bolt appears loose, tighten the bolt to the recommended torque of 1.5Nm. Do NOT over tighten these bolts as this may break the enclosure seal.

Install the engraved plate.

Install the comfort knobs as depicted. Tighten the grub screw to the recommended torque of 2.5Nm. Install the switch caps Install the switch guard. Tighten the switch guard M3 bolts to the recommended torque of 2.5Nm.

After reassembly, test the unit on the Remote Control Battery Charger to verify operation.

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Forced Potato Mining Electronics

B

O

Battery · 7

Options · 14

C

P

Cleaning · 21

Password Entry · 13 Power Up · 9 Preface · 3

D Diagnostics · 9 Disassembly · 20

E Ergonomics · 7

I Introduction · 4

R Radio Channel · 15 Radio Timeout · 15 Reassembly · 22 Remote Control Battery Charger · 8 Remote Control Diagnostics · 11

S Safety · 7 Safety Notice · 5 Size · 6

M Maintenance · 18

N

T Tilt Monitoring · 7 Tilt Switch · 16, 17 Tools · 19

Notes on “SERV” · 12 Notice · 4

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U

W

User Setup · 13

What’s New · 6

V Visual Diagnostics · 6

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