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Bucyrus America, Inc. reserves all rights to this publication. Its content is protected by copyright laws both domestic and international. No part of this publication may be reproduced without the written consent of Bucyrus America, Inc.
Bucyrus America, Inc. declines all liability for direct or indirect consequences of all printing / typing errors.
This publication can be revised without prior notice.
PREFACE
This manual is intended to provide basic operating information on Bucyrus 30M class continuous miners. Additional information can be obtained by referring to the Parts Book supplied with your machine, or by contacting your local Bucyrus America, Inc. representative. The illustrations, descriptions and procedures contained in this manual pertained to the machine as it was originally manufactured and delivered to your mine, and when the manual was approved for printing. Bucyrus America, Inc. reserves the right to discontinue or revise machine models at any time, or change specifications, designs or procedures, without notice and without incurring obligations.
The machine was manufactured under the guidelines, procedures and requirements of the appropriate government regulatory agencies. At the completion of manufacturing, this machine was issued the appropriate approval numbers and nameplates indicating that it met the technical requirements of the appropriate agencies. Any change to the design or structure of this machine, without the consent of Bucyrus America, Inc. and these agencies, may void these approvals and render the machine illegal or dangerous for use.
Strict compliance with all local and national laws, regulations and practices regarding the safe operation and maintenance of underground mining equipment is necessary to ensure the personal safety of those working on, or around, this machine.
About this manual
This chapter contains important information, which will simplify your work. In addition, it contains information about the structure of the manual and the characters and symbols used.
Before starting work
right operating manual If you use an operating manual, which has not been written for your 30M Continuous Miner type, you will endanger yourself and others. Ensure that the data on the 30M Continuous Miner corresponds to that in the operating manual.
type This operating manual belongs to:
BUCYRUS AMERICA, INC. 30M CONTINUOUS MINER
Serial No.: 02-07-08
The operating manual is to be used only for this 30M CONTINUOUS MINER.
new operating manual An operating manual for the 30M Continuous Miner must always be available at the place of operation. Send for a new 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 all persons working with or on the 30M Continuous Miner. All personnel working at the face or in the working section must have read this operating manual.
This includes persons: responsible for transport, developing the raise, carrying out erection / disassembly, operating the 30M Continuous Miner, eliminating faults, carrying out daily routine work at the face or in the entry, carrying out maintenance operations, carrying out repairs.
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 30M Continuous Miner. Read this operating manual completely and carefully. In particular, pay attention to the safety instructions. Note the appearance and meaning of the safety and warning symbols.
service If any points are not clear, please contact our Service Department. You will find our Service address in chapter 7 ”For Your Information”.
safety Pay particular attention to the chapter ”Your Safety”. It contains important information drawing your attention to possible sources of danger. Observe the information and follow the instructions contained in this operating manual.
Characters and symbols used
The following characters and symbols are used for safety instructions and important information in the operating manual. Pay particular attention to these points.
DANGER!
WARNING!
Points in the text marked with this symbol draw your attention to immediately impending danger. Possible consequences are: very serious injury or even death.
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 30M Continuous Miner 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.
Items in lists are marked with bullets. -- Points in sub-lists are marked with a long dash at the start of the line.
Points in the text marked in this way describe individual work steps. Follow these instructions step-by-step.
They will help you carry out your work faster and, more importantly, safer.
state-of-the-art
Your safety
This chapter contains important information for your safety.
Please read this chapter particularly carefully. The safety instructions and behavioral rules are intended to protect you from any dangerous situations and to help you carry out your work as safely as possible.
The 30M Continuous Miner has been manufactured to the state-ofthe-art and in accordance with recognized safety engineering 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 30M Continuous Miner. All modifications and changes must be approved by Bucyrus America, Inc.
In addition to this operating manual, please be sure to observe the relevant regulations and accident prevention ordinance applicable at your mine.
Observe the safety and accident prevention regulations: of the mine, of the Mine’s State and Federal Inspectors and of the mining supervisory authorities
further operating manuals Please read the operating manual, of the components required for operation, carefully and thoroughly. Clarify any questions before starting work.
Personnel
Erection and repair
As a fundamental rule - erection and repair work may only be carried out by personnel who have been adequately trained for these particular requirements.
Erection and repair work on: safety components (pressure relief valves, extinguishers, etc.) the electronics (controllers, etc.) the hydraulics
may only be carried out by service engineers from Bucyrus America, Inc. or by specially qualified personnel of the mine.
Operating conditions
Intended use
The 30M Continuous Miner, or the Miner, as it is commonly called, provides the means of:
Extracting coal,
Loading it onto a belt
Loading it into a shuttle car
Dumping it onto the ground and loading it later
PRODUCT TRANSPORT:
The chain/flights are driven by a sprocket meshing with the chain at the front end of the miner to ensure efficient transportation of the product. The sprocket is integral with the drive’s gear box.
To keep the correct tension on the chain, an essential part of successful operation, a Chain Tensioning Device is fitted to the tail end of the miner. This is a hydraulic chain tensioning system.
Applications not expressly listed as intended uses are unauthorized uses and must not be carried out with the Miner.
Bucyrus America, Inc. accepts no liability for injury or damage resulting from any such unauthorized use.
CABLE PROTECTION
High voltage cables and high-pressure water hoses run along the helper’s side of the Miner and require protection form moving equipment, the Miner and the general mining environment.
Cables and hoses must be kept safe from the environment, run without kinking and are visible for random inspection.
Unauthorized use Safety instructions
General rules
general
protective equipment
condition
information signs
EMERGENCY-STOP
Always work with full concentration.
Familiarize yourself with your working environment. Always wear your personal protective equipment.
This also means wearing ear protectors, as the noise emissions from the Miner is in excess of 85 dB(A).
Inform your colleagues: Where exactly you are working. What work you are carrying out. How long you expect the work to take.
Start the Miner only when it is in a good and safe condition and all protective devices, e.g. EMERGENCY STOP devices, cover plates, etc. are correctly installed.
Observe the signs on the Miner.
Press the EMERGENCY STOP palm button immediately in the event of faults or irregularities in operation. Report any peculiarity to your superior so that necessary measures can be immediately taken.
Secure to prevent restarting Secure the Miner to prevent restarting:
Maintenance operations
Inspection operations
Repair operations
block working area
moving parts
Isolate your working.
Never allow parts of your body to come between parts, which could move, such as e.g.:
Chains
Flights
Chain sprockets
Cutting Head
Loading Pan
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GENERAL SAFETY PRECAUTIONS
Safety procedures for operating a Bucyrus 30M continuous miner begin with understanding that the smallest incident of carelessness may result in serious injury or death to you and your co-workers.
The miner should never be regarded as harmless simply because the power is not on. It should always be treated with high respect as a dangerous piece of machinery. It is essential that you become completely familiar with your miner, its controls and where they are located – especially all emergency controls.
While operating the miner, you must be aware of what you and your machine are doing at all times. You must know where your co-workers are, what other operations are going on nearby, and the mining and geological conditions in which you are working.
When you are finished operating the miner, stop it and disconnect the power before starting any maintenance or adjustments. NEVER TAKE SHORTCUTS WHICH MAY RESULT IN SAFETY RISKS.
WARNING
AFTER TURNING OFF POWER TO THE MINER, NEVER WALK AWAY AND LEAVE THE TRANSMITTER TURNED ON. FAILURE TO TURN THE TRANSMITTER OFF COULD RESULT IN AN ACCIDENT CAUSING SERIOUS INJURY OR LOSS OF LIFE.
Observe proper safety procedures at all times. You must develop good safety habits which will be vital to your own safety and that of your coworkers. Remember, the life you protect will likely be your own.
GENERAL PRECAUTIONS
WARNING
Permissible Electrical Enclosures. These compartments have been designed, constructed and assembled by the manufacturer in compliance with the standards established for certified explosion-proof enclosures. The permissibility of these enclosures should be confirmed after service has been performed and at routine intervals thereafter. Failure to maintain components to OEM specifications could create a hazardous condition resulting in fire or explosion. Serious injury or death could occur if permissibility is not maintained.
WARNING
Before starting this machine or operating any controls, make certain that you have read this Operator’s Manual and have been trained in the proper operation of this machine, and are thoroughly familiar with all controls. Failure to do so could result in an accident causing serious injury or death to you or other personnel.
Your Safety
WARNING
WARNING
Do not make any type of temporary trailing cable connections on this machine. Severe injury or death from electrocution will occur if contact is made with the high voltage power supply.
Be certain that all electrical power to this machine has been disconnected before performing any adjustment, repair or parts replacement procedures. To “DISCONNECT”means to tag, lock out and physically remove the trailing cable from the power center by the person performing the maintenance work. Any other interpretation of the term “DISCONNECT”is not accurate as used in this manual. This equipment is electrically powered. Failure to comply with this warning could result in serious injury or death.
WARNING
Never work in the electrical enclosures, or perform any service or maintenance work, unless electrical power to the machine has been physically disconnected. Never use Emergency Stops as a means of disconnecting electrical power. Emergency Stopsare not intended to serve as electrical disconnects. Some merely interrupt the motor control circuits and do not remove line power to the machine. Failure to comply could result in an accident causing serious injury or death to you or other personnel.
WARNING
WARNING
WARNING
Do not alter, remove or bypass any emergency stop device. Failure to so could result in serious injury or death since the proper operation of these devices may be critical in emergency situations.
Shut off the machine and relieve the hydraulic pressure before disconnecting any hydraulic line or fitting. Hydraulic lines are under high pressure. Failure to relieve this pressure could result in serious injury from hot pressurized oil.
Never work under any part of this machine that is supported by a hydraulic cylinder, regardless of built-in safety features such as load-lock valve. Install enough blocking to support the machine component safely or lower that component to the ground. Failure to do so could result in serious injury or death from crushing if the component falls.
WARNING
WARNING
Perform welding or burning operations only in a safe and approved area, and in accordance with existing laws and safe practice. Failure to do so could cause a fire or explosion resulting in severe injury or death.
Never use fingers to check the alignment of pin bores. Pinched, broken or severed fingers could result if components shift while doing so.
transport safety device
Storage and Transport
Your Safety
Maintain the prescribed storage periods and observe the instructions for storage.
Do not store materials or parts in the travel route or in your working area.
Inform the persons involved about the intended transport route and the anticipated duration of the transport.
Ensure that the transport locks are correctly fitted.
Fix all moving parts with transport locks.
Never stand under unsupported parts or suspended loads.
striking device
Attach lifting equipment only to the lifting points provided. Pay attention to the different load limits of the lifting points. Observe the instructions on the transport sheets.
Use lifting equipment, which is in good condition and is designed for the loads to be handled.
Use only transport belts for lifting round parts. Never use chains or steel ropes.
Do not damage the treated surfaces of shafts, sealing surfaces, etc.
Erection and commissioning
Inclined storage If stored at an angle, secure all individual parts using chains or stell ropes to ensure the parts are secure.
environmental acceptability When working with oils, greases and other chemical substances, observe the safety regulations applicable to the product.
Dispose of cleaning rags, etc., which are soiled with oil, grease or other chemical substances in an environmentally safe manner.
Hydraulics
handling of
Avoid direct contact between the skin and hydraulic fluids. Hydraulic hydraulic fluids fluids can penetrate the skin and cause serious infections.
Never use hydraulic fluids for rinsing or cleaning. Hydraulic fluids represent a very serious danger to health.
maintenance, repair
permissible tubing
Only persons who have and can demonstrate a special knowledge of hydraulics may be allowed to work on the hydraulic system.
Carry out a visual inspection of all the hydraulic components at regular intervals. In particular, pay attention that:
The hoses are not pinched or trapped.
The hoses have no bubbles or blisters.
The hoses or the outer sheathes of the hoses are not abnormally rigid or hard.
The outer sheath of the hoses are 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.
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 pressuring 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 of a higher quality.
Observe the date of manufacture stamped on the hydraulic hoses. Never use hydraulic hoses, which are more than 2 years old, even if they have no visible signs of damage.
3
STORAGE and TRANSPORT
Storage and Transport
This chapter contains important information on the correct storage and transport of the Miner. Observance of the instructions and tips will increase the service life and availability of the Miner. You will also be able to carry out the transport work quicker and safer. Paying careful attention to the points in this chapter will help you to simplify your day-to-day work.
Storage
Storage of the Equipment
Components coated with temporary corrosion inhibitor are protected for around six months. Protect the equipment against direct exposure to sunlight. 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 78 F (25 C).
Protect all parts of the equipment stored outdoors against moisture and dirt, e.g. using tarpaulins.
The mounting surfaces of hydraulic components must be protected against corrosion and sealed with blind plates. Protect the hydraulic plug connectors and the connectors of the electrical cables with the caps and plugs supplied.
During short-term storage (approx. 4 weeks) of equipment outdoors, but at temperatures above freezing, electrical components must not be removed. Such components must be particularly protected against excessive temperatures, dirt and moisture.
During long-term storage (more than 4 weeks), the equipment must not be stored outdoors. It must be stored in a dry, well ventilated room.
After a storage period of approx. 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.
Even with proper storage, seals and hoses are subject to natural ageing. A storage period of approx. two years is therefore quoted as an indicative value for these parts.
IMPORTANT!
ENSURE WHEN STORING THAT ANY NEW SUPPLIES ARE STORED SEPARATELY FROM EXISTING STOCKS IN SUCH A WAY THAT ON REMOVAL, OLD STOCKS ARE TAKEN FIRST.
protection against frost Before transporting or storing gearboxes with oil cooler at ambient damage for oil cooling temperatures below freezing, the oil cooler must be flushed with antifreeze.
Transport
Load Units; Dimensions and Weights
Observe the transport sheets for the various transport units. They contain information on:
Dimensions
Weight
Lifting points
Center of gravity, etc.
Where technically possible, the load units have suitable lifting points for transport and erection.
WARNING!
USE ONLY LOAD HANDLING DEVICES COMPLYING WITH THE TECHNICAL AND LEGAL REGULATIONS FOR TRANSPORTING LOADS. YOU COULD BE SERIOUSLY INJURED OR EVEN KILLED BY FALLING LOADS. USE ONLY SUITABLE LOAD HANDLING DEVICES.
Before Transport
temperatures below freezing
Transport of equipment at temperatures between –21° C and40°C is only permissible when certain measures were taken, to meet these conditions, at the design and manufacturing stages. Nevertheless, the individual parts and devices of this equipment must not be subjected to sudden impact loads at low temperatures.
During transport of this equipment, measures must 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 maximum of 25 kph for truck transport.
Antifreeze Measures Before transporting, the oil cooler must be flushed with anti-freeze. for Oil Cooler
electrical and electronic Electrical and electronic components must be removed for over components seas transport or prolonged storage outdoors unless these components or the complete equipment is protected against harmful environmental influences by a suitable packaging.
If the electrical cables remain in the equipment, they must be carefully protected against transport damage and soiling of the connections.
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4 Installation
Hydraulics
handling of
Avoid direct contact between the skin and hydraulic fluids. Hydraulic hydraulic fluids fluids can penetrate the skin and cause serious infections.
Never use hydraulic fluids for rinsing or cleaning. Hydraulic fluids represent a very serious danger to health.
maintenance, repair
Only persons who have and can demonstrate a special knowledge of hydraulics may be allowed to work on the hydraulic system.
Carry out a visual inspection of all the hydraulic components at regular intervals. In particular, pay attention that:
The hoses are not pinched or trapped.
The hoses have no bubbles or blisters.
The hoses or the outer sheathes of the hoses are not abnormally rigid or hard.
The outer sheath of the hoses are 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.
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 pressuring the system again.
permissible tubing 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 of a higher quality.
Observe the date of manufacture stamped on the hydraulic hoses. Never use hydraulic hoses, which are more than 2 years old, even if they have no visible signs of damage.
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Start-Up
Miner Operator Qualifications
The miner operator must be completely familiar with all features and controls of this machine in order to operate it safely and productively. This requires OEM training as available, a thorough study of this manual, and a visual inspection of the actual machine.
The following sections of this manual outline essential procedures and cautions for starting the miner prior to mining operations.
Pre-Shift Inspection
ALL PRE-SHIFT INSPECTIONS AND MAINTENANCE WORK MUST BE DONE UNDER PROPERLY SUPPORTED ROOFin accordance with Federal, State and Local safetylaws and safety rules dictated by the mining company. WARNING
• Check the operational report from the prior shift to note any problems or discrepancies with the miner. If such problems still exist, notify the shift or maintenance foreman and determine a plan of action for correcting the problems. In any case, do not start up the machine if problems exist which may cause safety hazards or danger.
• Use the wash-down hose to clean off the machine as much as practical.
• Conduct a visual walk-around inspection of the miner to look for signs of leaks in hydraulic cylinders and hoses, water hoses and gear boxes, frayed electrical cables, damaged or plugged water sprays, or other visible problems.
• Check the dust collector filter screen and clean it with the washdown hose as necessary.
• Ensure that all machine covers are in place and properly secured.
• Ensure that maintenance personnel have checked all lubrication points on the miner for proper oil levels in gear boxes and adequate greasing at grease fittings in accordance with OEM recommended practice.
• Check the full length of the trailing cable for damage. Ensure that the trailing cable is properly suspended across intersections, and that the trailing cable clamp at the miner is secure.
Miner Start-Up
C CAUTION
Do not startup and operate the miner unlessall daily checks and scheduled maintenance have been completed. Do not start up the miner until any noted operational faults have been corrected.
C CAUTION
Only trained and authorized operators, or trainees under a supervising instructor, should operate this miner.
MAKE SURE, BY A VISUAL CHECK AND A SHOUTED WARNING, THAT ALL PERSONNEL ARE COMPLETELY CLEAR OF THE MINER BEFORE START-UP. Also check that any loose material, tools, oil cans or other objects are cleared from the area before starting the machine. WARNING
• Energize the main circuit breaker at the power center to enable power up to the miner.
• Turn the following manual circuit breaker handles, located on the control case and illustrated in Figure 2-1.2, to the ON position:
o MAIN CIRCUIT BREAKER (1000VAC power to the miner)
o CONTROL CIRCUIT BREAKER (120VAC power to machine controls)
o TRACTION MOTOR BREAKER (1000VAC power to the tram transformer and the dust collector fan motor)
For the following activities, the operator can refer to the radio transmitter control and operation details given in Section 2-2.
• Turn on the radio transmitter by pressing the green TX PWR ON pushbutton.
• Turn on the pump motor by first pressing the green ENABLE pushbutton, then moving the PUMP toggle switch to the START position. Listen for any abnormal sounds from the pump, which could indicate oil starvation of the pump.
WARNING
NOTICE
IF ANY OTHER MACHINE FUNCTION OPERATES AT THIS TIME, PUSH THE MACHINE STOP BUTTON TO DE-ENERGIZE THE MINER IMMEDIATELY; A FAULT IS PRESENT IN THE SYSTEM.
Before further operations, the operator should doanother visual walkaround inspection to check for hydraulic leaks and proper machine lighting.
• Turn on the machine lights by pressing the green LIGHTS pushbutton.
WARNING
STAND WELL CLEAR OF THE MINER DURING OPERATION AND MOVEMENT OF THE VARIOUS MACHINE COMPONENTS, AND ENSURE THAT OTHER PERSONNEL ARE ALSO AWAY FROM THE MINER.
• Using the CUTTING HEAD RAISE/LOWER toggle switch, raise and lower the cutting head and check for proper operation.
• Using the GATHERING HEAD RAISE/FLOAT toggle switch, raise and lower the gathering head and check for proper operation.
• Using the CONVEYOR RAISE/LOWER toggle switch, raise and lower the conveyor and check for proper operation.
• Using the CONV SWING LEFT/RIGHT toggle switch, swing the discharge conveyor right and left to full travel and check for smooth operation.
• Start the conveyor and CLAs by pressing the green ENABLE pushbutton, then moving the CONVEYOR START toggle switch to the START position. Check the conveyor chain and CLA’s for proper operation.
• Check the conveyor chain for proper tension by swinging the discharge conveyor right or left to its full 45o position and observing the chain behavior at the gathering head footshaft. A loose chain will tend to rise up off the deck immediately after disengaging from the footshaft sprocket.
• Before tramming the miner, observe these cautions:
• Ensure that all machine lights are on.
• Check both the trailing cable and water hose for sufficient slack and freedom.
• Lower the cutting head halfway and raise the gathering head off the mine bottom.
WARNING
PRIOR TO TRAMMING THE MACHINE, MAKE SURE BY A VISUAL CHECK AND A SHOUTED WARNING, THAT OTHER PERSONNEL ARE CLEAR OF THE MINER AND THAT THEY ARE AWARE THAT IT WILL BE TRAMMED.
NOTICE
Remember that the TRAM ENABLE signal is only valid for 2 seconds. If the operator delays tramming the miner for more than 2 seconds, the TRAM ENABLE switch must again be used. The TRAM ENABLE switch takes the place of the traditional “dead man” foot pedal on miners equipped with an operator’s pit.
• Select a tram speed by pressing the green TRAM HIGH or the red TRAM LOW pushbutton.
• The miner is trammed by moving the TRAM ENABLE toggle switch either forward or backward, then using the TRAM joystick controls to move the miner.
WARNING
AFTER TURNING OFF POWER TO THE MINER, NEVER WALK AWAY AND LEAVE THE TRANSMITTER TURNED ON. FAILURE TOP TURN THE TRANSMITTER OFF COULD RESULT IN AN ACCIDENT CAUSING SERIOUS INJURY OR LOSS OF LIFE.
5 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 miner operator will have his own methods and techniques which work best for him.
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.
Another important factor is 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
Figure 3-3.1 shows a continuous miner approaching a freshly cut face. The operator has the cutting 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.
Figure 3-3.2 shows the miner having made a 30” sump cut at the bottom of the face. The operator will now back the miner out of the cut and raise the cutting head to the mine roof.
3-3.2 Miner Approaches Face
As shown in Figure 3-3.3, the operator has backed out of the bottom cut and raised the cutting head to the roof, positioning the miner for making a top sump.
3-3.3
The Next Face Cut
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 Figure 3-3.4. He can commence his downcut until his gathering head pan is full.
Figure 3-3.4 Miner Sumps in at Top and Begins Downcut
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 downcut to the mine bottom, seen in Figure 3-3.5.
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 cutting head is running.
Figure 3-3.5 Miner Completes Downcut with Small Cusp Remaining
The miner is now in a similar position as that shown in Figure 3-2.1 and the operator can proceed with the next cutting cycle.
Figure
Miner Backs Out, Raises Cutting Head for Top Sump
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 downcut force at the coal face while shearing down during mining operations.
The advantage of increasing downcut force at the face while shearing down is important particularly when cutting hard coal seams. Figure 3-3.6 illustrates the advantage of the stabilizer shoe in the downcut application.
The miner is shown in the middle of its shearing down cycle. 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-of-mass to the rear of the crawlers is denoted in Figure 3-2.6 by “Lever Arm without 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 the 30M miners the lever arm with the stab shoe down is more than twice the lever arm without the stab shoe, thus doubling the down force available for shearing down. This increase in downcut force will improve the speed and efficiency of the shear down portion of the cutting cycle.
Downcut Force
Figure 3-3.6 Effect of Using Stabilizer Shoe on Downcut Force
Shearing Up and Down
Most continuous miners, including the 30M machines, have their centerof-mass 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 downcut force.
Shearing only downward requires the cutting 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 Figures 3-3.7 and 3-3.8.
Figure 3-3.7 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.
Figure 3-3.8 shows the miner in the middle of the downcut.
Figure 3-3.8 Miner Shearing Down
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