CAT OPERATOR’S MANUAL Bucyrus 30MB3 BI643666 - PDF DOWNLOAD

BI643666

30MB3 OPERATOR’S MANUAL Manual No.M01273

BI643666

Contents Section 1

Handbook Objective

Section 2

Notes to the Operator

Section 3

Defects and Hazards

Section 4

Access on and off the Machine

Section 5

Machine Description

Section 6

Controls and their Functions

Section 7

Pre-start Checks

Section 8

Start-up Procedure

Section 9

Operating Procedure

Section 10

Shutdown Procedure

Section 11

Emergency Shutdown

Section 12

Operators/Trades Servicing and Maintenance Features

Section 13

Trouble Shooting

Section 14

Roof and Rib Bolting Equipment

BI643666

30MB3 OPERATOR’S MANUAL SECTION 1 HANDBOOK OBJECTIVE

BI643666 Bucyrus Australia

Helensburgh 30MB3 Maintenance Manual

Title Page Document Title:

30MB3 Operator Manual

Document Number: Issue:

Version 0

Revision: Date of Issue:

August 2008

Author:

Signature:

Authorised:

Signature:

Revision History Issue Revision

Manual No.M01273

Status

Date

Page 2 of 3

By

Authorised

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Helensburgh 30MB3 Operator’s Manual

Handbook Objective This operator handbook has been compiled by BUCYRUS Australia Pty Limited to assist you, as part of the TEAM, to operate this machine with safety and efficiency.

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30MB3 OPERATOR’S MANUAL SECTION 2 NOTES TO THE OPERATOR

BI643666 Bucyrus Australia

Helensburgh 30MB3 Operator’s Manual

TABLE OF CONTENTS NOTES, CAUTIONS AND WARNINGS .....................................................................................................................3 OPERATING PROCEDURES ....................................................................................................................................4

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NOTES, CAUTIONS AND WARNINGS ALL applicable Notes, Cautions and Warnings listed in this Manual are to be included in the support documents following the same format as defined below.

Follow Notes, Cautions and Warnings found in the handout.

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NOTE:

Indicates a procedure or condition that is essential for the operator to know.

CAUTION:

Indicates an action or condition that, if not followed, could cause damage to the vehicle or other equipment.

WARNING:

Indicates an action or condition that, if not followed, could cause injury to the operator or other personnel.

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OPERATING PROCEDURES Operating procedures are written with the intention of being correct. If you do notice errors within the procedures, it is an important part of our company’s Quality Processes that we be notified quickly so that any problem can be corrected.

THOUGHT PROCESSES THAT WILL HELP TO KEEP OPERATORS INJURY FREE Is the procedure Correct?

YES

NO

Am I following the correct procedure?

STOP

YES

WAY TO GO

NO

Take corrective action!

If necessary consult with team members

STOP

Correction Resolved

WHY NOT

YES

NO

STOP ACT NOW! FOLLOW CORRECT PROCEDURE

Take corrective action!

Consult with Responsible Person/s Correction Resolved

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BI643666

30MB3 OPERATOR’S MANUAL SECTION 3 DEFECTS, HAZARDS AND SAFETY

BI643666 Bucyrus Australia

Helensburgh 30MB3 Operator’s Manual

TABLE OF CONTENTS DEFECTS AND HAZARDS .....................................................................................................................................3 SAFETY AND MAINTENANCE PRACTICES .............................................................................................................3 Safety Procedures ..........................................................................................................................................3 Isolation Procedures......................................................................................................................................4 Generic 12 Step Isolation Procedures ...........................................................................................................4 AUGER SAFETY STOPS ........................................................................................................................................7 CONVEYOR STOP .................................................................................................................................................9

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DEFECTS AND HAZARDS The machine should be regularly checked for any defects or hazards and rectified where possible or dealt with according to mine specific action plans.

SAFETY AND MAINTENANCE PRACTICES It is essential that all personnel are clear of machine prior to start, once operating all personnel to be clear of conveyor boom and cutter head. Operator must be aware of his location to avoid crush potential.

Never put yourself or any other person in any position that should machine fail to respond correctly or if in normal operation creates a position whereby no escape is possible.

“One fraction of a second of carelessness can result in a lifetime of suffering for yourself or other team members”.

To understand this statement is the beginning of effective safe work practices.

Safety risks are created when you shortcut Standard Procedures.

Machinery is like a loaded gun - even if it is not running or is switched off.

When doing tests with the machine running: −

Stop machine and isolate to set up test.

−

Stand clear and observe test.

− Stop machine and isolate before disconnecting test.

When repairing, replacing or fitting heavy components: −

Use blocks, and supports to prevent components tipping, sliding or moving out of position.

When working under the heads, shovel or tail:

− Make sure that safety stops are securely in place at all times.

When testing the machine in any way: −

Ensure that personnel are clear of the machine at all times during testing.

Safety Procedures All safety procedures shall comply with mine specific and relevant Mine Managers Rules and particularly any documents relating to the use and maintenance of Remote Control Continuous Miners.

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Isolation Procedures Below is an example of a generic isolation procedure which is common to some coal mines throughout NSW and QLD. NOTE:

Mine Specific Isolation Procedures are to be adhered to and take precedence over example isolation procedures mentioned in this document.

Generic 12 Step Isolation Procedures

The 12 steps must include consideration of the following actions:

1.

Identify all plant or equipment and their energy sources that require isolation

2.

Identify all primary energy sources and confirm that the isolation point e.g. switches, circuit breakers, contactors, whole current isolators, battery isolators, valves etc., you isolate are the correct ones for the plant or equipment. Where appropriate refer to schematic diagrams to confirm that the isolator will give complete isolation.

Identify any associated plant or equipment that could create a hazard.

Isolation can only be achieved by isolating the plant or equipment from all sources of energy. While the plant or equipment may be electrically isolated, other sources of energy must be considered e.g. hydraulic/water/air pressure, gravitational energy (continuous miner head or loader bucket in the air, conveyor counterweights) etc.

Determine the type of isolation that you will require (Individual, Group, High Voltage) and apply as required Check to see if any specific isolation procedures apply to that equipment or circuit.

Advise relevant parties

Notify all people who will be affected by the isolation to ensure no safety or operational problems will be created.

Where necessary advise operators that the plant or equipment is to be isolated to allow for machines to be left in a safe position prior to isolating.

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3.

Isolate and secure energy sources

Isolate primary isolator in an approved manner or using site procedures and/or manufacturers recommended instructions e.g., operate whole current isolator, remove plug, close valve etc. Shedding of loads prior to operating primary isolator may need to be considered in some instances.

Isolate or secure/control all secondary energy sources. For example:

-

bleed off stored hydraulic or pneumatic pressure from pressure vessels, accumulators etc,

-

Release stored energy such as springs, conveyor belt tension, etc. secure/barricade/chock elevated equipment or material hang-up in chutes, truck bodies etc

-

Chock machinery and equipment to prevent unplanned movement.

Do not use auxiliary devices for isolation e.g., push buttons, control circuit devices, emergency stop buttons, key-switches, conveyor lanyards, etc. except where these remote isolator devices control an approved (to relevant Australian Standard) whole of current isolation device e.g. Motorised lanyard controls on conveyors to AS1755.

4.

Apply Personal Danger Tags / Locks, or Permit Danger Tags / Locks

A Personal Danger Tag or lock is to be placed on the appropriate isolation point/s by a competent person.

In the case of a permit:

-

a Permit Danger Tag / Lock is to be placed on the relevant isolation point/s by the Authorised Isolator after the Permit Holder has raised the appropriate permit

-

All members of the work party shall sign onto, or attach their Personal Danger Tag or lock to the appropriate permit after checking the work they are performing is covered by the Permit.

Any visitor requiring to place a Personal Danger Tag or lock or sign onto a permit can only do so under direct supervision of a competent person or Permit Holder NB Depending on the circumstances, it may be necessary to reverse steps 4 and 5 e.g. When access to switchboards is necessary for verification purposes and a tag or lock will prevent entry.

5.

Verify the effectiveness of the isolation All isolations must be checked to verify the isolation has been effective by:

Testing the test equipment is in good operating condition and is set to correct scale eg.

Pressure gauges, non-contact voltage detector, multi-meters etc

Checking the operation of test equipment before and after isolation

Test the isolation has been effective by:

-

Checking for the presence of voltage for electrical isolations Attempting to start the equipment e.g. mobile equipment/machinery Opening valves in pipelines

Confirming secondary energies are secured e.g. Chocks etc.

Check for test methods that may have been developed and approved for use for various isolations.

6.

Commence Work

7.

Carry out the required tasks.

Monitor work area for any new introduced hazards

Complete Work

Complete all tasks related to the isolation.

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8.

Check Work

Review all work that has been carried out to confirm the work-area has been left in a safe condition e.g. Guards and covers are back in position etc.

Attach an Out of Service Tag to the plant or equipment isolation point if it is not safe or ready for service.

9.

Clear Area Ensure all persons working on the affected plant or equipment have completed their tasks and are clear of the work area.

Confirm area associated with restoring energy has been cleared i.e. remove rubbish from rotating parts, roll up hoses, removal of spare or replaced parts etc.

10.

Remove Personal Danger Tags / Locks, or Permit Danger Tags / Locks

Remove Personal Danger Tags / Locks associated with the work being done. Each person to remove only their own Personal Danger Tag / Lock.

In the case of a Permit, each individual is to sign off all permits, or remove Personal Danger Tag / Lock, associated with the Permit. The Permit Holder may then cancel the Permit.

Visitors may only remove their own Personal Danger Tags / Locks or sign off a Permit under the direct supervision of a Competent Person/Permit Holder.

11.

Restore Energy

12.

Advise all relevant or affected parties of your intention to restore energy.

Restore energy to the plant or equipment in accordance with the operation’s energy restoration procedures.

Check Operation

Tests run the plant or equipment to confirm that the work carried out has been successful and that the plant or equipment is operating normally.

Attach an Out of Service Tag to the plant or equipment isolation point if it is not safe or ready for service, or testing is required using approved procedures.

Attach an Information Tag if required.

Fill out shift report of status and works completed and communicate details of work undertaken to all relevant persons.

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AUGER SAFETY STOPS Before commencing work near or under auger head - fit head stops as shown in photo. Stops (L) (R) is carried on board machine.

1.

Also isolate main circuit breaker, traction, conveyor and cutter breakers and tag prior to working in this area. Procedure for fitting head stops are as follows:

Isolate cutter circuit breaker – conveyor circuit breaker – traction circuit breaker.

NOTE:

Refer to Mines Remote Control Operations for Continuous Miners.

With an operator by your side, start the machine, lower the gathering head to the floor and raise the auger head to a suitable height to fit stops.

Carefully slide stops into cutter head areas Left and Right hand sides.

With Miner still running slowly lower auger head onto the manufactured stops ensuring to take the weight of the auger head.

WARNING:

October 2008

Isolate Miner as per Mines isolation procedures.

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Auger Safety Support Pins

Auger Head Stop Positions

Handle and Locking Plate for Safety Support Pin

Side View

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CONVEYOR STOP Before commencing work in or around conveyors ensure the conveyor stop bar is used. Ensure conveyor is rested on conveyor stop before any work is commenced. Also isolate and tag machine prior to any work in this area. Procedure for fitting conveyor stop is as follows:

Isolate CONVEYER, CUTTER head and TRACTION circuit breakers.

With operator by your side, start the machine NOTE:

Refer to Mines Remote Control Operations Continuous Miner – RCCM rev.doc.

Raise the conveyor to a suitable height to slide the stop horizontally (3.3).

Check that the sliding bolt is secure and locked into place.

Lower the conveyor onto stop.

WARNING:

Isolate Miner as per Mines Isolation Procedures.

Position of the Conveyor Pin in Lock out Position L/H side of Machine

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30MB3 OPERATOR’S MANUAL SECTION 4 ACCESS ON AND OFF THE MACHINE

BI643666 Bucyrus Australia

Helensburgh 30MB3 Operator’s Manual

TABLE OF CONTENTS ACCESS ON AND OFF MACHINE .................................................................................................................3

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ACCESS ON AND OFF MACHINE Climb on and off the miner only where steps or grab irons are provided.

Use both hands when mounting and dismounting and face the vehicle.

Never get on or off a moving continuous miner, and never jump off a continuous miner.

• • • •

Climb up and down the ladders by facing the ladder.

Never climb down with your back facing the ladder rungs.

Be very careful on the bottom steps, especially in muddy conditions.

Always maintain three point contacts.

Access to Machine via steps

NOTE:

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Use access platforms when performing maintenance or bolting

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30MB3 OPERATOR’S MANUAL SECTION 5 MACHINE DESCRIPTION

BI643666 Bucyrus Australia

Helensburgh 30MB3 Operator’s Manual

TABLE OF CONTENTS MACHINE DESCRIPTION – 30MB3...............................................................................................................3 General ..........................................................................................................................................................3 Specifications .................................................................................................................................................4 Machine Weights............................................................................................................................................4 COMPONENT LAYOUT..................................................................................................................................5 Top View ........................................................................................................................................................5 Right Hand View ............................................................................................................................................6 Left Hand View ..............................................................................................................................................7 Main Chassis..................................................................................................................................................8 Cutting Head Assembly..................................................................................................................................9 Gathering Head Assembly ...........................................................................................................................10 Conveyor Assembly......................................................................................................................................11 Traction Drive System..................................................................................................................................12 Hydraulic System - CLA...............................................................................................................................13 Machine Hydraulic Layout ..........................................................................................................................14 Drill Rigs......................................................................................................................................................16 Rib Protection ..............................................................................................................................................16 Articulating Temporary Roof Support - ATRS.............................................................................................17 Bolting, Mining and Maintenance Modes....................................................................................................18 Water System................................................................................................................................................18 Water System................................................................................................................................................19 Machine Water Component Layout .............................................................................................................21 Water Circuit ...............................................................................................................................................22

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MACHINE DESCRIPTION – 30MB3

General The 30MB3 miner is a radio-controlled drum-type continuous miner with appropriate weight balance, cutting and loading power to enable the productive mining of coal and other soft mineral in seams ranging from 1,900 mm up to 4,000 mm thick.

The machine is mounted on crawler tracks that provide full mobility and sharp turning radius in both bord and pillar and long wall development mining plans. The ranging cutting head mines material from the solid face using a chainless rotating drum, and a CLA-type gathering head with high speed conveyor efficiently moves mined material to a haulage system behind the miner.

The machine's weight and balance is designed to mine most efficiently by either sumping into the face at the top or bottom of the seam, and ripping material to the bottom or top of the seam.

The above figure shows a general arrangement of major mechanical components. A full description of the various major sub-systems of the 30MB3 follows.

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Specifications Length

11931 mm

Cutting Width

5200 mm

Max Cutting Height

4100 mm

Weight

83000 kg - Total

Ground Clearance

350 mm

Undercut Capacity

249 mm st

1 = 0 – 10 Metres/Minute

Tramming Speed

2nd = 13 Metres/Minute 3rd = 26 Metres/Minute Tracks

Crawler Type LH & RH Independent

Brakes

Oil Flushed Spring Applied Park Brake

Drives

Electrical - Mechanical

Steering

Skid Steer

Machine Weights Complete Machine

83000 kg

-

Mainframe complete with track drive gear cases motors and tracks including pump motors

30650 kg

-

Total Cutter Head Assembly

22500 kg

a) Cutter Head Frame including motors

13500 kg

b) Cutter Head Gear case -

Conveyor Assembly Intermediate and discharge

-

Gathering Head Assembly complete with drill rigs and shields

TRS - OPTIONAL

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9000 kg

7900 kg 13600 kg 1500 kg

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COMPONENT LAYOUT Top View

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Right Hand View

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Left Hand View

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Main Chassis

CONVEYOR PIVOT POINT

GATHERING HEAD PIVOT POINT CUTTING HEAD PIVOT POINT GATHERING HEAD PIVOT POINT

HYDRAULIC TANK

GATHERING HEAD PIVOT POINT

The main chassis of the machine is a robust box-type structure of high-strength steel construction that provides the following: Mounting of the RH and LH crawler tracks and their independent drive systems and take-up provisions.

• • • •

Independent pivots for mounting the cutting head and gathering head and conveyor components and their associated hydraulic cylinders for articulation.

An integral hydraulic oil tank along with two electric motor/hydraulic pump assembly‘s and associated valves and piping.

A rear stabiliser and its articulating hydraulic cylinder for improving leverage forces during sheardown in the cutting sequence.

Mounting provisions for all major electrical system components and their associated wiring.

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Cutting Head Assembly The cutting head assembly is attached to the main chassis at RH and LH independent pivot points around which the assembly is articulated for vertical-ranging cutting of the coal seam.

The independent pivots allow removal of the cutting head assembly without disturbing the gathering head or conveyor components.

CENTRE CUTTER DRUM

LEFT CUTTER DRUM

RIGHT CUTTER DRUM RIGHT PULL-IN ASSEMBLY

LEFT PULL-IN ASSEMBLY

WATER SPRAY BLOCKS

WATER SPRAY BLOCKS INPUT GEARCASE RIGHT SIDE ELECTRIC MOTORS CUTTER CLUTCH

CUTTER CLUTCH

CUTTER HEAD COVERS

CUTTER HEAD COVERS

CUTTER HEAD PIVOT POINT CUTTER HEAD DUST BELT

The cutting head assembly consists of the following:

•

The cutting head support frame, a robust box structure which includes the RH/LH pivot points for attaching to the main chassis, upper mounting clevises for the two cutting head raise cylinders, and a major bolting flange to which the cutting head drive assembly mounts.

•

The cutting head gear case assembly, which consists of a input gear case and water-cooled 173 kW AC electric drive motor for each of the RH and LH sides, a final drive gear case which includes drive gearing, a main drive shaft and mounting points for the 1067mm diameter RH, LH, intermediate and centre drums, and a major bolting flange for mounting onto the cutting head support frame. The outer cutting drums are independently mounted to the major bolting flange and have an extension/retraction of 300mm each side from 5200mm to 4600mm and can be removed as an assembly.

The cutting head assembly is raised and lowered by two (2) heavy-duty hydraulic cylinders mounted to the main chassis at their lower ends and attached at their upper ends to main longitudinal structural members of the cutting head support frame. These cylinders enable the cutting head assembly to range from 249 mm below ground level to a maximum height of 4100mm.

The power train of the cutting head consists of RH and LH sides, which tie together at the common main drive shaft, allowing the combined power of both electric drive motors to be available at any point on the cutting drums.

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Gathering Head Assembly

The gathering head assembly is attached to the main chassis at RH and LH independent pivot points around which the assembly is articulated to adjust the gathering head for uneven floor conditions and for tramming the miner from place to place. The independent pivots allow removal of the gathering head assembly without disturbing the cutting head or discharge conveyor.

The gathering head assembly includes the following:

•

•

The gathering head structure consists of RH/LH pivot points for attaching to the main chassis, upper mounting clevises for the two gathering head raise cylinders, extendible plows compatible with extendible widths of the cutter head widths and shields mounted on rear of structure to support the roof bolting rigs.

RH and LH power trains, each of which include a water cooled 38 kW AC electric motor, an input gear case and a gathering head pot which drives a rotating centrifugal loading arm device.

•

Mounting provisions for the Temporary Roof Support (TRS) systems in the shields.

The gathering head assembly is raised and lowered by two hydraulic cylinders, which are mounted to the main chassis at their lower ends and attached to points of the gathering head structure at their upper ends. These cylinders allow vertical ranging of the forward edge of the gathering head from 200 mm below floor level to 537 mm above floor level.

The RH and LH power trains are connected to a common foot shaft which provides. (a) Proper timing of the rotating CLA loading arms and (b) Drive power to a sprocket which drives the conveyor chain. This conveyor chain drives is reversible to aid in clearing debris which might restrict conveyor chain movement.

The gathering head structure includes a special noise-damped running deck for the conveyor chain to minimise noise generation.

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Conveyor Assembly

TAIL ROLLER

REAR DISCHARGE CONVEYOR

CONVEYOR CHAIN

SWING CYLINDER

SWING CYLINDER

FANTAIL PIVOT

CROSS-OVER BRIDGE

INTERMEDIATE CONVEYOR

CONVEYOR PIVOT POINT

The conveyor assembly is attached to the main chassis at RH and LH independent pivot points around which the assembly is articulated vertically to assist in optimum loading into the haulage vehicle. Independent pivots allow removal of the conveyor assembly without disturbing the cutting head or gathering head components.

The conveyor assembly includes the following:

• •

An intermediate conveyor structure which includes the RH/LH pivot points for attaching to the main chassis, upper mounting clevises for the two conveyor raise cylinders, and a horizontal pivot arrangement at the rear for mounting the rear conveyor subassembly.

A rear conveyor sub-assembly which includes (a) a mating horizontal pivot arrangement allowing sideward swinging movement up to 45o on either side of the machine centre line to assist in Optimum loading into the haulage vehicle and (b) a tail roller shaft for the conveyor chain and two hydraulic cylinders to maintain proper tension in the chain when the geometry of conveyor assembly changes during the operation. The intermediate and discharge conveyor structures each include a special noise-damped running deck for the conveyor chain to minimise noise generation and 914mm throat clearance for optimum loading rates.

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Traction Drive System

The traction drive system provides the necessary mobility for the 30MB3 miner to mine coal and to tram from place to place as needed. It includes:

• •

Independent RH and LH drive systems, each consisting of a water-cooled 55 kW DC variablespeed electric motor mounted to a drive gear case that powers drive sprockets to provide motion to the respective RH or LH crawler chain.

A forward-mounted crawler chain idler roller on each side which is equipped with a greasepowered piston to adjust the crawler chain to its proper tension; once adjusted by movement of the grease, the idler roller is locked into position by a necessary number of shims, and pressure in the grease piston is relieved. An AC/DC solid-state electronic drive logic system which provides the operator with three speed ranges:

(a)

High speed which moves the miner at a rate of 26 metres/min, used mainly for flitting from one working face to another.

(b)

Intermediate speed at a rate of 13 metres/min, used mainly for rapid re-positioning of the miner within the face area.

(c)

Sump speed, fully adjustable by the operator to a preset value ranging from 0 to 10 metres/min for sumping the miner into the coal face. The adjustable sump speed setting allows the operator to select an optimum cutting speed when face hardness conditions vary, eg. Rock inclusions or roof/floor cutting.

The traction drive control system provides the operator with the capability to run either RH or LH crawler chain in forward or reverse independently for maximum manoeuvrability, i.e. the miner may be pivoted about its central vertical axis. The RH and LH drive trains are each equipped with fully enclosed multiple-disc fail-safe hydraulic flushed parking brakes that are spring-applied and hydraulically released.

The crawler chains are manufactured from high-alloy wear-resistant steel for maximum life, and are equipped with grouser ridges to enhance traction in both soft and hard floor conditions.

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Hydraulic System - CLA The 30MB3 hydraulic systems is fed from the main reservoir contained as an integral part of the main chassis structure. Capacity of the reservoir is 750 litres; capacity of the total system including the main reservoir, full cylinders, hoses, etc is 1000 litres. Hydraulic oil level in the reservoir can be monitored by sight glasses are which are fitted on either side of the mainframe beside traction motors and the tank is equipped with an oil level float switch which shuts off the machine operation in the event that reservoir level goes below a safe limit. Hydraulic power for the miner is provided by two 67 kW water-cooled AC electric motors which drives two (2) Rexroth variable displacement hydraulic pumps. The RH pump delivers oil to the main control valve for hydraulic mining functions. The LH pump delivers oil to the drill rigs and the rib protection system when switched into bolting modes. The pump/ motor assembly are located within the RH and LH crawler frames. The pumps provide 260 Litres/min @ a maximum pressure of 200 BAR.

Main Valve Bank

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Machine Hydraulic Layout

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Hydraulic Schematic

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Drill Rigs The 30MB3 miner drilling capabilities consist of two roof drilling units on a traversing slide and single rib drilling on both sides of the machine. The roof rigs are independently mounted to a shield which is coupled to the gathering head chassis and the rib drilling unit is mounted to the mainframe chassis.

Both units are operated from an operator’s platform and consist of side platforms down both sides of the machine for accessing roof bolting supplies.

Roof rig

Rib rig

Rib Protection Rib protection consists of a hydraulic extendible shield towards the rib horizontally for the operators placement and also vertically for his/her placement. This safety device must be used in conjunction with rib drilling. The shields are to be fully retracted before cutting can take place from face to face due to proximity switches fitted.

Rib protection

NOTE:

Manual No.M01273

Refer to Section 9 for the procedures to satisfy the Bolting Mode.

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Articulating Temporary Roof Support - ATRS The Temporary Roof support system consists of two cylinders, one each side of the machine located in the gathering head in bye of the Roof drilling rigs.

The cylinders are operated via the transmitter and can only be operated whilst you are in BOLTING mode.

When the selector valve is placed in bolting mode, oil is directed to the drilling rigs.

A diversion valve on the right hand side of the machine, situated above the main mode selector valve, is then positioned in the ATRS mode, directing the oil onwards to the cylinders.

By operating the [SHIFT] and ATRS UP or ATRS DOWN toggles on the transmitter, the cylinders will raise or lower in the desired direction.

When the cylinders are set to the roof, pressure is detected by a pressure switch. Once pressure has been detected, two pips will be heard from the banshee. This will also be known by a message on the main screen that ATRS mode is initiated.

When the ATRS cylinders are set to the roof and the main mode selector valve (MINING / MAINTENANCE / BOLTING) is selected in mining mode, the pumps will stop. Thus, this is protection of the ATRS cylinders via the pressure switches.

The machine is also fitted with two proximity switches, one each ATRS cylinder. These proximity switches indicate whether the cylinders are fully parked or retracted.

If for any reason the ATRS cylinders are not fully retracted and the operator proceeds to select MINING mode, a message will be displayed on the main screen – ATRS park switch fault and the machine will not be able to be operated for mining functions.

ATRS

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Helensburgh 30MB3 Operator’s Manual

Bolting, Mining and Maintenance Modes Bolting, Mining and maintenance modes have been fitted to the 30MB3 Miner and can be selected by operating a diversion valve as per its tagging, this valve is mounted upon the Right Hand side of the Miner beside the rib drilling rig.

The selections for the diversion valve are as follows: Mining Mode Raise the handle to the top position Maintenance Mode Move the handle to the centre position Bolting Mode Lower the handle to the lowest position

Mode selection valve

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Water System The water distribution system on the 30MB3 miner serves several primary purposes: a) It is circulated through the electric motors for the hydraulic pumps, cutting head, gathering head and traction system, the main control case and traction transformer case, to provide cooling, as well as supply to the bolting rigs. b) It feeds water sprays around the cutting head, gathering head and conveyor to help control and contain dusty air. Fitted in the spray circuit are two 3–way ball valves for changing the direction of spray patterns to suit mining conditions. (See below) These two valves are mounted on the top of the cutter head frame structure Auxiliary circuits provide flow to wash-down hoses on each side of the machine.

3-Way Ball Valve for Redirection of Sprays Mounted on Top of Cutter Head

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Essential components of the water system, and their locations, are shown on water spray schematic drawing located in this section.

A power tram unit can supply water to be pumped via the main supply inlet which provides cooling water to the pump and traction motors, the main control case, and the traction transformer and a quick-disconnect coupling allows water to be returned to the power tram unit (see above) during flitting of the machine from one working face to another.

The ball valve which isolates the discharge conveyor sprays when using a power tram for flitting.

Water inlet

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Machine Water Component Layout

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Water Circuit

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30MB3 OPERATOR’S MANUAL SECTION 6 CONTROLS AND THEIR FUNCTIONS

BI643666 Bucyrus Australia

Helensburgh 30MB3 Operator’s Manual

TABLE OF CONTENTS CONTROLS AND THEIR FUNCTIONS..........................................................................................................4 CIRCUIT ISOLATORS .....................................................................................................................................4 Main Circuit Breaker .....................................................................................................................................4 Cutter Circuit Breaker ...................................................................................................................................4 Pump - Traction Circuit Breaker ...................................................................................................................5 Gathering Heads (Conveyor) Circuit Breaker...............................................................................................5 Control and Light Breakers ...........................................................................................................................6 Traction AC Circuit Breakers ........................................................................................................................6 PUSH BUTTONS ..............................................................................................................................................7 110V Control E/L Test ...................................................................................................................................7 Traction Earth Leakage Test .........................................................................................................................7 Traction Earth Leakage Reset........................................................................................................................7 MACHINE EMERGENCY STOPS ...................................................................................................................8 Left Side Rear Lanyard Machine Emergency Stop ........................................................................................8 Right Side Rear Lanyard Machine Emergency Stop......................................................................................8 Left Side Bolting Platform Machine Emergency Stop....................................................................................9 Right Side Bolting Platform Machine Emergency Stop .................................................................................9 RADIO REMOTE CONTROL SYSTEM ........................................................................................................10 Remote Control Transmitter ........................................................................................................................10 Radio Signal Continuity...............................................................................................................................12 Turn the transmitter on ................................................................................................................................12 Turn the transmitter off................................................................................................................................12 Stop ..............................................................................................................................................................12 Siren .............................................................................................................................................................12 OPERATING FUNCTIONS ............................................................................................................................13 Start pump....................................................................................................................................................13 Stop pumps...................................................................................................................................................13 Raise Cutter .................................................................................................................................................13 Lower Cutter ................................................................................................................................................13 Conveyor up .................................................................................................................................................14 Conveyor down ............................................................................................................................................14 Conveyor left................................................................................................................................................14 Conveyor right .............................................................................................................................................14 Apron Float..................................................................................................................................................14 Apron up ......................................................................................................................................................14 Lower stabiliser ...........................................................................................................................................14 Raise stabiliser.............................................................................................................................................14 TRS...............................................................................................................................................................14 TRS – Up......................................................................................................................................................14 TRS – Down .................................................................................................................................................14 Water............................................................................................................................................................14 Cutters..........................................................................................................................................................15 Start Cutters .................................................................................................................................................15 Stop Cutters..................................................................................................................................................15 Tramming.....................................................................................................................................................15 Gathering Heads – Conveyor ......................................................................................................................16 Conveyor Forward.......................................................................................................................................16 Conveyor Reverse ........................................................................................................................................16 Conveyor Stop..............................................................................................................................................16 Lights ...........................................................................................................................................................16 TRANSMITTER MAINTENANCE & BATTERY CHARGER .....................................................................17 Display Unit .................................................................................................................................................18 Navigation Functions...................................................................................................................................18 Screen Scroll - Optional...............................................................................................................................18 Methane System ...........................................................................................................................................18 Main Monitor Screen ...................................................................................................................................19

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Main Monitor Screen .................................................................................................................................. 20 Production Monitor Screen No 1................................................................................................................ 21 Boom Override Control............................................................................................................................... 21 Production Monitor Screen No 2 – Boom Monitor .................................................................................... 22 Roof Datum Setting Control ........................................................................................................................ 22 Inclinometer ................................................................................................................................................ 23 INDICATOR LED’S ....................................................................................................................................... 24 MODES OF CONTROL.................................................................................................................................. 24 MODES OF CONTROL.................................................................................................................................. 25 Radio / Pendant Mode Switch ..................................................................................................................... 25 Radio Mode ................................................................................................................................................. 25 Pendant Mode ............................................................................................................................................. 25 Pendant ....................................................................................................................................................... 26

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CONTROLS AND THEIR FUNCTIONS NOTE:

The main circuit breaker does not remove power from the trailing cable or the incoming line side of the breaker. Always disconnect power from the machine at the power centre before major electrical repairs or maintenance.

NOTE:

Never attempt to start or move this machine unless you are familiar with all controls and emergency stop devices. Be certain the area around the machine is clear of other mine personnel whilst operating.

CIRCUIT ISOLATORS The 30MB3 has (6) six external Circuit Breaker operating handles: 1.

Main Circuit Breaker - opens all circuits.

2.

Cutter Circuit Breaker - opens Right & Left Cutter Motors.

3.

Pump - Traction Circuit Breaker - opens Pump Motor and Traction Transformer.

4.

Conveyor Circuit Breaker - opens Right & Left Gathering Head Motors.

5.

110V Control and 12V Lighting Circuit Breakers - opens control & lighting.

6.

Traction Circuit Breakers - opens 380V AC supplies to Right & Left Traction SCR Drive Units.

Main Circuit Breaker The Main Circuit Breaker is located in the lower compartment of the flameproof Display Enclosure located on the right hand side of the machine. The operating handle can be turned to the OFF position and removed.

This handle is used to unlock the main control case.

Cutter Circuit Breaker The Cutter Circuit Breaker is located in the top compartment of the flameproof Display Enclosure located on the right hand side of the machine. The operating handle can be turned to the OFF position and locked in the OFF position.

This circuit breaker is used to provide whole current isolation for the Cutter motors If this circuit breaker is OFF, tripped or isolated, it will be indicated on the display screen as “Cutter Circuit Breaker Trip”. When flitting the machine or in maintenance mode, turn Cutter Circuit Breaker “OFF” and tag out.

NOTE:

Manual No.M01273

This circuit breaker must be isolated to operate in maintenance mode

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Pump - Traction Circuit Breaker The Pump - Traction Circuit Breaker is located in the top compartment of the flameproof Display Enclosure located on the right hand side of the machine. The operating handle which is on the right hand end of the enclosure, can be turned to the OFF position and locked in the OFF position.

This circuit breaker is used to provide whole current isolation for the Pump motors & Traction Transformer.

If this circuit breaker is OFF, tripped or isolated, it will be indicated on the display screen as “Pump – Traction Circuit Breaker Trip”.

Gathering Heads (Conveyor) Circuit Breaker The Gathering Heads (Conveyor) Circuit Breaker is located in the top compartment of the flameproof Display Enclosure which is located on the right hand side of the machine. The operating handle can be turned to the OFF position and locked in the OFF position.

This circuit breaker is used to provide whole current isolation for the Gathering Head motors.

If this circuit breaker is OFF, tripped or isolated, it will be indicated on the display screen as “Gathering Heads Circuit Breaker Trip”. When flitting the machine or in maintenance mode, turn Gathering Heads Circuit Breaker “OFF” and tag out.

Note:

This circuit breaker must be isolated to operate in maintenance mode

Conveyor Circuit Breaker

Cutter Circuit Breaker

Pump-Traction Circuit Breaker

Main Circuit Breaker

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Control and Light Breakers The control and lights breaker handle is a thin lever located on the top right hand side of the flameproof Main Control Case, which is on the left hand side of the machine.

The lever is pushed in to turn both circuit breakers ON and pulled out to turn circuit breakers OFF. If the machine is powered and these circuit breakers are ON, the green 110V Control LED indication light should be indicating healthy, behind the viewing window on the Main Control Case.

Traction AC Circuit Breakers The Traction AC Circuit Breakers are located in the flameproof Main Control Case and operated via the operating handle located on the front right hand side on the Main Control Case.

These isolate the AC power to the SCR Traction Drive Units. The circuit breakers are switched on by moving the handle to the left. If a circuit breaker has tripped it must be reset by turning the handle fully to the OFF position before it can be turned back on.

Whenever working on the traction, setting conveyor stops or head stops ensure both circuit breakers are opened and operating handle tagged.

NOTE:

This circuit breaker must be isolated to operate in maintenance mode

Control & Lights Circuit Breakers Lever

Traction Circuit Breakers Handle

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PUSH BUTTONS On the front right hand side of the flameproof Main Control Case, there are (5) five push button operators.

The bottom (2) two push buttons are spare operators and are not used for any functions.

Control Earth Leakage Test Traction Earth Leakage Test Traction Earth Leakage Reset Spare – Not Used Spare – Not Used

110V Control E/L Test This is the first push button from the top and is used to carry out an earth leakage test on the 110V control circuit.

When pressed, the 110V Control Circuit Breaker, will trip. This circuit breaker is reset by operating the 110V Control Circuit Breaker operating lever.

Traction Earth Leakage Test This is the second push button from the top and is used to carry out an earth leakage test on the secondary of the Traction Transformer.

As an operation of a track is required for this test to be carried out, the machine is required to be jacked up so that the tracks are off the ground, allowing safe movement of the tracks whilst operating Traction E/L Test button.

Traction earth leakage trip is indicated via a red LED Traction E/L Trip behind the viewing window in the Main Control Case.

Traction will be disabled when Traction E/L is tripped. A message “Traction Earth Leakage Trip” will appear on the display screen.

Traction Earth Leakage Reset This is the third push button from the top and is used to reset an earth leakage fault on the secondary of the Traction Transformer.

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MACHINE EMERGENCY STOPS There are (4) four Machine Emergency Stops available around the machine.

•

Left Side Lanyard Machine Emergency Stop

•

Right Side Lanyard Machine Emergency Stop

•

Left Side Bolting Platform Machine Emergency Stop

• Right Side Bolting Platform Machine Emergency Stop Operation of any of the above Machine Emergency Stops will result in the pumps stopping. If a pump start is attempted whilst a Stop is latched, the message “Machine Emergency Stop Pressed” will be displayed to indicate the condition.

Left Side Rear Lanyard Machine Emergency Stop The Left Side Lanyard Machine Emergency Stop is located at the left side rear of the machine along side of the flameproof Display Enclosure.

The Stop is mounted on its side with a lanyard cable running from the stop switch operator to an anchor point on the out bye end of the Bolting Platform.

Operation of the lanyard cable or pushing the Stop mechanism will result in the pumps stopping. As the lanyard switch latches once it’s operated, should a pump start be attempted whilst the Stop is latched, the message “Machine Emergency Stop Pressed” will be displayed to indicate the condition.

To reset the lanyard mechanism, pull the labelled reset button on the side of the lanyard.

Left hand side of machine

Right Side Rear Lanyard Machine Emergency Stop The Right Side Lanyard Machine Emergency Stop is located at the right side rear of the machine along side of the flameproof Main Control Case.

The Stop is mounted on its side with a lanyard cable running from the stop switch operator to an anchor point on the out bye end of the Bolting Platform.

Operation of the lanyard cable or pushing the Stop mechanism will result in the pumps stopping. As the lanyard switch latches once it is operated, should a pump start be attempted whilst the Stop is latched, the message “Machine Emergency Stop Pressed” will be displayed to indicate the condition.

To reset the lanyard mechanism, push the operator on the front of the enclosure in.

Right Hand side in centre of machine

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Left Side Bolting Platform Machine Emergency Stop The Left Side Bolting Platform Machine Emergency Stop is located on the conveyor side of the left side bolting platform.

Operation of the emergency stop will result in the pumps stopping. As the stop switch latches once operated, if a pump start is attempted whilst the Stop is latched, the message “Machine Emergency Stop Pressed” will be displayed to indicate the condition.

To reset the stop switch, pull out the push button head.

LHS Bolting Platform Machine Emergency Stop Button

Right Side Bolting Platform Machine Emergency Stop The Right Side Bolting Platform Machine Emergency Stop is located on the conveyor side of the right side bolting platform.

Operation of the emergency stop will result in the pumps stopping. As the stop switch latches once operated, if a pump start is attempted whilst the Stop is latched, the message “Machine Emergency Stop Pressed” will be displayed to indicate the condition.

To reset the stop switch, pull out the push button head.

RHS Bolting Platform Machine Emergency Stop Button

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RADIO REMOTE CONTROL SYSTEM NOTE:

At all times, the machine must be operated in a safe manner. This means operating within the rules stipulated by the mine management and regulatory authorities. Refer to Mines Remote Control Management Plan. And Managers Rules Remote Control Operations.

Operating under remote control requires that a number of specific safety precautions be followed.

Operators must fully familiarise themselves with the radio control functions and how they operate.

The cable handler must be in full view of the operator at all times, and only proceed forward of the operator after the operator has been informed.

Only one transmitter should be available to control the machine at any one time.

The control system automates the mining operation and enables remote control, so that the operator can operate machines from the best vantage point. The system also has a series of interlocks to prevent incorrect operating sequences.

Remote Control Transmitter The remote control transmitter provides control of the machine’s functions. The portable remote control unit uses a sophisticated communications protocol to protect against interference and spurious operation of the miner. It communicates with the microprocessor control unit mounted on the miner using radio signals in the UHF band.

The remote control unit has rechargeable batteries that have enough capacity for up to 18 hours of continuous use.

The remote control transmitter has 12 switches. All of these are spring-loaded in the centre position.

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CAUTION:

October 2008

For some functions, such as turning on the cutters, you need to press the switch only momentarily. For other functions you need to press and hold the switches while the operation continues, such as tramming.

Most switches have two (2) functions - these functions are identified and selected as follows: Primary function - the switch operation is coloured black. To activate the primary function of a switch, you need to press only that switch.

Secondary function - the switch operation is enclosed in square brackets. To activate a secondary function, you need to first press the switch [SHIFT] and then, while still holding the [SHIFT] switch, press the other switches within two (2) seconds. The [SHIFT] switch should always be pressed slightly before the other switches. The switches can then be released in any order.

Emergency or stop functions are coloured red.

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Radio Signal Continuity If the remote control is turned off or stops transmitting for any reason, the receiver unit will detect the loss of the radio signal and stop the machine. If no function is selected for five (5) minutes, the console will automatically turn itself off, causing the machine to stop as well.

Turn the transmitter on •

Press the ON switch and hold it for two seconds until transmitter number and the message ‘ON’ are displayed. This is called “Handshaking” with the receiver.

If you have successfully turned the transmitter on, it will maintain continuous communications with the control unit until turned off.

NOTE;

Transmitter must be turned on beside the machine. If power is lost, the transmitter must be turned off and then on again

Turn the transmitter off • Press the OFF switch.

This will also stop any machine that is turned on or operating after a delay of one second.

Stop Pressing the STOP switch in either direction will cause all functions on the mining machine to cease immediately. The hydraulic pump will be turned off.

Siren The 30MB3 miners are equipped with a warning siren that sounds when you select certain functions, such as starting the pump. The duration of the siren sound is adjustable.

The selected function will not operate until after the siren has stopped.

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OPERATING FUNCTIONS Start pump •

Press and hold the [SHIFT] and [PUMP ON] switches together. The Siren will sound for two seconds and then the pump will start.

• Release both switches.

Be careful to release the pump switch before the select switch or you will turn the pump off.

From here, you can perform either tramming or cutting operations.

Stop pumps •

Press [PUMP OFF] NOTE:

The pumps will also stop immediately if the STOP is activated

Raise Cutter • Press the SHEARER UP switch.

The cutter will rise until the preset upper boom limit is reached or the switch is released.

Lower Cutter • Press the SHEARER DWN switch.

The cutter will lower until the preset lower boom limit is reached or the switch is released.

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Conveyor up •

Press the CONVEYOR UP switch. The conveyor will continue to rise until it reaches the upper limit or you release-the switch.

Conveyor down •

Press the CONVEYOR DWN switch. The conveyor will continue to lower until it reaches the lower limit or you release the switch.

Conveyor left •

Press the CONVEYOR LEFT switch. The conveyor will continue to move left until it reaches the left limit or you release the switch.

Conveyor right •

Press the CONVEYOR RIGHT switch. The conveyor will continue to move right until it reaches the right limit or you release the switch.

Apron Float • Press and hold the APRON FLOAT switch to lower the apron.

The apron will keep lowering until it is fully down.

Note:

It will then be in floating mode. It will stay in floating mode until raised or pump is switched off

Apron up • Press and hold the Apron UP switch to raise the apron.

The apron will keep rising until it is fully up or the switch is released.

Lower stabiliser • Press and hold the STAB DWN switch to raise the machine.

The stabilisers will keep lowering until they are fully extended or the switch is released.

Raise stabiliser • Press and hold the STAB UP switch to lower the machine.

The stabilisers will keep rising until they are fully extended or the switch is released.

TRS The TRS system can only be operated when the miner is in Bolting Mode. After Bolt mode has been selected a diversion valve located on the right hand side of the machine above the mode selector has to be positioned in TRS mode to allow the transmitter to operate the TRS cylinders.

TRS – Up •

Press and hold the TRS UP switch to raise the TRS system.

TRS – Down •

Press and hold the TRS DOWN switch to lower the TRS system.

Water There is one (1) water circuit for the cutter head sprays. You can start and stop the head sprays manually.

To start the head sprays: •

Toggle WATER switch to start the high-pressure water jets.

•

Toggle WATER switch again to stop the high-pressure water jets.

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Cutters Starting of the Cutter motors is staggered to avoid excessive current inrush that might result if both motors were started at the same time. After the first motor is started, there is a delay of two or three seconds before the second motor starts.

The first motor to be started is chosen automatically by the control system and alternates from left to right for successive starts.

Start Cutters • Press the [SHIFT] and [CUTTER ON] switches.

The siren will sound for two seconds before the cutters are started.

The water sprays will come on automatically.

•

Release both switches.

Stop Cutters •

Press CUTTER OFF switch.

•

Release both switches.

•

Machine sprays stop.

NOTE:

The cutters will stop immediately whenever the STOP is activated or the hydraulic pumps are stopped

Tramming The left and right tramming switches can be used: •

Together (for same direction)

•

Singularly (one at a time for turning)

• Differentially (opposite directions for pirouetting).

The siren sounds intermittently (beep, beep, beep) whenever either of the tramming switches is selected to reverse. The siren stops as soon as the switch (or switches) are released or moved to forward.

The machine can tram at any of three speeds, both in the forward direction and in reverse. The actual speed can be changed in Setup mode.

The continuous miner is always in Speed 1 when tramming mode is first selected. To engage the next speed range, toggle the TRAM 2-3 switch while operating one or both tramming switches.

When the miner has been tramming: • Press the TRAM 2 - 3 switches to increase speed.

While the miner is still running: • Press TRAM 2 - 3 switch to increase the speed again.

While the miner continues to run, you can only change between speeds 2 and 3. To return to speed 1, you must stop tramming and start again.

Tram reverse can operate in all 3 speeds, however if the cutters are running, once speed 2 is activated, the cutters will stop.

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Gathering Heads – Conveyor The Gathering Head motors spin the CLA’s and also drives the chain conveyor in the same direction.

Conveyor forward and reverse functions on the transmitter start the gathering heads.

Conveyor Forward • Press the [SHIFT] and CONVEYOR [ON] switches together.

The siren will sound for two (2) seconds before conveyor starts.

Conveyor Reverse • Press and hold the [SHIFT] and CONVEYOR [REV] switches together.

After a short delay, the conveyor will start running in the reverse direction and continue to do so until the switches are released.

Conveyor Stop If the conveyor is already operating in forward, pressing the CONVEYOR OFF switch will stop it.

Lights The lights can be operated on and off by [SHIFT] and [LIGHTS].

While holding the [SHIFT] key, toggle the [LIGHTS] key to alternate through the range of light settings i.e. Area lights, Rear light only, Front only and All On.

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TRANSMITTER MAINTENANCE & BATTERY CHARGER

Before taking the transmitter off charge, ensure the green light is on the appropriate channel of the charger to indicate the battery has been fully charged and is in good order.

Switch on the transmitter and ensure the battery/charger is receiving a signal from the transmitter.

Operate each switch to ensure each function is indicated on the battery charger screen.

Ensure all dirt and moisture is removed from the top of the transmitter before it is placed on charge after each shift. Inspect transmitter for any damage.

Every week the top plate should be removed from the transmitter and all material removed from around the switches by soft brush and all switches inspected for any damage including membrane around switches.

When transporting to machine ensure transmitter is secured to prevent damage. Also ensure whenever transmitter is put down at face that it is located in safe position.

NOTE:

October 2008

Procedures listed in Mine Management Plans Procedures for the Remote Control Operations for Continuous Miners.

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Display Unit A display screen is provided on the right hand side of the machine. This provides the operator/tradesman with fault information, machine modes and performance information. A switch is situated under the display screen which selects either ‘Radio’ mode or ‘Pendant’ mode.

Navigation Functions The main machine display can be changed using the new Navigation System. To enter the radio system Navigation mode the following steps must be followed.

1. Press [SHIFT] and [MENU] (WATER switch) and hold for approx 2 seconds 2. Press [SHIFT] and [NAV] (CONV left or right) to move through consecutive screens or enter the page number of the screen to be viewed using the numbers 1 through to 0. i.e. to access page 201 use and hold [SHIFT] then press [MENU] and release, press switches 2 (STAB DOWN), then 0 (FAN OFF), then 1 (TRAM 2-3), then # (CONV UP). This will then open page 201 Remote Console.

If an error is made when inputting page numbers, then * (CUTTER OFF) can be used to start over.

After pressing # the [SHIFT] and [MENU] key needs to be used again, this navigation function will also time out after a short period

Screen Scroll - Optional This button is located on the display enclosure near the pendant/remote selector. This button can be used to scroll through screen pages 1 to 20 on the display. A password is not required for this operation.

Methane System The methane system fitted to the 30MB3 miner is a Gasguard system manufactured by Ampcontrol.

There is 1 LED display, one on the right hand side of the machine and a monitoring panel as can be seen from the photographs below. The monitoring panel has a methane battery reset and also a lockable trip reset located on the front door and can be accessed without removing any machine covers.

Right Hand Side Display

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Methane Monitor

Methane Battery

UPS Timer reset Not in use

Monitoring Panel

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Main Monitor Screen

General Body

Cutter Head

This Main Monitor display screen includes:1.

Machine statuses indicated by Fault (red), Trip (orange), or OK (green).

2.

Machine Mode Selected – Mining, Bolting or Maintenance is indicated in blue.

3.

Radio frequency channels 1 through to 8 indicated under remote graphic and red.

4.

Page title, page number plus time and date in the top section.

5.

Transmitter functions in use indicated in yellow and by top right remote graphic (toggle turns red) 6.

Faults and Trips (scrolling if more than one) indicated in red 7.

Motor States, if running lit in red to indicate warning of operation 8.

Left and right pump currents (Amps) and Motor Temperature (Celsius) 9.

Left and right cutter currents (Amps) and Motor Temperature (Celsius) 10. Left and right gathering head currents (Amps) and Motor Temperature (Celsius) 11. Left and right traction currents (Amps) and Motor Temperature (Celsius) 12. Machine Voltage and Methane Level.

13. Methane Displays – Typically L/H is General Body and is set to 2.00%; R/H is Located in Conveyor throat and is set to drop cutter heads off at 2.00%. NOTE: Methane is not fitted to all machines but displays are still on screen.

14. Remote indications including : •

SIGNAL:

•

BATTERY: Indicates flashing red when transmitter battery is low

•

STOP:

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Indicates green when transmitter signal is healthy Indicates red when transmitter remote stop activated

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Production Monitor Screen No 1

The Production Monitor is Page 2 on the display screen menu and this screen includes:•

Left and right Cutter motor currents by phase and displays overall current on a real time graph.

•

Indicates the % speed of the Traction, and gives the ability to monitor Traction ramp up and down relative to Cutter Load when cutting

•

Indicates roof and floor clearance of the cutting drum via onboard Inclinometers. These values can be adjusted and are stored in the Set up area.

•

Running status of cutting drum via animation and colour, if running, the drum animation spins, and is red. If drum colour is flashing, this indicates the drum is outside inclinometer values.

•

Direction arrows, change red to represent the drum travelling vertically up or down.

Boom Override Control To operate the Boom Override mode operate [SHIFT], TRAM 3 and TRAM 4 keys and hold together for one second. The audible alarm will sound when the mode has changed.

To return to limits mode operate [SHIFT], TRAM 3 and TRAM 4 keys again and the Cutter Head will now shear between the top and bottom limits.

NOTE: The operation will reset to limits mode whenever the Pump Motor is restarted.

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Production Monitor Screen No 2 – Boom Monitor

The production monitor is found on page 9 The changes incorporate: •

Large numerical display

•

The diameter of the Cutter Drum has been included in the readout.

As shown on the example, when the Cutter Drum is on the floor (0 cm) the roof reference will read 106 cm (Cutter Drum diameter).

•

The display will display a negative reading when the Cutter Boom is taken below 0 cm (floor reading).

The maximum negative reading will be -30cm.

•

The Boom Override will be illuminated in RED when it is in use.

•

The Roof Datum (top limit) displayed at the bottom right of the production page.

Roof Datum Setting Control •

The ability to set the Roof Datum (top limit) from the production page when required To set a new roof datum (top limit) operate the [SHIFT], TRAM 1 and TRAM 2 keys and hold together for one second.

The new roof datum will then be displayed on the bottom right of the screen.

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Inclinometer The inclinometer is used to indicate the cutting head height. The top and bottom cutting heights are referenced to the horizontal zero position. You will not be able to shear beyond these limits unless boom override mode is enabled.

To override the Inclinometer with the pumps running, using the transmitter operate the [SHIFT] then TRAM 3 and TRAM 4.

Override will stay on until the pumps are turned off.

The ability to set the Roof Datum (top limit) from the production page when required.

To set a new roof datum (top limit) operate the [SHIFT], TRAM 1 and TRAM 2 keys and hold together for one second.

The new roof datum will then be displayed on the bottom right of the screen.

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INDICATOR LED’S A panel of LED’s is visible through the viewing window in the Main Control Case. The LED’s indicate the following:1.

110V Control – (Green – healthy) Control supply is ON 2.

Radio 24V – (Amber – healthy) 24V supply to Radio system is ON 3.

E/Stops Healthy – (Green – healthy) Machine Emergency Stops are all out 4.

Traction E/L Trip – (Red – Tripped) this will appear on power up, after a Traction E/L Test or if there is an earth fault on the traction circuit.

5.

Pendant Mode – (Green – on) Indicates that pendant mode is selected. Radio is not able to be used in this mode.

6.

Pump Overload – (Red – Tripped) Indicates that the manual pump overload had tripped. This will only operated when pendant mode is selected.

7.

12V lights – (Green – on) Indicates lights are ON. 8. Lights E/L Trip – (Red – Tripped) this will appear when there is an earth leakage in the lighting circuit.

LED Indicators inside Panel Window

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MODES OF CONTROL Radio / Pendant Mode Switch The miner can be operated in (2) two modes of control:•

Radio Mode

• Pendant Mode The mode selector switch is located on the front of the flameproof Display Enclosure and has an OFF position between the two modes.

Radio/ Pendent Mode Switch

Screen Scroll Pushbutton

CH4 Selector Switch

Diode Selector Switch

Radio Mode When the miner is in Radio mode, it is controlled via the radio system and transmitter. The pendant circuits are isolated via the mode switch.

Pendant Mode The Pendant mode provides the ability to start the pump and tram at sump speed in both forward and reverse directions in the event of an EMERGENCY ONLY. It does not provide for production or maintenance operation.

NOTE: The mode switch has an off position that isolates power to the control system If the pendant stop button is not pressed in the pump will start as soon as pendant mode is selected

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Pendant The Pendant consists of four tramming buttons: •

Left Tram Forward

•

Right Tram Forward

•

Left Tram Reverse

• Right Tram Reverse All tramming buttons are spring return to the off / neutral position. There is also a latched Machine stop button, which is normally in the “in” position when not in use. This stop button is only in use when the pendant mode is selected.

To activate the Pendant, turn the mode selector switch to Pendant. When the Pendant stop button is pulled out, the pumps will start and the tramming buttons are ready for operation.

NOTE:

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The siren will sound continuously while Pendant mode is selected.

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30MB3 OPERATOR’S MANUAL SECTION 7 PRE START CHECKS

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TABLE OF CONTENTS PRE-START FUNCTIONS ...............................................................................................................................3 Inspections .....................................................................................................................................................3

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PRE-START FUNCTIONS Prior to putting the miner into operation the machine and surrounding area should be subjected to a systematic inspection to ensure that: 1.

The area about to be worked can be done so in safety for both the operator and machine.

2.

The miner can be operated safely.

NOTE: Pre-Start Procedures listed in the Mines - Remote Control Operations - Continuous Miner - Document – Energy Control and Isolation Management Plan is to be followed.

Inspections The inspections should include the following items prior to starting the miner: 1.

Ensure that you are aware of section plan and at what stage the mining sequence is up too.

2.

Examine water hose and cable from gate end box to the miner: 3.

Ensure cable and water hose will not be damaged by large amounts of coal and debris (free falling from rib or roof) or by other machinery running over the cable and/or water hose.

4.

Check the condition of roof and face in the immediate area of operations and check the state of ventilation.

5.

Check that there are no “Out of Service” or “Danger” locks on the machine.

6.

Ensure all guards are in correct position and are secure.

7.

Ensure that miner is free of large amounts of coal and debris.

8.

Ensure that all exposed hoses and cables are safely positioned and free from damage.

9.

Ensure lights are secure and lenses are clean and not cracked or broken.

10. Ensure stop buttons are in the correct position. Correct position is out for drill rig stops.

11. Ensure that no foreign items (eg. service tools and equipment) have been left on and/or in the miner and/or in front or at the rear of the miner.

12. Ensure all safety posts drill rigs and platforms are in position and secure.

13. Check that fire extinguisher is in position and in a serviceable condition.

14. Ensure all visible flameproof equipment including cables and glands are not damaged which may render miner not flameproof.

15. Ensure operator service points have been checked: a.

Cutter head has a full complement of sharp picks. b.

All oil levels register the correct amount of fluid. c.

The inlet water filter is clean (bag type). Remove and clean bag. d.

Water sprays are in place and clear. e.

Hydraulic filter indicators (If fitted).

16. Check that the operating area is clear and that personnel are aware the miner is about to start.

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30MB3 OPERATOR’S MANUAL SECTION 8 START UP PROCEDURE

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TABLE OF CONTENTS START UP FUNCTIONS ..................................................................................................................................3

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NOTE:

NOTE:

Having completed the Pre-Start checks and rectified any anomalies found, the miner can then be started and placed into production.

Pre-Start Procedures listed in the Mines - Remote Control Operations - Continuous Miner - Document – Energy Control and Isolation Management Plan is to be followed.

START UP FUNCTIONS • Check main circuit breaker is on.

• Check handle on inlet water filter handle is in the correct position.

• Check if the receiver box displayed is lit.

Using the radio transmitter outlined in Section 6: • Activate the headlights.

• Ensure all personnel are well clear of miner before starting.

• Audible alarm.

Start the pump motors.

• • Check the operation of the stop switch. Restarting the miner, check that the following functions operated correctly.

Stand well clear of the miner and ensure all personnel are well clear when checking for the following functions: 1.

Cutter head - raise and lower.

2.

Shovel - raise and lower.

3.

Stabiliser - raise and lower.

4.

Conveyor - raise and lower.

5.

Conveyor Swing - right and left.

6.

Traction - forward and reverse (in all three (3) speeds).

7.

Water Sprays - on and off.

8.

TRS raise and lower (if fitted ).

Check the following operations: 1.

Pump - on and off.

2.

Cutter Head - on and off.

3.

Conveyor - on and off 4.

Mining, Maintenance and bolting modes on the manual diversion valve.

• Check that there are no unusual noises or vibrations.

• Check (with pump motor only running) for any oil and/or water leaks around miner.

NOTE: Refer to the Mines – Continuous Miner Remote Control (RC) Transmitter Function Test Report Document.

NOTE: Whilst each of these items should be checked before starting the miner at the beginning of each shift, it is also necessary to maintain a constant awareness of these points each time the miner is restarted in the course of the shift CAUTION:

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Never operate the miner if any picks are missing, blunt or damaged. These must be replaced immediately.

Failure to do so may cause. Damage to cutter drums.

Checking of cutter drums is outlined in “Pre-Start Functions” Section 7.

Providing the items in sections “Pre-Start Functions” and “Start-Up Functions” have been checked positive, the miner is now ready for coal production.

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30MB3 OPERATOR’S MANUAL SECTION 9 OPERATING

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TABLE OF CONTENTS USING 30MB3 MINER .....................................................................................................................................3 Precautions ....................................................................................................................................................3 BOLTING, MINING & MAINTENANCE MODE SELECTOR ......................................................................3 Cutting Cycle .................................................................................................................................................4 Flitting Modes................................................................................................................................................4 Flitting Normal ..............................................................................................................................................4 Water Override Flitting .................................................................................................................................5 MAINTENANCE MODE ..................................................................................................................................5 Hydraulic Oil Power Fill ...............................................................................................................................5 Gear Case Oil Power Fill ..............................................................................................................................6 BOLTING MODE..............................................................................................................................................6

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USING 30MB3 MINER Before starting coal production in a single pass environment, a procedure will have to be in place and all members of the crew must be aware of their tasks and when each member is required to perform the task ensuring the system operates safely and effectively.

Precautions To operate the 30MB3 miners efficiently in this type of coal cutting system a number of items are required to be in place: 1.

Correct power supply to Section.

2.

Correct Colliery ventilation supply.

3.

Ensure water is on machine.

NOTE: Pre-Start Procedures listed in the Mines - Remote Control Operations - Continuous Miner - Document – Energy Control and Isolation Management Plan is to be followed.

BOLTING, MINING & MAINTENANCE MODE SELECTOR Selection of the (3) three different modes able to be selected, is controlled by the hydraulic diversion valve located on the right hand side bolting platform.

The three different modes available are:1.

Mining Mode 2.

Maintenance Mode 3.

Bolting Mode Each mode is selected by operating the diversion valve lever to the required mode. Each mode is monitored by the electrical control system via pressure switches.

There is both electrical and hydraulic isolation interlocking provided on each mode.

Mode Selection Valve

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MINING MODE Cutting Cycle NOTE:

Ensure that the both roof drill rigs and ATRS cylinders are in the parked position. If not, go to Bolting Mode and park both drill rigs and ATRS cylinders and return back to Mining Mode.

NOTE:

The ATRS cylinders must be in the parked position or the machine will shutdown the pump when the mode valve is placed in MINING mode. If the drill rigs are not parked, they could be damaged during the mining cycle.

Select “Mining Mode” on the Mode Selector diversion valve. Mining mode will allow the miner to cut and tram.

Steps for cutting cycle are as per following steps: 1.

Carry out pre start checks 2.

Start pump motors.

3.

Raise conveyor to allow haulage vehicle to move under the conveyor.

4.

Lower apron.

5.

Start gathering head.

6.

Start cutter head. Note: water start auto with cutter start.

7.

Tram miner to coal face, cleaning up coal spillage on the way.

8.

Raise cutter head to roof height.

9.

Tram miner forward 1 metre cutting.

10. Progressively lower cutting head cutting to floor height.

11. Tram miner forward 1 metre cutting.

12. Progressively raise cutter head cutting to roof height.

13. Continue the cycle until the cut has been advanced far enough.

NOTE: The length of the cut will primarily be determined by the roof and rib conditions. Bolt roof and ribs as per Managers rules. Refer to Drill Rig Operators Manual for correct procedures NOTE:

Refer to the Mines - Remote Control Operations Continuous Miner - Document – Energy Control and Isolation Management Plan are to be followed.

Flitting Modes There are (2) two versions of Flitting Modes available on the miner.

1. Flitting Normal – allows for flitting of the miner with full hydraulic functions available to the operator.

2. Water Override Flitting – When activated using the software (enabled or disabled), the machine can be trammed without water with only the pumps operating. If a hydraulic function, except for the brake release solenoid, is operated for more than 10 seconds, the machine will shut down the pump motors. The same applies for any motor start-ups (cutter or conveyor).

Flitting Normal Flitting Normal allows for flitting of the miner with full hydraulic functions available to the operator.

NOTE: Drilling Rigs and the ATRS cylinders on both sides need to be in the parked position before tramming in Flitting Normal is available. If not, go to Bolting Mode and park both drill rigs and return back to Mining Mode.

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NOTE:

1.

2.

3.

4.

5.

6.

7.

Prior to flitting, isolate the cutter and gathering head circuit breakers and tag out as per mine isolation procedures.

Ensure the cutter and gathering head circuit breakers are isolated and tagged out as per mine isolation procedures.

Select “Mining Mode” on the Mode Selector diversion valve.

Remove/fold up rear platforms as well as side platforms if needed.

Ensure all personnel are clear of machine prior to start up.

Once personnel clear, start machine and raise lower head to suit tramming, check conveyor boom, retract cutter barrel extensions and gathering head plows etc prior to flit or bolting operation.

Operate machine to suit conditions - flit machine in slow speed. If flitting on grades up or down - ensure extra distance and time is allowed to stop. Poor floor conditions could cause machine to slip.

Ensure cable handlers and cable is clear and free from possible damage.

Water Override Flitting The flow switches (ITEM 4) in the water schematic are used to monitor water flow through the machine. As per cutter head flow switches, the cutter head will stop if there is no water flowing through there respective flow switches via the cutter motors.

There is also two flow switches monitoring water flow through the TRACTION and PUMP motors.

Both water flow switches are set at 5 litres a minute. The system software can enable or disable the use of the flow switches where required.

When enabled the machine can be trammed without water with only the pumps operating. If a hydraulic function, except for the brake release solenoid, is operated for more than 10 seconds, the machine will stop the pump motors. The same would apply for any motor start-ups (cutter and conveyor).

MAINTENANCE MODE There are (2) two power on operations available in Maintenance Mode on the miner.

1.

Hydraulic Oil Power Fill 2.

Gear Case Oil Power Fill NOTE: Prior to selecting Maintenance Mode, isolate the CUTTER, CONVEYOR & TRACTION circuit breakers and tag out as per mine isolation procedures. Interlocking in the radio system will stop pumps if all three circuit breakers are not isolated.

Hydraulic Oil Power Fill The following procedure is to be followed to carryout hydraulic oil power fill tasks safely: 1. Ensure Cutter, Gathering Head and Traction circuit breakers are isolated and tagged out.

2. Connect oil drum line to the fill hose located on the in bye end of the flameproof Main Control Case enclosure.

3. Open the oil full ball valve which is mounted near the filler hose.

4. Place the Power Fill diversion valve to the Hydraulic Oil position (pull forward) 5. Select “Maintenance Mode” on the Mode Selector diversion valve.

6. Start pumps and leave Power Fill diversion valve in the Hydraulic Oil position until oil runs out of the oil full ball valve.

7. Place Power Fill diversion valve into the neutral position.

8. Close oil full ball valve.

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Gear Case Oil Power Fill The following procedure is to be followed to carryout gear case oil power fill tasks safely:1.

Ensure Cutter, Gathering Head and Traction circuit breakers are isolated and tagged out.

2.

Connect gear oil drum line to the fill hose located on the out bye end of the flameproof Main Control Case enclosure.

3.

Place the Power Fill diversion valve to the Gear Case Oil position (push back) 4.

Select “Maintenance Mode” on the Mode Selector diversion valve.

5.

Start pumps and leave Power Fill diversion valve in the Gear Case Oil position.

6.

Gear case oil should be present at the filler gun.

7.

Place Power Fill diversion valve into the neutral position when finished.

BOLTING MODE NOTE:

When Bolting mode is selected, all hydraulic functions other than those associated with the drill rigs are disabled.

The following procedure should be used to gain access to bolting mode: 1.

Position the miner where bolting is required.

2.

Select “Bolting Mode” on the Mode Selector diversion valve.

3.

Select ATRS mode using diversion valve.

4.

Set the ATRS cylinders to the roof. (If mesh is required, place mesh panels on top of ATRS cylinder pads prior to setting to the roof.

5.

Carry out bolting as required.

6.

Park both side drill rigs and TRS system if fitted, when finished.

7.

Select “Mining Mode” on the Mode Selector diversion valve so that cutting and tram cycle can precede.

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30MB3 OPERATOR’S MANUAL SECTION 10 SHUTDOWN PROCEDURE

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TABLE OF CONTENTS SHUTDOWN FUNCTIONS..............................................................................................................................3 Parking...........................................................................................................................................................3 Shutdown Checks ...........................................................................................................................................3

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SHUTDOWN FUNCTIONS Parking On completion of the shift, the miner should be parked in an area where the following conditions prevail: 1. The roof and rib have been secured.

2. The area is well ventilated.

3. The miner will not be affected by a slow or sudden influx of water.

Shutdown Checks Before shutting the miner down, the following items should be completed: 1. The shovel lowered to the ground and empty.

2. The cutter head lowered to the ground.

3. The conveyor lowered.

4. Ensure the stabiliser is up.

5. Park or close up all drill rigs, TRS systems (if fitted) and associated platforms 6. Stop the pump motors using the off toggle on the transmitter or by using one of the (4) four different points around the miner (if a stop button is used, be sure to reset the stop button when the miner has stopped, that is pull stop buttons out or push lanyard button in to reset).

7. Turn off or remove the water supply to the miner.

8. Any unusual noises or vibrations are to be reported to the section supervisor and/or to maintenance personnel.

9. Any components or part of the miner that has been damaged or partly dislodged during the shift should be reported to the section's supervisor or maintenance personnel.

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30MB3 OPERATOR’S MANUAL SECTION 11 EMERGENCY SHUTDOWN

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TABLE OF CONTENTS EMERGENCY SHUTDOWN – 30MB3 CONTINUOUS MINER ...................................................................3 Transmitter Stops ...........................................................................................................................................3 RIGHT MACHINE EMERGENCY STOP ........................................................................................................3 RIGHT MACHINE EMERGENCY STOP ........................................................................................................4 LEFT MACHINE EMERGENCY STOP...........................................................................................................4 RIGHT SIDE BOLTING PLATFORM MACHINE EMERGENCY STOP ......................................................5 LEFT BOLTING PLATFORM MACHINE EMERGENCY STOP...................................................................5 EMERGENCY PROCEDURES WHILST OPERATING .................................................................................6 Fire Emergency Procedure............................................................................................................................6 Basic Emergency Procedure..........................................................................................................................6 What to Do In The Case of Emergency..........................................................................................................6

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EMERGENCY SHUTDOWN – 30MB3 CONTINUOUS MINER In the event of an emergency, the miner can be shutdown in a number of ways.

1. The electrical power is removed from all drive motors, resulting in all moving parts coming to rest and the tram brakes being applied. a) By toggling the STOP key on the radio transmitter. b) By operating either side rear lanyard machine emergency stops. c) By operating a machine emergency stop switch located on either side bolting platforms. d) By operating the handle of the main circuit breaker to the OFF position. e) By toggling the [SHIFT] key to ON and the STOP key to [PILOT] on the radio transmitter.

This will activate the radio PILOT TRIP function, opening the pilot circuit and will remove power from the miner at the DCB or transformer.

2. Following a 2 second time delay for this function to active, the electrical power is removed from all drive motors resulting in all moving parts coming to rest and the tram brakes being applied. a) By toggling the [SHIFT] key on the radio transmitter to the OFF position for (2) two seconds.

NOTE:

This is not an instantaneous shutdown. There is a 2 second time delay.

Transmitter Stops

Transmitter STOP Key and [PILOT] Key

Transmitter [SHIFT] Key and OFF Key

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RIGHT MACHINE EMERGENCY STOP

Reset Button

Stop Button

Lanyards

LEFT MACHINE EMERGENCY STOP

Reset Button

Stop Button

Lanyards

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RIGHT SIDE BOLTING PLATFORM MACHINE EMERGENCY STOP

Platform Stop

LEFT BOLTING PLATFORM MACHINE EMERGENCY STOP

Platform Stop

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EMERGENCY PROCEDURES WHILST OPERATING Fire Emergency Procedure In the case of fire on or around the miner: 1. Stop all face equipment immediately.

2. Have the power to the face isolated at the D.C.B. 3. If it is safe to do so, retrieve the fire extinguisher from the miner and move to the intake side of the fire zone.

4. If it is not safe, then collect an extinguisher from the nearest location.

5. Attempt to extinguish the fire from the intake side. If unable to extinguish the fire, commence mine fire fighting procedures.

6. If able to extinguish the fire: • Do not attempt to move the miner • Place a “Danger Tag” on the miner and the D.C.B. • Advise the Mining Official and the control room immediately.

NOTE: The miner should be equipped with one (1) dry chemical fire extinguisher with a rating of 80 BE. Always check that it is serviceable as part of the miner’s pre-start checks. Report any deficiencies.

Basic Emergency Procedure The Coal Mining Act defines an “emergency situation” as any set of circumstances occurring at a mine which involves the loss of life, or injury to any person, or a real or apparent immediate danger of the loss of life of or injury to any person and which requires a co-ordinated response.

If a person becomes aware of any situation which requires, or may require, prompt first aid and/or emergency assistance, that person should put into effect the emergency procedure at the mine to report the incident.

What to Do In The Case of Emergency NOTE:

Refer to the mine’s procedures. Do not hang up immediately as you may be required to give further information or receive instructions on dealing with the emergency.

MINIMISE THE USE OF COMMUNICATION SYSTEMS TO LEAVE THE LINES CLEAR FOR EMERGENCY COMMUNICATIONS TRAFFIC.

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30MB3 OPERATOR’S MANUAL SECTION 12 OPERATOR/TRADES SERVICING AND MAINTENANCE

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TABLE OF CONTENTS OPERATOR/TRADESMAN SERVICING AND MAINTENANCE ...............................................................3 TOP VIEW LUBRICATION .............................................................................................................................4 LEFT HAND SIDE LUBRICATION.................................................................................................................5 RIGHT HAND SIDE LUBRICATION..............................................................................................................6 LUBRICATION CHART...................................................................................................................................7 LUBRICATION – GEAR OIL ...........................................................................................................................8 Tram Gear cases ............................................................................................................................................8 Cutter Head Gear Cases ................................................................................................................................9 Cutter Head Input Gear Cases ....................................................................................................................10 Gathering Head (POT) Gear Cases.............................................................................................................11 Gathering Head Input Gear Cases ..............................................................................................................12 Traction Idler Roller ....................................................................................................................................13 GREASING......................................................................................................................................................14 TRAM BRAKES..............................................................................................................................................14 FILTERS ..........................................................................................................................................................14 Left Hand Filters..........................................................................................................................................14 Right Hand Filters .......................................................................................................................................15 CHAIN ADJUSTMENTS ................................................................................................................................16 Crawler Track Chain Adjustment ................................................................................................................16 Conveyor Chain Adjustment ........................................................................................................................17 MAINTENANCE MODE ................................................................................................................................19 Check and Fill Hydraulic Oil Reservoir ......................................................................................................19 Hydraulic Oil Power Fill .............................................................................................................................20 Gear Case Oil Power Fill ............................................................................................................................22 REPAIR OR REPLACE WATER SPRAYS ....................................................................................................22 REPAIR OR REPLACE WATER SPRAYS ....................................................................................................23 MACHINE CUTTING PICKS.........................................................................................................................24

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OPERATOR/TRADESMAN SERVICING AND MAINTENANCE Prior to any work taking place on miner, full isolation is to be done as per Mine’s Remote Control Operations-Continuous Miner and Energy Control and Isolation Management Plan.

The above statement applies to any work on continuous miner including changing picks, sprays or any other work procedure.

WARNING:

October 2008

Full current isolation required as per mine Management Plan Energy Control and isolation.

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TOP VIEW LUBRICATION

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LEFT HAND SIDE LUBRICATION

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RIGHT HAND SIDE LUBRICATION

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LUBRICATION CHART

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LUBRICATION – GEAR OIL All gear cases are filled via an on board gear oil pump mounted on the LH Side WARNING:

Auger gear case and input boxes which are to be done by manual hand pump at lube point, this is a full current isolation activity

Fill via a handgun connected to the gear oil pump. Specifics for each of the gear cases are as follows:

Tram Gear cases Fill Level Check Drain

Via external source - connect fill hose to RH or LH tram case fill hose connection located on top of the outer planetary housing.

Via single sight glass in the final drive output planetary cover. Proper level is when the sight glass is completely full.

To completely drain the tram case, two (2) drain plugs have to be removed: •

½” magnetic drain plug on underneath side of the outer planetary.

•

¾” magnetic drain plug underneath front rear corner of Tram case for the reach gears. This plug is only accessible from underneath the machine.

Oil fill point

Gear Case Sight Glass Level

Gearbox drain plug

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Cutter Head Gear Cases WARNING:

Fill Level Check

Drain

Full current isolation required as per mine Managers Rules.

Via external source remove 1 1/2 “plug located on top of the cutting head banjo sections (L) (R).

Via ½” pipe plug on front side of “banjo” section by core breaker. The RH and LH side of this gear case have separate oil sumps. Thus, there are check plugs for both sides of the gear case. Level is to be checked with the cutting drum resting on the ground from the same filling point.

Ensure to fit auger stops before attempting to drain! Via 1½” magnetic drain plug in bottom of each “banjo” section which the oil is put into.

Main Gear Case Fill Plug

Main Gear Case Level Plugs

Extension Arm Assembly Level Plug

Extension arm assembly fill plug

Main Gear Case Drain Plug

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Cutter Head Input Gear Cases WARNING:

Fill

Level Check

Drain

Full current isolation required as per mine Managers Rules AND ENSURE TO FIT SAFETY SUPPORT PINS IF REQUIRED.

Via external source connect to oil fill point located at top of auger head mounting in the box like section. Remove 3” plug to access a ¾” plug and level dipstick on top of input case.

By removing 3" pipe plug in cutting head gear case at the fill point in the box like section just in front of a “flat back” split line. Proper level is when the dipstick markings indicate that the box is full. Ensure to check these levels with the head resting on the floor. This gear case may overheat if it is overfilled.

Ensure to fit auger stops before attempting to drain! First, a 3” pipe plug must be removed from the under side of the box like section of the cutting head gear case just in front of the “flat back” split line. This will expose the ½” magnetic drain plug in the bottom of the cutting head input case.

Input Gear Cases Fill Point

Input Gear Case Level Point via Internal Dipstick

Input Gear Case Drain Points RH & LH

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Helensburgh 30MB3 Operator’s Manual

Gathering Head (POT) Gear Cases Fill

Connect external source to CLA gear case fill point located on WITHIN THE SHOVEL. (See below).

Via ¾” pipe plug protruding from the tee piece that holds the gear box breather. This is also mounted on the same manifold block as indicated below. The best way to ensure that this gear case is at the proper oil level is to do the following:

Level Check

•

make sure gathering blade is resting on the ground

•

remove ¾ ” plug

• lubricate until oil runs out of level check hole Due to the pot-like shape of this gear case, three (3) drain plugs have to be removed in order to completely drain it. The drain plugs are only accessible from underneath the gathering head.

Drain

Gear Case Drain Plugs

Gear Case Level, Fill and Breather Ports

NOTE:

October 2008

RH side manifold shown.

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Helensburgh 30MB3 Operator’s Manual

Gathering Head Input Gear Cases Fill

Connecting external source to a lube line fitting located at the top of manifold block mounted at the rear of the roof bolting shield. (See below)

Level Check

Via ¾” pipe plug protruding from the tee piece that holds the gear box breather. This is also mounted on the same manifold block as indicated below. The best way to ensure that this gear case is at the proper oil level is to do the following:

Drain

•

make sure gathering blade is resting on the ground

•

remove ¾ ” plug

•

Lubricate until oil runs out of level check hole.

Via 1½” magnetic drain plug on the under side of the gear case, this plug is only accessible by doing the following: •

raise gathering head to it’s full height

•

Use suitable packing to support the gathering head structure.

•

Crawl underneath gathering head frame.

Gear Case Drain Plug

Input Gear Case Fill, Level and Breather Plug

NOTE:

Manual No.M01273

LH side manifold shown.

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Helensburgh 30MB3 Operator’s Manual

Traction Idler Roller Fill Level Check Drain

Position Idler Roller so that the ½” plugs are between 2 o’clock or 4 o’clock. Remove both plugs and fill with external source.

Oil level is achieved when it runs out either hole.

Position ½” plugs at 12 o’clock and 6 o’clock and remove plugs to Drain roller.

½” Drain and Level Plugs

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Helensburgh 30MB3 Operator’s Manual

GREASING As per the Lubrication Chart page 7.

TRAM BRAKES The brakes are spring applied and hydraulically released. The units are hydraulically flushed back to tank through filtration mounted on the LH side above traction unit.

FILTERS

Brake Circuit Flushing Filter

Left Hand Filters

LH Tank Breather

Pressure Filter Hydraulic Return Filter

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Helensburgh 30MB3 Operator’s Manual

Right Hand Filters

Return Filter

Pressure Filter

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Helensburgh 30MB3 Operator’s Manual

CHAIN ADJUSTMENTS Crawler Track Chain Adjustment WARNING:

Full current isolation required as per mine Managers Rules after machine is set off the ground.

To adjust the crawler track chain tension: Raise the auger head off the floor and in turn raise the gathering head from the floor. Following these steps lower the stab jack to the floor and allow the rear of machine to lift. Once rear is lifted, float the gathering head to the floor and lower auger head into the floor until the entire machine chassis is raised from floor. Isolate the machine. Apply grease pressure to the take-up assembly and tighten the track chain until there is between 1½ and 3 inches (38 & 75mm). Install the shims required to retain the take-up roller in that position. Once shims are in place relieve the grease pressure in the take-up by releasing the 9/16” JIC cap to the side of the take up nipple manifold.

Grease take-up relieving JIC cap

Grease take-up nipple

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Helensburgh 30MB3 Operator’s Manual

Conveyor Chain Adjustment The correct tension/pressure must be kept on the conveyor chain. The conveyor chain is tensioned hydraulically by two single acting cylinders mounted inside the discharge section of the conveyor. The cylinder circuit is auto adjusting with system pressure, when the machine pump is turned on and is set at 20 Bar (See Hydraulic Schematic). Periodic checks during servicing are required to ensure correct chain tension and pressure. The pressure gauge for this can be found on the right hand side of the machine.

With the right side pump running raise the stabilizing cylinder.

CAUTION: A chain too tight will ride the side of the conveyor pan and may break when loaded. A chain too loose will cause more wear and damage to the conveyor frame, or jam in the foot shaft area.

With the stabilizer fully retracted and pressure still on the stab raise check pressure gauge. Pressure gauge should read 300psi – 20bar.

Release pressure to stabilizer cylinder and check pressure gauge. Pressure should still read 300psi – 20 bar.

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Helensburgh 30MB3 Operator’s Manual

Tail roller

Manual No.M01273

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MAINTENANCE MODE There are (2) two power on operations available in Maintenance Mode on the miner.

1 Hydraulic Oil Power Fill 2 Gear Case Oil Power Fill NOTE:

If running, stop pumps prior to either of the power fill mode procedures.

NOTE:

Prior to selecting Maintenance Mode, isolate the CUTTER, GATHERING HEAD & TRACTION circuit breakers and tag out as per mine isolation procedures.

Interlocking in the radio system will stop pumps if all three circuit breakers are not in the off position.

Check and Fill Hydraulic Oil Reservoir The Hydraulic Reservoir upon the 30MB3 Miner contains 750 litres of 68 grade oil with the tank full.

System capacity is 1000 Litres. Procedures for checking levels and filling are as follows: Low levels can be known in two ways. Either by a low oil level siren (and message on screen) or cutter head motors are disabled.

Oil level checks can be done via the sight glass manifolds mounted beside the traction gear cases as shown below. Right Hand side shown only. The oil level should be higher than the bottom sight glass and lower than the top sight glass.

Hydraulic oil level sight glasses

If oil levels are deemed to be low, source Hydraulic 68 grade oil and place at the left hand side of the machine, in bye of the electrical panel. Here there is the Hydraulic oil fill hose and a ball valve for visual oil fills requirements whilst filling only. See filling procedure below.

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Helensburgh 30MB3 Operator’s Manual

Hydraulic Oil Power Fill The following procedure is to be followed to carryout hydraulic oil power fill tasks safely:1 Ensure Cutter, Gathering Head and Traction circuit breakers are isolated as per mines procedures.

2 Place selector valve handle in maintenance mode (lever in centre position).

3 Start machine.

NOTE:

4 5 6

Pump Motor will turn off if the Circuit breakers mentioned in point 1 are not open or in the off position.

Remove ¾” JIC cap from fill hose located forward of the left side main electrical control case and place in hydraulic oil drum.

Open ball valve located forward of the electrical control case.

Position oil fill valve into hydraulic oil fill.

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Helensburgh 30MB3 Operator’s Manual

Full the hydraulic tank until oil flows from the ball valve.

NOTE:

A continual flow is required as the line to the ball valve may have some residual oil left from past filling.

Hydraulic power fills oil level ball valve in closed position.

7 8

When full place hydraulic full valve handle into neutral (centre) position.

Close oil level ball valve.

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Helensburgh 30MB3 Operator’s Manual

Gear Case Oil Power Fill The following procedure is to be followed to carryout gear case oil power fill tasks safely:1 Ensure Cutter, Gathering Head and Traction circuit breakers are in the off position and isolated as per mines procedures.

2 Place selector valve in maintenance mode.

3 Start machine.

NOTE:

4 5 6 7

Pump motor will turn off if the 3 circuit breakers as described in point 1 is not in the off/open position.

Remove ¾” JIC cap from suction hose located rear side of main electrical enclosure on left side of machine. Place in drum 460 gear oil Position oil fill valve into gear oil fill.

Using lube gun top up gear cases as required.

Place Power Fill handles in neutral position when finished.

Power fills pump/motor assembly

Hydraulic and Gear Oil fill diversion valve

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Helensburgh 30MB3 Operator’s Manual

REPAIR OR REPLACE WATER SPRAYS The water system on the miner provides for water cooling of electric motors and dust suppression during normal machine operations. The water used during normal machine operations, dust control, is firstly passed through the motor water jackets and second to the water sprays. The water spray circuit has been fitted with two 3 – way ball valves which are for changing the direction of the sprays as required by the mine. (Refer to water schematic).

Place the head in the horizontal plane with the shovel on the floor and conveyor boom down.

Open cutter circuit breaker on the main panel.

WARNING:

Full current isolation required as per mine Management plan – Energy Control and Isolation.

NOTE:

Refer to the Mine’s Remote Control Operations Continuous Miner and Remote Control Operations – Continuous Miner.

Turn the water by-pass valve (located above reverse flush filter) on and walk around the machine checking for correct spray operation.

Turn water off once blocked sprays are located and lock out the ball valve with locking device fitted to handle.

Remove any spray not working correctly, then dismantle, clean and replace.

The miner is fitted with a bag type water filter that is located in the driver’s compartment.

Water flow meters

By pass ball valve

Reverse Flush Filter

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Helensburgh 30MB3 Operator’s Manual

MACHINE CUTTING PICKS The cutting head on the 30MB3 Miner plays an integral part in the machines performance and its targets. It is highly important that the cutting picks are inspected during and before each shift and replaced as required. Procedure is as follows: 1 Place the head in the horizontal plane upon the manufactured head stops with the shovel on the floor and conveyor boom down.

2 Open cutter circuit breaker on the main panel.

3

WARNING:

Full current isolation required as per mine Managers Rules.

NOTE:

Refer to the Mine’s - Remote Control Operations Continuous Miner - Document – Energy Control and Isolation Management Plan are to be followed.

Replace picks as required and report and cracks or missing blocks immediately.

Cutter Head Picks

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30MB3 OPERATOR’S MANUAL SECTION 13 TROUBLESHOOTING

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Helensburgh 30MB3 Operator’s Manual

TABLE OF CONTENTS TROUBLESHOOTING .....................................................................................................................................3 Pumps.............................................................................................................................................................3 Traction..........................................................................................................................................................3 Cutters............................................................................................................................................................4 Conveyor ........................................................................................................................................................4 Event Monitor ................................................................................................................................................5 Fault Log inside Event Monitor .....................................................................................................................6 MAIN CONTROL CASE INDICATORS..........................................................................................................7 WATER TROUBLESHOOTING GUIDE .........................................................................................................8

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TROUBLESHOOTING Pumps There are a number of safety and machine protection interlocks that will stop the machine pumps or prevent it from starting: •

Transmitter must be logged on

•

Machine Emergency Stop or Lanyard is operated

•

Electronic Module fault

•

Lost radio signal

•

Left or Right pump overload (4 min.reset)

•

Left or Right over-temperature (RTD) fault

•

Incorrect Transmitter frequency

•

In “Maintenance Mode”, either of the (3) circuit breakers not open

•

Incorrect Combination of mode pressure switches.

NOTE: Turning off power to the miner or control circuits will not reset the 4 minute overload reset timers. If power is removed during an overload reset time period, the reset timer will restart at the time remaining when power was removed.

Traction There are a number of safety and machine protection interlocks that prevent tramming.

•

Pumps - these have to be running.

•

Earth leakage detected in traction circuit.

•

Traction transformer over-temperature (RTD) has tripped.

•

Either left or right traction motors have overloaded (Reset time is 4 minutes).

•

A shutdown in SCR traction drives electronics.

•

Deadman pressure - the brake solenoid has not operated or the pressure switch is closed. This has to be energised to allow tramming.

•

Traction circuit breakers tripped.

• Traction transformer Overload trip. (Reset time is 4 minutes).

If any of these conditions are not satisfied, a corresponding message will be displayed.

Note: Turning off power to the miner or control circuits will not reset the 4 minute overload reset timers. If power is removed during an overload reset time period, the reset timer will restart at the time remaining when power was removed.

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Helensburgh 30MB3 Operator’s Manual

Cutters There are a number of safety and machine protection interlocks that prevent the cutters from being started, or stop them if they are already operating: •

Pumps - these have to be running.

•

Either left or right cutter motor has overloaded (i.e. the motor current is too high). Reset time is 4 minutes.

•

Either left or right cutter motor over-temperature (RTD) has tripped.

•

Water spray for cutter head has failed (low flow) or has been turned off.

•

Tramming SPEED 2 or SPEED 3 has been selected whilst in reverse.

•

Low oil level

•

High oil temperature.

•

Variation above 50% between current of each cutter motor.

•

The machine has to be in mining mode.

Note: Turning off power to the miner or control circuits will not reset the 4 minute overload reset timers. If power is removed during an overload reset time period, the reset timer will restart at the time remaining when power was removed.

Conveyor There are a number of safety and machine protection interlocks that prevent the conveyor from being started, or stop it when it has already been started.

•

Pumps - these have to be running.

•

Gathering Heads reverse has to be stopped, to start the gathering heads in forward.

•

Gathering Heads forward has to be stopped, to start the gathering heads in reverse.

•

Either left or right gathering head motor is overloaded (i.e. the motor current is too high).

•

Either left or right gathering head motor over-temperature (RTD) has tripped.

•

Variation of 50% in motor currents.

•

The machine has to be in Mining mode.

NOTE: Turning off power to the miner or control circuits will not reset the 4 minute overload reset timers. If power is removed during an overload reset time period, the reset timer will restart at the time remaining when power was removed.

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FAULT LOG

The Fault Log is accessed from the Main Menu by highlighting the Fault Log option and pressing [SHIFT] and [MENU]. To exit the Fault Log operate [SHIFT] and [REMOTE] • Event logging of current and previous fault history up to 100 events, at which time the oldest log will then be dropped off replaced with most current event.

• Indicates the number of events logged at the bottom of the screen.

• Current or uncleared faults are shown in red and have flashing warning triangle.

• Indicates time and date event occurred and time and date event was cleared.

• To erase Fault Log you need to be at the Engineers or OEM Password Level

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Helensburgh 30MB3 Operator’s Manual

Fault Explanation

The fault explanation pictured above can be accessed from the fault log by highlighting the event you want explained using CONV DWN. Operate [SHIFT] and [MENU] to bring the above screen up which is the fault guide.

To return back to the Event Log press [SHIFT] and [REMOTE]

Manual No.M01273

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MAIN CONTROL CASE INDICATORS A panel of LEDs are visible through the viewing window in the Main Control Case. The LEDs indicate the following:1. 110V Control – (Green – healthy) Control supply is ON 2. Radio 24V – (Amber – healthy) 24V supply to Radio system is ON 3. E/Stops Healthy – (Green – healthy) Machine Emergency Stops are all out 4. Traction E/L Trip – (Red – Tripped) this will appear on power up, after a Traction E/L Test or if there is an earth fault on the traction circuit.

5. Pendant Mode – (Green – on) Indicates that pendant mode is selected. Radio is not able to be used in this mode.

6. Pump Overload – (Red – Tripped) Indicates that the manual pump overload had tripped. This will only operated when pendant mode is selected.

7. 12V Lights – (Green – on) Indicates lights are on.

8. Lights E/L Trip – (Red – Tripped) this will appear when there is an earth leakage in the lighting circuit.

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Helensburgh 30MB3 Operator’s Manual

WATER TROUBLESHOOTING GUIDE PROBLEM: Lack of water reaching miner - water sprays Water Troubleshooting chart for Drill Rigs in Drill Rig section.

WATER ISISWATER FROM REEL CONNECTED TO CONNECTED TO MINER? MINER?

CONNECT HOSE AND OPEN WATER VALVE

NO

YES NO

WATER ISISWATER PRESSURE

NO

PRESSURE AT SUPPLY SOURCE AT HOSE REEL

CORRECT WATER PRESSURE AT MINER? 100 PSI MINIMUM.

MECHANICAL SKILLS REQUIRED

YES

NO

ISISWATERFLOW PASSING WATER FLOW THROUGH BAG PASSINGINLET THROUGH LTER.CHECK FLOW AT FIINLET FILTER? FLOW AT ASHDOWN HOSES? WCHECK

NO

REPLACE FILTER BAG CLEAN FILTER

MECHANICAL SKILLS REQUIRED

WASH DOWN HOSES

YES

IS WATER PASSING THROUGH PILOT OPERATED WATER VALVES?

NO

REFER HYDRAULIC SHEET

YES

ARE MINER WATER SPRAYS OPERATING

Manual No.M01273

NO

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MECHANICAL SKILLS REQUIRED

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BI643666

30MB3 OPERATOR’S MANUAL SECTION 14 ROOF & RIB BOLTING EQUIPMENT