CAT Bucyrus Continuous Miner 25M1AC Operation Manual A6474X307 - PDF DOWNLOAD (1)

Operation Manual Bucyrus - Continuous Miner Model - 25M1AC Doc. No.: A6474X307

Bucyrus America, Inc. ________________________________________ 2045 West Pike Street Houston, PA 15342

Telephone: 724-743-1200 Fax: 724-743-1201

Internet: www.bucyrus.com

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This manual is intended to provide GENERAL product information for the Model 25M1AC Continuous Miner. The illustrations, descriptions and procedures contained in this publication apply only to THIS machine. Bucyrus America, Inc. reserves the right to revise models and designs without prior notice.

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

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

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

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

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

© BUCYRUS AMERICA, INC.

ALL RIGHTS RESERVED

_________________________________________________Table of contents

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

2. Your safety

© BUCYRUS AMERICA, INC.

Your safety............................................................................... 2.3 Personnel ............................................................................. 2.4 Operation......................................................................... 2.4 Installation and repair ...................................................... 2.4 Operating conditions ............................................................ 2.5 Intended use.................................................................... 2.5 Unauthorized use ............................................................ 2.5 Safety instructions ................................................................ 2.6 General rules:.................................................................. 2.6 Storage and transport...................................................... 2.7 Pre-start inspection ......................................................... 2.7 Installation and start-up ................................................... 2.8 Operation......................................................................... 2.8 Stopping ........................................................................ 2.9 Maintenance and repair................................................. 2.10

3. Storage and transport Storage and transport............................................................. 3.3 Storage................................................................................. 3.3 Storage of the machine and spare parts ......................... 3.3 Long-term storage of spare components ........................ 3.4 Transport .............................................................................. 3.5 Load units: dimensions and weights ............................... 3.5 Transport environment .................................................... 3.6

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

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Table of contents _________________________________________________

Operation ................................................................................. 5.3 How to operate the Continuous Miner.................................. 5.3 Who is allowed to operate the Continuous Miner............ 5.3 When can operation be started? ..................................... 5.3 Controls and indicators......................................................... 5.4 Machine control system........................................................ 5.17 Red zone ............................................................................ 5.26 Safety precautions for underground operation................... 5.31 Tramming safety rules........................................................ 5.31 Starting procedure.............................................................. 5.32 Shutdown procedure .......................................................... 5.34 Tramming the miner ........................................................... 5.35 Cutter head operation......................................................... 5.37 Conveyor operation ............................................................ 5.39 Scrubber motor operation .................................................. 5.39 Area and headlight operation ............................................. 5.39 Fire suppression in radio remote operation ....................... 5.40 Conveyor raise/lower/left/right in radio remote operation .. 5.40 Stabilizer cylinder raise/lower in radio remote operation ... 5.41 Shear up/down in radio remote operation .......................... 5.41 Gathering head raise/float in radio remote operation......... 5.41 Breaker on/off in radio remote operation ........................... 5.42 Mechanical assemblies ...................................................... 5.43 Hydraulic system ................................................................ 5.49 Water system ..................................................................... 5.81 Electrical system ................................................................ 5.91 Instructions on the maintenance .......................................5.125 Important notes ............................................................5.125 Before maintenance .....................................................5.125 Torque values...............................................................5.126 Lubricants, fluids and capacities ..................................5.127 Specific lubrication and maintenance instructions ............5.128 Every shift.....................................................................5.131 Every third shift (daily) ..................................................5.133 Weekly..........................................................................5.138 Monthly .........................................................................5.141 Every three months ......................................................5.148 Every six months ..........................................................5.151 Adjustment procedures .....................................................5.153 Setting hydraulic pressures...........................................5.153 Load holding valve .......................................................5.154 Pilot pump circuit relief .................................................5.155 Main control valve ........................................................5.156 Port relief ......................................................................5.158 Tram track ....................................................................5.160 Tail shim .......................................................................5.165 Chain tension ...............................................................5.167 Hydraulic ..............................................................5.167

________________________________________________________________ Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

5. Operation

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© BUCYRUS AMERICA, INC.

Instructions on replacement of wear parts ........................5.168 Cutter head (boom) assembly......................................5.168 Boom pivot pin..............................................................5.172 Shear cylinder ..............................................................5.177 Center cutter drum .......................................................5.182 End cutter drum ............................................................5.186 Drum drive motor..........................................................5.188 Drum drive gear case ...................................................5.193 Gathering head assembly ............................................5.195 Gathering head drive motor .........................................5.201 Gathering head gear case............................................5.206 Gathering head foot shaft.............................................5.212 Gathering head lift cylinder...........................................5.215 CLA...............................................................................5.218 CLA tip replacement.....................................................5.221 Tram motor ...................................................................5.222 Tram primary planetary gear ........................................5.227 Tram secondary planetary gear ...................................5.230 Tram case ....................................................................5.235 Tram reach gear set .....................................................5.240 Tram sprocket ..............................................................5.248 Tram track front idler ....................................................5.255 Front idler take-up cylinder...........................................5.259 Hydraulic pump ............................................................5.261 Hydraulic pump motor ..................................................5.264 Scrubber fan/motor.......................................................5.267 Stabilizer cylinder .........................................................5.270 Swivel pin assembly .....................................................5.273 Tail roller.......................................................................5.275 Conveyor chain replacement .......................................5.277 Troubleshooting procedures.........................................5.278 Typical hydraulic problems...........................................5.279 Contaminants in hydraulic systems..............................5.280 Specific hydraulic circuits .............................................5.281 Multi-function failure .............................................5.281 Oil tank fill.............................................................5.282 Cutter head raise..................................................5.282 Cutter head lower .................................................5.282 Gathering head raise............................................5.283 Gathering head float.............................................5.283 Conveyor raise .....................................................5.283 Conveyor lower ....................................................5.284 Conveyor swing....................................................5.284 Stabilizer raise......................................................5.284 Stabilizer lower .....................................................5.284

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Table of contents _________________________________________________ General safety procedure for shutdown ...................... 5.285 Excessive noise ........................................................... 5.286 Excessive heat............................................................. 5.287 Incorrect flow ............................................................... 5.288 Incorrect pressure........................................................ 5.289 Faulty operation ........................................................... 5.290 Restarting checklist...................................................... 5.291 Water system ............................................................... 5.292 Bearings....................................................................... 5.294 Electrical system .......................................................... 5.295

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

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

________________________________________________________________ Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

7. For your information

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1

About this manual

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________________________________________Before starting to work

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

Before starting to work applicable operating manual machine type

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

This operating manual is intended for: Bucyrus Model 25M1 Continuous Miner Serial No.: N/A and is only permitted to be used for equipment of this type.

© BUCYRUS AMERICA, INC.

new operation manual

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

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

Who is this operating manual intended for?

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

This includes persons who: ■

are in charge of transport

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perform assembly / disassembly work

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operate the machine

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eliminate faults

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perform daily routine work on the face or in the entry

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perform maintenance work

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perform repair work

supervisory personnel who: ■

initiate and/or supervise the activities just indicated.

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

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

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

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

safety

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

© BUCYRUS AMERICA, INC.

service

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

Try to memorize the symbols and their meanings.

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

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

© BUCYRUS AMERICA, INC.

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

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

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

■

Items in lists are marked with bullets.

–

Points in sub-lists are marked with a long dash at the start of the line.

 Points in text marked in this way describe individual operations.

Follow these instructions step by step. They will help you carry out your work faster and more importantly, safer.

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© BUCYRUS AMERICA, INC.

Before starting to work ________________________________________

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2

Your safety

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___________________________________________________Personnel

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

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

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

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

© BUCYRUS AMERICA, INC.

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

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

Observe the safety and accident prevention regulations

further operating manuals

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of the mine,

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of the mine inspector, and

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of the mining supervisory authorities.

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

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Personnel ___________________________________________________ Personnel Operation training

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

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

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

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mechanics,

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hydraulics, and

■

control engineering

and must be able to prove this knowledge.

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

Installation and repair work on: ■

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

■

the electrics (motors, controllers, etc.)

■

the hydraulics (controls, cylinders, etc.)

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

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© BUCYRUS AMERICA, INC.

You must have adequate knowledge of the

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

Intended uses include: ■

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

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

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operation on grades of less than 10 degrees

© BUCYRUS AMERICA, INC.

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

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the transport of persons

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stone development or extraction

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

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Safety instructions ____________________________________________ Safety instructions General rules: general

Always work with full concentration.

Familiarize yourself with your working environment.

noise emissions

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

safety equipment

■

your exact location,

■

the work you are performing, and

■

the time that you will probably require.

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

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

symbol plates emergency stop

lock-out and tag-out

cordon off working area moving parts

Observe the symbol plates on the machine.

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

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

maintenance work

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inspection work

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repair work

Cordon off your working area widely for the machine.

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

chains, flights, and chain sprockets

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pivot points

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cutter head and loading head

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crawler assemblies and conveyors

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cutter and gathering head assemblies

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© BUCYRUS AMERICA, INC.

Inform your colleagues of

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

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

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

Ensure that the transport safety devices are correctly fitted.

Fix all moving parts with transport locks.

Never stand under unsupported parts or suspended loads.

© BUCYRUS AMERICA, INC.

means of attachment

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

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

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

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

mobile handling equipment

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

Pre-start inspection operation

Read this entire manual before attempting to operate this machine.

inspection

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

maintenance instruction and safety tags operator’s compartment (optional) cab/canopy (optional)

Verify that all maintenance has been performed.

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

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

Clean any foreign material from the operator’s compartment.

This machine may be shipped from the factory equipped with a protective cab/canopy. The cab/canopy must be securely in place before operating the unit.

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Safety instructions ____________________________________________ Installation and start-up inclined face

environmental acceptability

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

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

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

controls

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

starting procedures

Follow the starting procedure instructions in the operations manual.

red zone

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

training

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

before start-up

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

protective devices

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

operator’s compartment (optional)

Clean the operator’s compartment at regular intervals. Ensure that the operating symbols are legible in order to avoid any operator errors and resulting accidents.

Never climb onto, or climb out of the machine while it is in motion.

Do not operate the machine with any part of your body outside of the operator’s compartment in order to prevent body parts from being crushed between the machine and outside objects .

traveling

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

passengers

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

safety rules

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

problems and malfunctions

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

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© BUCYRUS AMERICA, INC.

Operation

___________________________________________ Safety instructions Stopping operator’s compartment (optional)

Do not leave the operator’s compartment with the unit running. Always properly shutdown the unit before leaving the operator’s compartment.

parking

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

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

radio

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

© BUCYRUS AMERICA, INC.

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

Inform the supervisory personnel and the face crew of any maintenance and repair operations. Give them information on the intended operations and the anticipated duration.

trailing cable uncoupled and locked-out

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

Follow all applicable regulations regarding lockout/tagout.

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

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

Protect your work area against falling rocks.

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

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

original parts

Use only spare parts which satisfy the specified technical requirements.

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

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

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

methane monitoring

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Safety instructions ____________________________________________ lifting

handling of hydraulic fluids

For raising the Continuous Miner use only: ■

crib blocks with adequate load-holding capacity.

■

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

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

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

maintenance, repair

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

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

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

Always replace damaged or lost decals and metal instruction plates.

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

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

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

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© BUCYRUS AMERICA, INC.

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

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

© BUCYRUS AMERICA, INC.

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

the hoses are not pinched or trapped.

■

the hoses have no bubbles or blisters.

■

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

■

the outer sheath of the hoses is not damaged.

■

the connectors are securely inserted into the sockets.

■

the connections are leak-tight.

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

Flush out the hydraulic lines thoroughly before connecting. permissible hoses

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

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

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

Use only hydraulic hoses approved for the prevailing pressures.

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

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

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

Never try to repair damaged hydraulic hoses.

Replace hydraulic hoses at the first suspicion of damage.

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Safety instructions ____________________________________________ installing hydraulic hoses

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

Always install hydraulic hoses so they: ■

always have a little slack.

Fig. 1: Installing hydraulic hoses, slack Right

■

Wrong

are not twisted.

Right

■

Wrong

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

Fig. 3: Installing hydraulic hoses, bending Right

Wrong

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© BUCYRUS AMERICA, INC.

Fig. 2: Installing hydraulic hoses, twisting

___________________________________________ Safety instructions ■

always have a little slack.

■

are not kinked.

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do not have to withstand tensile strains.

■

are protected against thermal radiation.

■

are accessible at all times.

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

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

© BUCYRUS AMERICA, INC.

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

torn out,

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kinked,

■

crushed,

■

driven over or

■

twisted by movement of the machine.

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

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© BUCYRUS AMERICA, INC.

Safety instructions ____________________________________________

________________________________________________________________ 2.14 Bucyrus – Model 25M1AC Continuous Miner

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3

Storage and transport

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________________________________________ Storage and transport

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

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

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

Storage corrosion protection

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

© BUCYRUS AMERICA, INC.

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

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

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

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

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

short-term storage

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

long-term storage

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

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

■ Completely fill the hydraulic oil tank with oil.

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

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

■ Completely drain the water system and refill with a 50/50 antifreeze/water solution. Pump the antifreeze mix through the system until the antifreeze mix comes out the water sprays. ENSURE THAT THE SYSTEM IS COMPLETELY PURGED AND NO WATER OR AIR POCKETS EXIST. ■ The equipment must be stored in a well ventilated, dry room. Do not store outdoors. ______________________________________________________________ A6474X307

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3.3

Storage and transport _________________________________________ machine electrical components

Forced Potato electronic components have the following storage requirements: ■ ■ ■

traction drives

Graphic displays must be stored at temperatures above 14 °F (-10 °C) Power supplies (part number 295275) must be stored at temperatures above -3 °F (-20 °C) Other components must be stored at temperatures above -13 °F (-25 °C)

The traction drives should be stored at -10 to 50 °C (14 to 122 °F).

random sample inspection

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

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

natural aging

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

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

Long-term storage of spare components hydraulic components

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

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

miscellaneous components

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

fan assembly

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

plastic deformation

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

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© BUCYRUS AMERICA, INC.

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

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

dimensions,

■

weights,

■

lifting points, etc.

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

© BUCYRUS AMERICA, INC.

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

Use only suitable load handling devices.

Table 1: Lifting weights of Continuous Miner Assemblies

removal and installation of heavy components

Description

Approximate Weight

Complete Machine

120,000 lbs.

Tractor Frame Assembly

45,000 lbs.

Gathering Head Assembly

20,000 lbs.

Conveyor Assembly

15,000 lbs.

Cutter Head Assembly

40,000 lbs.

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

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

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

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

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

______________________________________________________________ A6474X307 VASS/0 3.5

Storage and transport _________________________________________ Transport environment temperatures below freezing

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

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

electronic components

Electrical and electronic components must be protected against harmful environmental influences by a suitable packaging. The electrical cables remain in the equipment. They must be carefully protected against transport damage and soiling of the connections.

________________________________________________________________ 3.6 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

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

_______________________________________________________________

4

Installation

________________________________________________________________

_______________________________________________________________

________________________________________________________________

__________________________________________________ Installation

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

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

© BUCYRUS AMERICA, INC.

Work on: ■

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

■

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

■

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

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

Which tools are required for installation? tool box

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

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

These include: ■

hoists with adequate lifting capacity

■

means of attachment with adequate lifting capacity

■

unloading dock and crib blocks

■

jacks with adequate lifting capacity

■

950V to attach temporarily to SHD-G 2/0 shielded cable

______________________________________________________________ A6474X307 SUSV/00 4.3

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

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

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

reassembly instructions

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

________________________________________________________________ 4.4 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

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

__________________________________________________ Installation Pre-installation check list

© BUCYRUS AMERICA, INC.

NOTICE! The machine was inspected prior to shipment from the factory to ensure proper functioning and installation of all components.

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

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

■

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

■

check the full length of the trailing cable for damage

■

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

■

clean any foreign material from the optional operator’s compartment, conveyor, and gathering pan

■

start up the machine and check for correct operation of all stop switches.

■

perform daily maintenance

■

visually inspect all hydraulic hoses and electrical cables for damage

■

check safety provisions for operational condition on fire suppression system

■

start up the machine and check for correct operation of E-stop and machine stop buttons

■

check that all covers and guards are in place and secure

■

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

■

check that operator’s canopy (optional) is secure and in place

■

start the machine and allow the hydraulic system to warm up for five (5) to ten (10) minutes

■

check hydraulic system pressures (refer to the hydraulic schematic supplied for your particular machine for pressure settings)

■

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

■

check the tension of the conveyor chain and crawler chain

______________________________________________________________ A6474X307 SUSV/00 4.5

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

machine stop button

The machine is equipped with a machine stop button located on the offside . The machine stop button (s) are used to break the control circuit only in emergency situations, stopping all motors. Striking with a small amount of force will actuate the machine stop button.

canopy/cab (optional)

The machine may be shipped from the factory with a protective canopy/ cab (optional). Ensure that the canopy/cab is in place and secure at all times to protect the operator from falling debris.

fire suppression

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

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

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

fire sprays

Water can be directed to the fire spray nozzles manually from the fire spray valve above the switch box in the operator's compartment or by the fire spray valve on the left hand side of the machine.

On radio units, an electronically actuated solenoid is used to actuate the fire spray system from the remote position.

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

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

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

________________________________________________________________ 4.6 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

Safety features include: (Reference Fig. 5)

__________________________________________________ Installation scrubber/dust suppression (optional)

© BUCYRUS AMERICA, INC.

guards and covers

The Continuous Miner may be equipped with an optional dust suppression package (scrubber). The dust suppressor allows the Miner operator to use fan induced ventilation at the face. The fan suction draws in the dust and liberated methane from the intake duct(s). The dust laden air is then drawn through the scrubber screen, which is constantly flooded with water spray. The dirty water is then removed from the air stream by a de-mister which is located directly behind the scrubber screen. The dirty water flows down to a sump tank where a water powered jet pump empties the sump and dumps the dirty water onto the conveyor or gathering pan. The clean, dry air exits the de-mister and is discharged into the mine atmosphere at the rear of the miner, diffused downward and towards the rib to prevent coal fines from being blown on the offside shuttle car operator.

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

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

cutter boom safety supports (optional)

There are two cutter boom safety supports, one on each side of the cutter boom. The supports are used to block up the cutter boom during maintenance operations.

conveyor safety supports (optional)

There are two conveyor safety supports, one on each side of the conveyor. The supports are used to block up the conveyor during maintenance operations.

start switch safety covers

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

methane monitor

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

______________________________________________________________ A6474X307 SUSV/00 4.7

Installation___________________________________________________ Fig. 5: Safety features on the Continuous Miner

Machine stop (location typical)

Panic bar/ machine stop Methane monitor display

Radio Antenna

Manual circuit breaker reset (optional)

________________________________________________________________ 4.8 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

Methane sniffer (location typical)

__________________________________________________ Installation Fig. 6: Overview of the Continuous Miner Conveyor boom

Scrubber intake

Cutter boom

Operator’s station Tram case

Gathering head assembly

© BUCYRUS AMERICA, INC.

Crawler assembly

______________________________________________________________ A6474X307 SUSV/00 4.9

© BUCYRUS AMERICA, INC.

__________________________________________________ Installation

______________________________________________________________ A6474X307 SUSV/00 4.10

_______________________________________________________________

5

Operation

________________________________________________________________

___________________________________________________ Operation

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

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

How to operate the Continuous Miner

© BUCYRUS AMERICA, INC.

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

Who is allowed to operate the Continuous Miner?

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

This also includes: ■

what safety devices are installed on the machine.

■

where these safety devices are located.

■

how these safety devices are to be operated.

When can operation be started?

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

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

______________________________________________________________ A6474X307 VASS/0 5.2

Operation____________________________________________________ Controls and indicators The 25M1 continuous miner is operated through the use of a radio remote transmitter.

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

The right side machine stop (panic bar), pump start, control breaker reset buttons, manual/remote selector switch, light switch and hour meters are located on the case. Two (2) manual circuit breaker reset levers are located at the front bottom of the case: one is for breaker “CB1” and the other is for breaker “CB2”. The hydraulic reset option allows for the breakers to be reset from the transmitter or manual reset lever.

Panic bar

Control breakers

Pump start

Manual/remote switch

“CB1” breaker reset

Light switch

Hour meters

“CB2” breaker reset

________________________________________________________________ 5.3 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

Fig. 7: Operator’s case

___________________________________________________ Operation tram control levers

The tram control levers (Fig. 9) control the speed and direction of each (left and right) crawler drive. The tram control levers can be used together (to tram straight forward or straight backwards), in opposite directions (for fast turns), or individually (for slow turns). When in manual mode, the “TRAM DEADMAN” switch must be depressed and the tram control levers in the center (neutral) position, prior to starting the pump or tram motors.

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

© BUCYRUS AMERICA, INC.

IMPORTANT! MANUAL ONLY: The Continuous Miner’s tram and steering speed is variable. This means that the farther the tram handle is actuated the faster the Continuous Miner will travel or turn.

IMPORTANT! Once the tram/steering control lever is released by the operator the control lever automatically returns to the centered (neutral) position.

To tram forward, push the tram lever forward, away from the operator.

To tram in reverse, pull the lever back, toward the operator. The further the lever is pushed or pulled, the faster the tramming. When released, the tram lever returns to the centered (neutral) position.

To tram straight forward, push both levers forward at the same time.

To tram straight back, pull both levers back at the same time.

To turn left, pull the left crawler lever back and push the right crawler lever forward. To turn right, push the left crawler lever forward and pull the right crawler lever back. The speed of the turn is determined by whether the levers are operated at the same time or separately.

Fig. 9: Tram control levers

Left tram control lever

Right tram control lever

______________________________________________________________ A6474X307 VASS/0 5.4

___________________________________________________ Operation machine stop/panic bar

Pressing the machine stop (Fig. 8) will shutdown the pump, causing the miner to shutdown. To restart the machine after striking the machine stop, follow normal pump start up procedure (see Start procedure in this chapter).

Fig. 8: Machine stop

Machine stop

Electrical switches

© BUCYRUS AMERICA, INC.

The electrical switches (Fig. 9) that control the machine operation are a group of push button switches located on the control case.

WARNING! Manual operation of the Continuous Miner is not allowed for production operation unless the miner has an operator’s pit and canopy. Manual operation is generally for troubleshooting and maintenance under roof support. Operating the Continuous Miner manually from the operator’s station may result in serious injury or death.

“PUMP START”

The “PUMP START” switch starts the pump motor. To start the motor, depress the switch.

“PUMP STOP”

The “PUMP STOP” switch stops the pump motor. To stop the motor, depress the switch.

“CUTTER START”

Starting the cutter motor is a two-hand start: push the “PUMP START” and the “CUTTER START” switch at the same time. The left cutter motor will start first and, after a preset time, the right cutter motor will start.

“CUTTER STOP”

The “CUTTER STOP” switch shuts down both cutter motors. Both motors stop when the “CUTTER STOP” switch is depressed.

“CONVEYOR FWD”

The conveyor motors cannot be started until the pump motor is started.

Depressing the “CONVEYOR FWD” switch starts the conveyor motors.

The forward direction of the conveyor chain is always away from the cutter head.

“CONVEYOR REV”

The conveyor motors cannot be started until the pump motor is started.

Depress and hold the “CONVEYOR REV” switch to start the conveyor motors. When the conveyor motors are running in reverse, the conveyor chain is moving in the direction of the cutter head. The conveyor will continue to run in reverse until the “CONVEYOR REV” switch is released. The conveyor cannot be started in the forward direction until a preset amount of time has elapsed from running the conveyor in reverse. ______________________________________________________________ A6474X307

VASS/0

5.5

“CONVEYOR STOP”

Depressing the “CONVEYOR STOP” switch will stop the conveyor motors when the conveyor is running forward (away from the cutter head).

“SCRUBBER”

The pump motor must be running before the scrubber motor will start.

Depress and hold the “SCRUBBER” switch to start the scrubber motors and to energize the screen sprays. To stop the scrubber motor, release the ‘SCRUBBER” switch.

“TRAM DEADMAN”

The “TRAM DEADMAN” switch must be depressed and held to tram.

Releasing the “TRAM DEADMAN” switch will stop tramming functions.

“LIGHTS”

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

“RADIO/MANUAL SW. 1”

The “RADIO/MANUAL SW. 1” switch puts the machine under manual or radio control.

“RADIO/MANUAL SW. 2”

The “RADIO/MANUAL SW. 2” switch connects motor control to the manual push buttons and isolates control from the machine controller.

In the radio position, “RADIO/MANUAL SW. 2” isolates the push buttons and connects motor control to the machine controller.

control breakers

The control breaker switches turn the breakers on and off and are also used to reset a breaker that has tripped. All control breakers are turned on by pushing the button in and are turned off by pulling the button out.

If a breaker trips, the button must be pulled out to reset the breaker, then pushed in to turn it on. The control breakers may vary and can be identified by the labels on the front of the operator’s case.

________________________________________________________________ 5.6 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

Operation____________________________________________________

___________________________________________________ Operation Fig. 9: Electrical control switches “PUMP START”

“CUTTER START”

“CONVEYOR FWD”

“SCRUBBER”

“CUTTER STOP”

“PUMP STOP” “CONVEYOR STOP”

© BUCYRUS AMERICA, INC.

Circuit breaker reset panel “TRAM DEADMAN”

“CONVEYOR REV”

“RADIO/ MANUAL SW. 1”

“RADIO/ MANUAL SW. 2”

“LIGHTS”

______________________________________________________________ A6474X307 VASS/0 5.7

Operation____________________________________________________ Electrical metering package (optional)

“LEFT CUTTER MOTOR” and “RIGHT CUTTER MOTOR”

The “LEFT CUTTER MOTOR” and “RIGHT CUTTER MOTOR” ammeters monitor the current draw by the cutter motors. During normal operation, the two meters should indicate approximately the same current draw. If one meter consistently reads higher than the other meter, shutdown the machine (see Shutdown procedure in this chapter) and contact Maintenance.

“LEFT CONVEYOR MOTOR” and “RIGHT CONVEYOR MOTOR”

The “LEFT CONVEYOR MOTOR” and “RIGHT CONVEYOR MOTOR” ammeters monitor the current draw by the conveyor motors. During normal operation, the two meters should indicate approximately the same current draw. If one meter consistently reads higher than the other meter, shutdown the machine (see Shutdown procedure in this chapter) and contact Maintenance.

“MACHINE VOLTAGE”

The “MACHINE VOLTAGE” voltmeter indicates the control circuit voltage. During normal operation, the indicator should stay between 855 and 1,045 volts (950V ± 10%). Should the meter indicate high or low voltage, shutdown the machine (see Shutdown procedure in this chapter) and contact Maintenance.

“CUTTER HOURS”

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

“CONVEYOR HOURS”

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

Fig. 10: Electrical metering package (optional) “LEFT CUTTER MOTOR” ammeter

“RIGHT CUTTER MOTOR” ammeter

“LEFT CONVEYOR MOTOR” ammeter

“RIGHT CONVEYOR MOTOR” ammeter

“MACHINE VOLTAGE” volt meter

“CUTTER HOURS” meter

“CONVEYOR HOURS” meter

________________________________________________________________ 5.8 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

The optional electrical metering package (Fig. 10) consists of a group of meters that monitor current draw on the motors, machine voltage, and cutter and conveyor hours of operation.

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

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

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

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

To reset the circuit breakers with the hydraulic manual reset (Fig. 11):

© BUCYRUS AMERICA, INC.

 Move the hydraulic lever to “OFF” to reset all three circuit breakers.  Move the hydraulic lever to “ON” to turn all three circuit breakers on.

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

Fig. 11: Hydraulic manual breaker reset lever location

“MANUAL BREAKER RESET” lever

______________________________________________________________ A6474X307 VASS/0 5.9

Operation____________________________________________________ manual circuit breaker reset with levers

To reset the circuit breakers with the levers (Fig. 12):  Move both the main and auxiliary circuit breaker levers to the “OFF” position.  Move both the main and auxiliary circuit breaker levers to the “ON” position.

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

 Turn the circuit breakers on with either the remote transmitter of the manual hydraulic circuit breaker reset lever.

Fig. 12: Circuit breaker reset levers

Circuit breaker “CB1” reset lever

Circuit breaker “CB2” reset lever

________________________________________________________________ 5.10 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

 Turn the circuit breakers off with either the remote transmitter or the manual hydraulic circuit breaker reset lever.

___________________________________________________ Operation “LOW OIL” light (optional)

The optional “LOW OIL” light (Fig. 13) illuminates when the hydraulic oil level in the machine is low. If the “LOW OIL” light comes on, shutdown the machine (see Shutdown procedure in this chapter) and check the hydraulic oil level. If oil is needed, add oil (see procedure in Maintenance section of this chapter).

Fig. 13: “LOW OIL” light (optional)

© BUCYRUS AMERICA, INC.

“LOW OIL”

______________________________________________________________ A6474X307 VASS/0 5.11

Operation____________________________________________________ Valve bank The manually operated valve bank (Fig. 14) is located on the near the operator’s station and is used to operate the miner during maintenance and troubleshooting functions while under supported roof.

“STABILIZER”

The first lever from the operator’s left, “STABILIZER”, controls the cylinder that raises and lowers the stabilizer shoe. To raise the stabilizer shoe off of the floor, pull the lever toward the operator. To lower the stabilizer shoe to the floor, push the lever away from the operator.

“CONVEYOR” RAISE/LOWER

The second lever from the operator’s left, “CONVEYOR”-RAISE/ LOWER”, controls the cylinders that raise and lower the conveyor boom. To raise the conveyor, pull the lever toward the operator. To lower the conveyor, push the lever away from the operator.

“CONVEYOR” LEFT/RIGHT

The third lever from the operator’s left, “CONVEYOR”-LEFT/RIGHT, controls the conveyor swing cylinders. To swing the conveyor boom to the left, push the lever away from the operator. To swing the conveyor boom to the right, pull the lever toward the operator.

“GATH HD”

The fourth lever from the operator’s left, “GATH HD”, controls the cylinders that position the gathering head. To raise the gathering head, push the lever away from the operator. To float the gathering head, pull the lever toward the operator.

“CUTTING HD”

The fifth lever from the operator’s left, “CUTTING HD”, controls the cylinders that raise and lower the cutting head. To raise the cutting head, pull the lever toward the operator. To lower the cutting head, push the lever away from the operator.

Fig. 14: Valve bank

“STABILIZER”

“CONVEYOR” RAISE/LOWER

“CUTTING HD”

“GATH HD”

“CONVEYOR” LEFT/RIGHT

________________________________________________________________ 5.12 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

NOTICE! Once a hydraulic control valve handle is released by the operator, the lever will automatically return to the centered (“HOLD”) position.

___________________________________________________ Operation Gauge panel (optional)

© BUCYRUS AMERICA, INC.

The optional gauge panel (Fig. 15) consists of gauges used to monitor water and hydraulic pressure throughout the miner.

“MINE WATER PRESSURE”

The “MINE WATER PRESSURE.” This gauge monitors the pressure of the supply water coming into the water system from the mine. See the water supply circuit in the hydraulic section of this chapter for further information.

“MINER WATER PRESSURE”

The “MINER WATER PRESSURE” gauge monitors the pressure at the main distribution manifold for the water system on the miner. See the miner water pressure circuit in the hydraulic section of this chapter for further information.

“MAIN PRESSURE”

The “MAIN PRESSURE” gauge is used to measure the pressure in main flow - primary pressure circuit. See the main flow - primary pressure circuit in the hydraulic section of this chapter for further information.

“PILOT CIRCUIT PRESSURE”

The “PILOT CIRCUIT PRESSURE” gauge is used to monitor the supply pressure for all pilot functions. See the pilot pressure circuit in the hydraulic section of this chapter for further information.

“MCV PILOT CIRCUIT PRESSURE”

The “MCV PILOT CIRCUIT PRESSURE” gauge is used to monitor the supply pressure between the pressure reducing valve and the main control valve. See the reduced MCV pilot pressure circuit in the hydraulic section of this chapter for further information.

“ACCUMULATOR PRESSURE”

The “ACCUMULATOR PRESSURE” gauge is used to monitor accumulator pressure. The purpose of the accumulator is to store the necessary pilot pressure to allow remote operation of the fire suppression and breaker on/off control valves when the pump is not operational.

The accumulator pressure should closely track the pilot circuit pressure. If the accumulator does not hold pressure when the pump is shutdown, call maintenance. See the accumulator pressure circuit in the hydraulic section of this chapter for further information.

______________________________________________________________ A6474X307 VASS/0 5.13

Operation____________________________________________________

“SHEAR DOWN PRESSURE”

The “GH FLOAT PRESSURE” gauge monitors the pressure of the extend port of the gathering head float cylinders. This pressure gauge displays different readings depending on the operating condition of the cylinders: ■

With the gathering head working section of the main control valve in the Gathering Head Up (GHU) position and the cylinder fully extended, the gauge will display the setting of the relief valve “CR” and the valve can be adjusted using the gauge.

■

With the gathering head working section of the main control valve in the Gathering Head Float (GHD/F) position, the gauge can be used to adjust the pressure in the gathering head float counterbalance valve “VR” and the valve can be adjusted using the gauge.

■

With the gathering head working section of the main control valve in the center position, the gauge displays the pilot pressure at the valve manifold.

■

The gauge will also display high pressures seen by the gathering head cylinders during normal operation.

The “SHEAR DOWN PRESSURE” gauge is used to monitor the pressure of the cutting head cylinder circuit during shear down operations.

See the shear down/maintenance (anti-chatter) valve in the cutter head cylinder circuit in the hydraulic section of this chapter for further information.

Fig. 15: Gauge panel (optional) “MINER WATER PRESSURE”

“MINE WATER PRESSURE”

“PILOT CIRCUIT PRESSURE”

“MAIN PRESSURE”

“ACCUMULATOR PRESSURE”

“MCV PILOT PRESSURE”

“SHEAR DOWN PRESSURE”

“GH FLOAT PRESSURE”

________________________________________________________________ 5.14 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

“GH FLOAT PRESSURE” (gathering head)

___________________________________________________ Operation “LH HEAD SPRAY PRESSURE”

The “LH HEAD SPRAY PRESSURE” gauge (Fig 16) monitors the water pressure at the left hand cutter head spray manifold in the dust suppression system. The gauge readings are dependent on the individual mine requirements. Consult the schematic in the Bucyrus America, Inc. parts manual supplied with your machine.

“RH HEAD SPRAY PRESSURE”

The “RH HEAD SPRAY PRESSURE” gauge (Fig. 16) monitors the water pressure at the right hand cutter head spray manifold in the dust suppression system. The gauge readings are dependent on the individual mine requirements. Consult the schematic in the Bucyrus America, Inc. parts manual supplied with your machine.

Fig. 16: Cutter head spray pressure gauges

© BUCYRUS AMERICA, INC.

“RH HEAD SPRAY PRESSURE” gauge

“LH HEAD SPRAY PRESSURE” gauge

fire suppression spray valvepilot operated

The pilot operated fire suppression spray valve (Fig. 17) is located on the right hand center of the machine. This pilot operated, 2-way, 2position valve can also be operated manually. The spool is detented so that it stays in the open position until it is manually closed by pulling on the knob.

Fig. 17: Fire suppression spray valve-pilot operated

Fire suppression spray valve-pilot operated

______________________________________________________________ A6474X307 VASS/0 5.15

Operation____________________________________________________ machine stop

The miner is equipped with a machine stop buttons located on the left side of the machine (Fig. 18). The machine stop is used to break the control circuit in emergency situations, stopping all motors. Striking with a small amount of force will actuate the machine stop.

Machine stop (location typical)

methane monitoring system

The methane monitoring system consists of three parts - the readout module (Fig. 19), the power supply, and the sensor ("sniffer"). When the methane monitoring system is energized, the sensor constantly monitors the air for the presence of methane.

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

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

Fig. 19: Methane monitor readout module (location typical)

Methane monitor readout module

________________________________________________________________ 5.16 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

Fig. 18: Machine stop

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

Machine controller

■

Power supply

■

Input/Output (I/O) modules

■

Radio remote

■

Text display

© BUCYRUS AMERICA, INC.

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

power supply

input/output modules

The machine controller is the main control unit of the system. It includes the radio data receiver which is used to receive and decode commands from the radio remote.

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

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

Cutter motors (left and right)

■

Gathering head motors (left and right)

■

Traction motors (left and right)

■

Pump motor

■

Hydraulic oil level

■

Methane monitoring

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

______________________________________________________________ A6474X307 VASS/0 5.17

Operation____________________________________________________ radio remote

The radio remote (Fig. 20) is a battery powered remote used to control the continuous miner during normal operations. To use the radio remote control, the “CONTROL MODE” of operation switch on the operator’s panel in the machine pit must be set to “RADIO.” WARNING! Radio remote control systems are dangerous. The continuous miner operator cannot operate a remote system until he is properly trained in the operation of the system. Remote control systems sometimes have automatic features of which untrained operators and workers may not be aware.

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

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

________________________________________________________________ 5.18 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

Fig. 20: Radio remote (typical)

___________________________________________________ Operation display

There is a text display located on the right hand side of the machine behind the pit (Fig. 21). This screen is used to display diagnostic information on the miner.

Fig. 21: Control system display locations (typical)

© BUCYRUS AMERICA, INC.

Text display

Fig. 22: Text display main menu, example

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Operation____________________________________________________ System Menu The control system provides information, diagnostic, and setup screens that are grouped together in the system menu (Fig. 23). The system menu is accessed by using either display module and a remote control handset.

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

IMPORTANT! All functions and motors are shut down and disable when the system menu is selected.  Press CONV UP or CONV DOWN to move the cursor up and down the list.

 To leave the menu and return to remote mode, press SHIFT and REMOTE. Fig. 23: System menu, example

________________________________________________________________ 5.20 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

 Press SHIFT and MENU to select the highlighted item

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

To navigate through the screens, hold the SHIFT switch while pressing a conveyor switch. To return to the main menu, press SHIFT and MENU.

© BUCYRUS AMERICA, INC.

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

Main monitor Machine information Pump diagnostics Cutter diagnostics Conveyor diagnostics Fan diagnostics Tram diagnostics 24VDC digital input I/O monitor - relay board I/O monitor - solenoid board I/O monitor - analog outputs Solenoid board diagnostics Relay board status Power supply status Thermistor module status

See Fig. 24 for example screen shots of various diagnostic pages.

______________________________________________________________ A6474X307 VASS/0 5.21

Operation____________________________________________________

© BUCYRUS AMERICA, INC.

Fig. 24: Text display diagnostic pages, examples

________________________________________________________________ 5.22 Bucyrus – Model 25M1AC Continuous Miner

___________________________________________________ Operation Fault log The fault log (Fig. 25) allows the user to view the last 100 faults that have occurred since the log was last cleared.

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

© BUCYRUS AMERICA, INC.

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

IMPORTANT! It is not recommended that the fault log be cleared unless the machine controller has been replaced. Retaining the faults is very helpful in troubleshooting a problem when a controller is sent for service. Faults cannot be retrieved once they have been cleared.

Use caution and only clear the log if it is absolutely necessary.

Once a fault has been selected, the SHIFT and MENU keys can be used to access more information on the fault.

Fig 25: Fault log, example

Once a fault has been selected, the SHIFT and MENU keys can be used to access more information on the fault.

______________________________________________________________ A6474X307 VASS/0 5.23

Operation____________________________________________________ Hour meters Selecting hour meters (Fig. 26) from the Main Menu will display runtime for the following motors: pump, fan, left cutter, right cutter, and conveyor. Time is displayed in hours:minutes:seconds format. This runtime only reflects accumulated time since the controller has been installed or since the counter was last reset. The hour meters can be cleared under the Engineering Setup Menu, which is password protected.

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

© BUCYRUS AMERICA, INC.

Fig. 26: Hour meters, examples

________________________________________________________________ 5.24 Bucyrus – Model 25M1AC Continuous Miner

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

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

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

© BUCYRUS AMERICA, INC.

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

Fig. 28: Red zone

______________________________________________________________ A6474X307 VASS/0 5.25

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

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

Tramming the miner red zone

Beginning 1st sump red zone

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

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

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

________________________________________________________________ 5.26 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

Fig. 29: Red zones

___________________________________________________ Operation

Fig. 30: Red zones

Repositioning miner for right hand cut red zone

© BUCYRUS AMERICA, INC.

Sumping on the left hand side red zone

Sumping in the right hand cut red zone

______________________________________________________________ A6474X307 VASS/0 5.27

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

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

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

Beginning a right hand crosscut red zone

© BUCYRUS AMERICA, INC.

Fig. 31: Crosscut red zones

Right hand crosscut development

________________________________________________________________ 5.28 Bucyrus – Model 25M1AC Continuous Miner

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

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

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

© BUCYRUS AMERICA, INC.

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

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

Fig. 32: Pillaring red zones

Pillaring in a left hand cut red zone

Pillaring in a end cut red zone

Pillaring in a right hand cut red zone

______________________________________________________________ A6474X307 VASS/0 5.29

Operation____________________________________________________ Safety precautions for underground operation

■

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

■

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

■

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

■

Make a visual check of the Continuous Miner before energizing.

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

■

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

Tramming safety rules ■

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

■

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

■

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

■

Position the cutter and gathering head for tramming.

■

Position the stabilizer shoe and booms for tramming.

■

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

■

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

________________________________________________________________ 5.30 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

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

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

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

© BUCYRUS AMERICA, INC.

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

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

WARNING! Before starting the Continuous Miner, make sure that no one is in the red zone (Fig. 26 through Fig. 30).

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

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

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

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

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

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

______________________________________________________________ A6474X307 VASS/0 5.31

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

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

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

 Turn the main circuit breaker to the “ON” position.  Select “TRAM RADIO” on the “TRAM MANUAL/TRAM RADIO SW. 1” and “RADIO/MANUAL SW. 2” on the operator’s case on the miner.  Turn the power switch on radio transmitter to the on position.  Press “SHIFT” and wait 1/4 second.  While pressing “SHIFT”, press “PUMP ON”. Hold both keys in until the pump starts.  Release the “PUMP ON” key.

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

________________________________________________________________ 5.32 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

WARNING! Visually check for other personnel and verbally shout a warning before starting this machine. Make sure all personnel are completely clear of the machine and it’s components and check that any loose material, tools, oil cans or other objects are clear from the area before starting the machine.

___________________________________________________ Operation Shutdown procedure The Continuous Miner must be properly shutdown before leaving the area or before performing any maintenance or service. Some maintenance or service procedures may require additional steps to insure the safety of the maintenance personnel working on or around the machine and will be listed in the maintenance section of this guide.  Back the miner about one foot from the face providing sufficient clearance and shut off the cutter head motors (see Cutter operation in this section).

© BUCYRUS AMERICA, INC.

 Tram the miner to an area of well supported roof. Park the machine in its designated parking area out of traffic, on flat, solid ground. If it is not possible to park the machine on flat ground, park the machine at a right angle to the slope.

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

______________________________________________________________ A6474X307 VASS/0 5.33

Operation____________________________________________________ Tramming the miner Tramming requires cooling water to prevent damage. The pump motor must be running to tram the miner.

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

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

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

Be aware of people, equipment, and cables.

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

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

________________________________________________________________ 5.34 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

 Adjust conveyor boom to best possible position to allow clearance from roof, walls, and floor.

___________________________________________________ Operation Remote console - tram speed control: The system allows the tramming to be driven in three discrete speeds (SPEED 1, SPEED 2, and SPEED 3). SPEED 1 is the default tramming speed.

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

© BUCYRUS AMERICA, INC.

The following tramming configurations are enforced by the control system for safety reasons: ■

Spilt track tramming is limited to SPEED 1 when cutter motors are not running.

■

Single track tramming is normally limited to SPEED 1.

■

It is possible to speed up a single track from SPEED 1 to SPEED 2 providing that tramming is started in SPEED 1.

■

Tramming is limited to sump speed while the cutters are on.

■

While the cutters are running, reverse speed can be incremented even while the reverse tram keys are being pressed. Note that this option is used when the miner is retreating or pillar mining.

______________________________________________________________ A6474X307 VASS/0 5.35

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

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

 Ensure that the pump motor is running. The cutter motors will not run if the pump motor is not running.  Press “SHIFT” and wait 1/4 second.  While holding in “SHIFT”, press “CUTTER ON”. Continue to hold both keys in until the cutter motors turn on.

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

IMPORTANT! The “CUTTER ON” key must be released before “SHIFT”.

If “SHIFT” is released first, the cutter motors will shut off.  Release the “SHIFT” key.

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

________________________________________________________________ 5.36 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

WARNING! Warn “ALL CLEAR” before starting the cutter head. Failure to do so may result in serious injury or death.

___________________________________________________ Operation Conveyor operation To start the conveyor motors in forward:  Place conveyor boom in desired position.  Warn “ALL CLEAR” before starting the conveyor.

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

 Release the “CONV ON” key.

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

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

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

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

______________________________________________________________ A6474X307 VASS/0 5.37

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

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

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

Control headlights and area lights The light switch has three positions: manual, off & radio. When the power is turned on to the continuous miner, the methane monitor relay is closed and the light switch is off. When the light switch is turned to the manual position, the headlights and the area lights (Fig. 29) will come on. When the light switch is turned to the radio position, the headlights only (not the area lights) can be turned on and off with the radio.

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

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

________________________________________________________________ 5.38 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

 Release the “SHIFT” key.

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

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

© BUCYRUS AMERICA, INC.

 After two seconds, the fire suppression system will activate. At this time, the “SHIFT” and “FIRE” keys can be released.

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

Conveyor raise/lower and left/right in radio remote The pump motor must be running in order to control the conveyor raise, lower, and swing left/right.

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

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

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

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

______________________________________________________________ A6474X307 VASS/0 5.39

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

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

Shear up/down in radio remote

 Press “SHEAR UP” to move the cutter head up. The shear up solenoid remains energized until the key is released (unless height limiting is in force).  Press “SHEAR DOWN” to move the cutter head down. The shear down solenoid remains energized until the key is released.

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

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

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

________________________________________________________________ 5.40 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

The pump motor must be running in order to raise or lower the cutter head.

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

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

© BUCYRUS AMERICA, INC.

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

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

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

______________________________________________________________ A6474X307 VASS/0 5.41

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

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

Main Chassis

■

Mounting of the right and left hand crawler tracks and their independent drive systems and take-up provisions.

■

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

■

An integral hydraulic oil tank, along with an electric motor/hydraulic pump assemblies and associated valves and piping.

■

A rear stabilizer and its hydraulic cylinder for improving leverage forces during shear down in the cutting sequence.

■

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

Fig. 33: Main Chassis Scrubber fan Rear bumper plate

Oil tank Cutter head pivot Cutter head cylinder clevis Gather head cylinder clevis

Pit area Conveyor raise cylinder clevis

Gathering head cylinder clevis

________________________________________________________________ 5.42 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

The main chassis of the machine (Fig. 33) is a heavy duty box type structure of high-strength steel that provides the following:

_______________________________________ Mechanical assemblies Gathering head assembly The gathering head assembly (Fig. 34) is attached to the main chassis at right and left hand pivot points. The assembly is articulated around these pivot points to adjust the gathering head for uneven floor conditions and when tramming the miner. The independent pivots allow removal of the gathering assembly without disturbing the cutting head or discharge conveyor.

© BUCYRUS AMERICA, INC.

The gathering head assembly includes: ■

Upper mounting clevises for the two externally mounted gathering head cylinders.

■

A water cooled electric motor, an input gear case, and a gathering head pot which drives a rotating centrifugal loading arm device.

The gathering head assembly is raised and lowered by two hydraulic cylinders which are mounted to the main chassis at their lower ends and to the gathering head structure at their upper ends. These cylinders allow vertical ranging of the forward edge of the gathering head (see the general arrangement drawing for you machine for dimensions).

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

Fig. 34: Gathering head assembly

Gear case and pot assembly (under cover)

Foot shaft

CLA

______________________________________________________________ A6474X307 VASS/0 5.43

Mechanical assemblies ________________________________________ Traction drive system

■

Independent right and left drive systems, each consisting of a water cooled electric motor mounted to a drive gear case that powers drive sprockets to provide motion to the respective right or left crawler chain.

■

A forward mounted crawler chain idler roller on each side which is equipped with a grease powered piston to adjust the crawler chain tension.

■

A drive system which provides the operator with three variable speed ranges: –

High speed - used mainly for tramming from one working face to another.

–

Intermediate speed - used mainly for rapid repositioning of the miner within the face area.

–

Sump speed - fully adjustable by the operator to a preset value - used for sumping the miner into the face. The adjustable sump speed allows the operator to select an optimum cutting speed based on varying hardness conditions. The sumping speed is maximized through a proportional and differential cutter feedback system.

The traction drive control system provides the operator with the capability to run either right or left hand crawler chain in forward or reverse independently for maximum maneuverability (for example, the miner may be pivoted about its central vertical axis). Both drive trains are 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 hard and soft floor conditions.

Fig. 35: Traction drive system

Crawler track

Idler roller

________________________________________________________________ 5.44 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

The traction drive system (Fig. 35) provides the mobility for mining operations and for tramming from place to place. It includes:

_______________________________________ Mechanical assemblies Stabilizer shoe A stabilizer shoe (Fig. 36), located beneath and at the rear of the tractor frame, may be lowered to anchor the back end of the machine and provides a greater downward thrust of the cutter head for hard-cutting while preventing backward creep of the miner. The stabilizer shoe is raised and lowered hydraulically by a double acting cylinder that moves the shoe bracket up or down.

© BUCYRUS AMERICA, INC.

Fig. 36: Stabilizer shoe

Stabilizer shoe

______________________________________________________________ A6474X307 VASS/0 5.45

Mechanical assemblies ________________________________________ Cutting head assembly The cutting head assembly (Fig. 37) is attached to the main chassis at right and left hand independent pivot points around which the assembly is articulated for vertical ranging cutting. The independent pivots allow removal of the cutting head assembly without disturbing the gathering head or conveyor components.

■

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

■

The cutting head gear case assembly, which consists of an input gear case and water-cooled electric drive motor for each of the right and left hand sides, a final drive gear case which includes drive gearing, a main drive shaft, and mounting points for the right, left, and center drums, and a bolting flange for mounting onto the cutting head support frame.

■

Provides for both front and rear flange support of the cutter motors.

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 to the main longitudinal structural members of the cutting head support frame at their upper ends. These cylinders enable the cutting head assembly over a predesigned range (see the general arrangement drawing for you machine for dimensions).

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

Fig. 37: Cutting head assembly Cutter head gear case Cutter head drum assembly

Cutter head motor

Cutter head pivot

________________________________________________________________ 5.46 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

The cutting head assembly consists of the following:

_______________________________________ Mechanical assemblies Conveyor assembly The conveyor assembly (Fig. 38) is attached to the main chassis at right and left hand independent pivot points. The conveyor is articulated vertically around these pivot points to assist in optimum loading into a haulage vehicle. Independent pivots allow removal of the conveyor assembly without disturbing the cutting head or gathering head components.

© BUCYRUS AMERICA, INC.

The conveyor assembly includes the following: ■

An intermediate conveyor structure that includes the right and left hand 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 subassembly that includes: –

a mating horizontal pivot arrangement allowing sideward swinging movement up to 45° on either side of the machine center line to assist in optimum loading into a haulage vehicle, and

–

a tail roller shaft for the conveyor chain and two hydraulic cylinders to maintain proper tension in the chain when the geometry of the conveyor assembly changes during the operation.

The intermediate and discharge conveyor structures each include a special noise dampening running deck for the conveyor chain and a throat clearance designed for optimum loading rates (see the general arrangement drawing for you machine for dimensions).

Fig. 38: Conveyor assembly

Rear conveyor section Conveyor pivot pin

Intermediate conveyor section

Chassis pivot points

______________________________________________________________ A6474X307 VASS/0 5.47

Hydraulic ____________________________________________________ Continuous Miner hydraulic system overview Hydraulic power for all hydraulically-actuated functions originates with the pump assembly. This includes power for cylinders, hydraulic motors, control valves, and pilot valves.

Fig. 39 gives an overview of hydraulic cylinders located on the 25M1AC Continuous Miner. Fig. 40 depicts the location of other hydraulic components.

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

Operation considerations

■

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

■

maintaining a sufficient oil level in the tank

■

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

■

changing filters and fluids at prescribed intervals

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

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

________________________________________________________________ 5.48 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

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

___________________________________________________ Hydraulic Fig. 39: Hydraulic cylinder locations

Gathering head raise cylinder

Gathering head cylinder

© BUCYRUS AMERICA, INC.

Gathering head raise cylinder Cutter head raise cylinder Cutter head raise cylinder

Cutter head raise cylinder

Stabilizer shoe cylinder

Stabilizer shoe cylinder

Stabilizer shoe cylinder

Conveyor lift cylinder

Conveyor lift cylinder Conveyor lift cylinder

Conveyor swing cylinder

Conveyor chain take-up cylinder (optional)

Conveyor swing cylinder

Conveyor chain take-up cylinder (optional)

Conveyor chain take-up cylinder (optional)

______________________________________________________________ A6474X307 VASS/0 5.49

Hydraulic ____________________________________________________ Fig. 40: Hydraulic component location

Accumulator

Breather

Anti-chatter/maintenance valve

2-unit valve solenoid 1/4” shuttle valve (Qty: 2) 3-unit valve solenoid

Oil level float

10 port pressure manifold 0-1500 psi pressure gauge (Qty: 3) 0-5000 psi pressure gauge (Qty: 1)

Hydraulic P350/P315 (32/5 gpm) pump 1/2” NPT flow control

3 micron Nonbypassing pilot filter 3 micron replacement element 100-1400 psi SAE-8 relief valve

10 micron Bypassing pilot filter 10 micron replacement element 3/4” check valve 1” jet pump

Pressure reducing valve

SAE-6 control valve Manual breaker reset

Return filter 10 micron Replacement element 10 micron

________________________________________________________________ 5.50 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

Breather

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

© BUCYRUS AMERICA, INC.

Graphic symbols denote the type of function a component performs but do not necessarily s h o w its s h a pe o r c ons tr uc t i on . T h es e schematic symbols are used to trace the system flow from the reservoir to the actual work being performed and then back again to the reservoir. The symbols used are shown individually with a functional description where needed. The study of these symbols helps in understanding the system and thereby aids in troubleshooting the system.

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

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

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

Cavitation: Briefly, cavitation means that air bubbles are forming in the liquid that is being pumped. These bubbles are usually formed in the suction line of a pump when an obstruction causes the suction pressure (which is a vacuum) to go significantly below atmospheric pressure.

The actual pressure at which these bubbles form is dependant on the tank fluid level and the integrity of the seal on the suction line components. When these air bubbles are compressed in the pump gears they can cause surface pitting, corrosion and/or erosion. These bubbles can also coalesce to create erratic operation of water hammer problems.

Closed center circuit: A circuit in which flow through the system is blocked in neutral and pressure at the pump outlet is maintained at the maximum pressure control setting by a relief. Example: the pilot circuit.

Contamination: Any material foreign to hydraulic fluid that has a harmful effect on its performance in a system.

Differential pressure: Pressure measured as the absolute difference between the inlet and outlet pressure of a device.

Fixed displacement pump: A pump in which the displacement per cycle cannot be varied.

GPM (gpm): Gallons per minute (unit of flow per unit of time).

______________________________________________________________ A6474X307 VASS/0 5.51

Hydraulic ____________________________________________________

Micron: 1/1000th of a millimeter (0.00003937 inches). The measure used to determine the particle size of contaminants in a fluid system.

Micron rating: The size, in microns, of particles a filter will remove.

PSI (psi): Pounds per square inch (unit of pressure).

Open center circuit: A circuit in which flow through the system and back to the oil tank reservoir is open in neutral. Example: the main flow-primary pressure circuit.

Viscosity: A measure of the internal friction, or resistance to flow, of a fluid.

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

To follow oil flow through a system, visually imagine the valve spool shifting as shown in Fig. 41.

© BUCYRUS AMERICA, INC.

Fig. 41: Oil flow through a spool

________________________________________________________________ 5.52 Bucyrus – Model 25M1AC Continuous Miner

___________________________________________________ Hydraulic accumulator

A bladder accumulator (Fig. 42) is essentially a fluid pressure storage chamber in which the potential energy of a fluid under pressure can be stored against a compressible force of a gas to do useful work. This stored fluid is readily available to perform a given task when called upon by the requirements of the system in which it is used.

breather

A breather (Fig. 42) permits air to move in and out of the oil tank reservoir to maintain atmospheric pressure.

cylinders

Cylinders (Fig. 42) are bored and honed steel tubes enclosing a piston connected to a rod that extends out the end of the cylinder.

Working surfaces are ground and finely finished with the seals and gaskets incorporated to prevent leakage. Fig. 43 illustrates the location of the hydraulic cylinders on the miner.

© BUCYRUS AMERICA, INC.

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

There are four single-acting cylinders on the miner: the conveyor lift cylinders (2) and the gathering head raise cylinders (2). Optionally, there may be conveyor chain take-up cylinders (2), which are also single acting.

There are normally five different double-acting cylinders on a miner: the cutter head raise cylinders (2), the conveyor swing cylinder, and the stabilizer shoe cylinders (2). There is also an optional second conveyor swing cylinder for attaching haulage.

Fig. 42: Accumulator and cylinder hydraulic symbols

Breather

Cylinder, single acting

Cylinder, double acting

Cylinder, single acting with dry pocket

Accumulator

Cylinder, single acting with external spring

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

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

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

______________________________________________________________ A6474X307 VASS/0 5.53

Hydraulic ____________________________________________________ filters and strainers

Filters and strainers are designed to protect a hydraulic oil system from harmful levels of particulate contamination. High levels of contaminants accelerate wear of components, cause improper functioning, and add to system sluggishness. Other problems such as seizure of parts, higher temperatures due to increased fluid friction, leakage, and loss of control may occur. Contamination also contributes to oxidation and chemical breakdown of the fluid. Filter and strainer hydraulic symbols are shown in Fig. 43.

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

y- strainer

There is a y-strainer (Fig. 43) in the supply line of the hydraulic oil fill circuit. The y-strainer contains a replaceable element to filter out contaminants when adding oil to the system. Nevertheless, oil stocked to be added to this system should be kept in closed containers to prevent contamination of the hydraulic system.

Fig. 43: Filter and Y-strainer hydraulic symbols

Filter, bypassing

Filter, non-bypassing

Y-strainer, hydraulic

________________________________________________________________ 5.54 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

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

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

___________________________________________________ Hydraulic flow meter

© BUCYRUS AMERICA, INC.

orifice

A flow meter (Fig. 44) is a visual device which indicates the volume of fluid passing through it per unit time.

An orifice (Fig. 44) is a device that restricts flow.

pressure/return manifold

A pressure manifold (Fig. 44) has one inlet port and many outlet ports to supply flow to many circuits. A return manifold has many inlet ports and only one outlet port for flow to return to tank. Note: You can have the same part number for a pressure or return manifold.

pressure gauge

A pressure gauge (Fig. 44) is a visual device used to indicate the pressure in a hydraulic or water circuit.

pump

The purpose of a pump (Fig. 44) is to produce flow; it does not produce pressure. Pressure is caused by a resistance to flow. All system components have some resistance to flow. Hydraulic cylinders, which power machine functions, are the major components causing this resistance. Each circuit is protected by a relief valve so that the pressure in the system will not exceed the rating of its components. To ensure that everything works correctly and in proper sequence, relief valve pressure settings closely match the load requirements.

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

pump, jet (venturi)

quick disconnect female/male coupling

The miner may be equipped with optional venturi jet pumps (Fig. 44).

These pumps have no moving parts and are made from a metal tube that narrows over its full length. When liquid passes through the narrowing tube, a vacuum is formed according to the “Venturi” principle.

This vacuum is used to draw liquid into or out of reservoirs. For more information, reference the detailed circuit descriptions.

A quick disconnect (Fig. 48) is a coupling which can quickly join or separate lines.

Fig. 44: Hydraulic symbols

Pressure/return manifold

Flow meter

Orifice

Pressure gauge

Pump, jet

Quick disconnect male half coupling

Pump, hydraulic two section

Quick disconnect female half coupling

______________________________________________________________ A6474X307 VASS/0 5.55

Hydraulic ____________________________________________________ shuttle valve

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

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

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

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

solenoid pilot valve, hydraulic control (with radio option)

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

water valve, hydraulic piloted

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

water valve, detented hydraulic piloted

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

________________________________________________________________ 5.56 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

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

___________________________________________________ Hydraulic valves ball valve

check valve

© BUCYRUS AMERICA, INC.

directional control valve

The hydraulic symbols for the different types of valves are given in Fig. 45.

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

A valve that allows fluid flow in one direction only.

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

flow control valve

A valve with a primary function of controlling flow rate.

flow control valve with internal check

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

load holding valve

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

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

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

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

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

MSHA directives of 1980 demand that load holding valves be required on all miners with elevating cutter heads and conveyors, and that they be integrally-mounted to the cylinder. The miner has four (4) of these valves.

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

______________________________________________________________ A6474X307 VASS/0 5.57

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

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

There are no adjustments required on the load holding valves.

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

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

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

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

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

Some relief valves are atmospheric. These valves are used for overpressure protection only. Should the preset pressure be reached, they discharge oil into the air. An example of this is on the conveyor raise circuit where the pressure is set to relieve at 3,000 psi, which is well above expected operating pressures. There are a number of relief valves in the hydraulic system that are set for individual sub-circuit protection (conveyor elevation, gathering head, etc.) Each pump section also has a main relief valve for protection against over-pressurization.

The main hydraulic pump section is typically set at 3000 psi. The pilot section is typically set at 600 psi. If your system has 3 pump sections, consult your system schematic in your Bucyrus parts manual for the auxiliary pump section relief valve setting. For relief valve adjustment procedures, see the Adjustment section of this chapter. ________________________________________________________________ relief valve

5.58

Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

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

___________________________________________________ Hydraulic Fig. 45: Valve hydraulic symbols

Check valve

Ball valve

Conveyor chain take -up valve

© BUCYRUS AMERICA, INC.

Anti-chatter/maintenance valve

Flow control valve

Flow control valve with internal check Gathering head float valve

Directional control valve

Load holding valve Pressure reducing/ relieving valve (pressure regulator)

Relief valve

Shuttle valve

Solenoid valve 2-unit

Water valve, detent hydraulic operated

Water valve, hydraulically piloted

______________________________________________________________ A6474X307 VASS/0 5.59

Hydraulic ____________________________________________________ Major hydraulic circuit components main control valve (MCV)

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

The main control valve (Fig. 46) is typically located on the right side of the machine.

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

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

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

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

■

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

________________________________________________________________ 5.60 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

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

___________________________________________________ Hydraulic ■

Spools not detented should return to neutral automatically when the control is released. The standard centering spring force is about 12-14 pounds at the handle. If more force is necessary, the spool may be binding, or else control linkage may be faulty.

© BUCYRUS AMERICA, INC.

Fig. 46: Main control valve schematic symbols (typical)

______________________________________________________________ A6474X307 VASS/0 5.61

Hydraulic ____________________________________________________ Hydraulic pump assembly circuit Hydraulic power for all of the hydraulically actuated functions originates with the pump assembly (Fig. 47). This pump assembly is made up of single-stage pump with a piggy-back hydraulic pump (2-section tandem pump). The pump outlets are designated A1 (main flow) and A2 (pilot flow). The pump assembly is typically mounted on the left side of the machine frame. Oil is supplied from the oil tank reservoir to the suction side of pump through a 2” suction line.

Fig. 47: Hydraulic pump circuit

TO MAIN CONTROL VALVE

© BUCYRUS AMERICA, INC.

TO PRESSURE MANIFOLD

________________________________________________________________ 5.62 Bucyrus – Model 25M1AC Continuous Miner

___________________________________________________ Hydraulic Main flow - primary pressure circuit The main flow-primary pressure circuit (Fig. 48) is powered by the main pressure section of the hydraulic pump, which is rated at 32 gpm at a pressure of 3,000 psi. The system is an open-center circuit and it supplies oil flow to the main control valve. The main control valve operates the cutter head, conveyor raise and swing, gathering head, and stabilizer shoe cylinders along with oil tank fill. After passing through the pump gear, oil enters the main control valve whose relief is set at 3,000 psi. On the return side of the system, oil exits the main control valve.

There is a tee to allow external filling of the reservoir (see cutter head raise/lower circuit). Oil enters a 10 micron by-passing return filter before entering the oil reservoir. Once in the reservoir, the oil is forced to flow through and around baffle plates for cooling and de-aerating before re-entering the suction line. Also, located in the reservoir are floor magnets which will trap ferrous metal particles.

© BUCYRUS AMERICA, INC.

The schematic shown in Fig. 48 is a typical primary pressure circuit.

Always refer to the schematic in your Bucyrus America, Inc. Parts Book for your machine.

Fig. 48: Main flow-primary pressure

T4 T5

______________________________________________________________ A6474X307 VASS/0 5.63

Hydraulic ____________________________________________________ Pilot pressure circuit The pilot hydraulic section is a closed-center system powered by pilot pressure gear section. It supplies oil flow to the pressure manifold.

The pilot gear section is rated at 5 gpm at 600 psi. After passing through the hydraulic pump, oil enters a 10-micron by-passing pressure filter (tri-filter) and circuit relief valve set at 1000 psi. Oil then flows to a 3-micron non by-passing pressure filter. The oil continues to the pilot pressure manifold where the oil separates to the accumulator, all solenoid valves, the gathering head float valve and the main control valve.

The schematic shown is Fig. 49 is typical for a pilot pump circuit. Always refer to the schematic in your Bucyrus America, Inc. Parts Book for your machine.

© BUCYRUS AMERICA, INC.

Fig. 49: Pilot pressure circuit

________________________________________________________________ 5.64 Bucyrus – Model 25M1AC Continuous Miner

___________________________________________________ Hydraulic Tank Ports Bucyrus filters the oil system on all new Continuous Miners according to a minimum ISO code 19/17/14 for cleanliness. There is a quick disconnect (w/plug) to hook up a filtering cart and can also be used underground for contamination clean-up of the hydraulic system. Return oil from hydraulic components connect to a return manifold. Oil flows from the return manifold to the oil tank reservoir. The oil tank reservoir includes two oil tank manifolds and two tank breathers.

The schematic shown in Fig. 50 is typical for tank port connections.

Always refer to the schematic in your Bucyrus America, Inc. Parts Book for your machine.

© BUCYRUS AMERICA, INC.

Fig. 50: Tank port connections

______________________________________________________________ A6474X307 VASS/0 5.65

Hydraulic ____________________________________________________ Stabilizer shoe cylinders circuit Oil is supplied by the main pressure section of the hydraulic pump to the stabilizer shoe working section on the main control valve. By manual or remote solenoid control, the spool allows oil to enter the stabilizer shoe circuit. The stabilizer shoe cylinder is a double-acting cylinder.

There are two stabilizer shoe cylinders.

There are two port reliefs in the working section on the main control valve. Port relief to lower the stabilizer shoe is set at 2,500 psi. Port relief to raise the stabilizer shoe is sat at 1,200 psi. Push the handle it extends the cylinders and lowers the stabilizer shoe. Pull the handle it retracts the cylinders and raise the stabilizer shoe. Solenoid designations are SSU (stabilizer shoe up and SSD stabilizer shoe down).

The schematic shown is Fig. 51 is a typical stabilizer shoe cylinder circuit. Always refer to the schematic in your Bucyrus America, Inc. Parts Book for your machine.

© BUCYRUS AMERICA, INC.

Fig. 51: Stabilizer shoe circuit

________________________________________________________________ 5.66 Bucyrus – Model 25M1AC Continuous Miner

___________________________________________________ Hydraulic

© BUCYRUS AMERICA, INC.

Conveyor raise/lower circuit conveyor raise/lower

Oil is supplied by the main pressure section of the hydraulic pump to the conveyor raise/lower working section on the main valve control. By manual or remote solenoid control, the spool allows oil to enter the conveyor raise/lower cylinder circuit. The conveyor raise/lower cylinder is a single-acting cylinder with a load holding cartridge. There are two (2) conveyor raise/lower cylinders. There are two (2) port reliefs in the working section on the main control valve. The front port relief for raising the conveyor is set at 2,500 psi and the rear port relief for lowering the conveyor is set at 1,400 psi. Pull the handle to extend the cylinders and raise the conveyor. Oil free flows through the flow control check valve to the extend port of the cylinders free flowing through the check valve of the load holding cartridge to extend the cylinders. Push the handle to retract the cylinders and lower the conveyor. Oil goes to the retract port of the cylinders and pilots open the load holding cartridge, allowing oil to exit the cylinders. Oil then passes through a flow control valve to adjust the speed of the conveyor lowering and continues to the main control valve. Oil then travels thru a 10-micron bypassing return filter to tank.

oil tank fill

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

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

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

When referring to Fig. 52, note that solenoid designations are CD (conveyor down) and CU (conveyor up).

The schematic is typical conveyor raise/lower circuit. Always refer to the schematic in your Bucyrus America, Inc. Parts Book for your machine.

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Hydraulic ____________________________________________________

© BUCYRUS AMERICA, INC.

Fig. 52: Conveyor raise/lower - oil tank fill circuit

________________________________________________________________ 5.68 Bucyrus – Model 25M1AC Continuous Miner

___________________________________________________ Hydraulic Conveyor swing circuit Oil is supplied by the main pressure section of the hydraulic pump to the conveyor swing working section on the main control valve. By manual or remote solenoid control, the spool allows oil to pass through the conveyor swing pivot manifold and enter the swing circuit. The swing cylinder is a double-acting cylinder. The range on the cylinder will allow the conveyor tail to move 45 degrees off the centerline of machine in both directions. There are two (2) port reliefs in the working section on the main control valve both of which are set at 1,800 psi. The purpose of the port reliefs is to protect the swing cylinder from damage in either right or left direction in the event of an excessive external load due to the impact of the conveyor tail with the rib, haulage vehicle, or some other object.

© BUCYRUS AMERICA, INC.

Push the handle and the left hand cylinder will retract, moving the conveyor tail to left. Pull the handle out and the cylinder will extend, moving the discharge conveyor to the right. The left and right movement is based off standing at the rear of machine looking forward to the cutter head.

An optional right hand cylinder may be required for attached haulage.

The flow output to the two cylinders powers each in the opposite direction. The right hand cylinder retracts as the left hand cylinder extends and vice-versa.

The schematic shown is Fig. 53 is a typical conveyor swing cylinder circuit. Always refer to the schematic in your Bucyrus America, Inc. Parts Book for your machine.

Note: Solenoid designations are CSL (conveyor swing left) and CSR (conveyor swing right).

Fig. 53: Conveyor swing cylinder circuit

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Hydraulic ____________________________________________________ Gathering head raise/hold/float-lower circuit

The Gathering Head Lower function is controlled through the working section of the main control valve and through the Gathering Head Float valve block. The spool in the main control valve is open to tank which allows control of the gathering head lower to be controlled by the Gathering Head Float valve block. The counterbalance valve stamped “VR” is set to relieve at 1,200 psi to allow the gathering head to drift down at a controlled rate of speed. This valve is adjustable and the rate of retract speed for the cylinders can be increased by decreasing the pressure setting of the valve. Conversely, the retract speed for the cylinders can be decreased by increasing the pressure setting of the valve.

The oil from the gathering head cylinders returns to the gathering head working section of the main control valve then through a 10 micron bypassing return filter to tank.

The counterbalance valve that is stamped “CR” is set to relieve at 1,800 psi. This fixed setting will relieve pressure directly to the tank in the event of a forced movement of the gathering head to grade level.

This can occur if the cutter head is lowered onto a raised gathering pan, or by some other external force.

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

The pilot pressure oil supply for the gathering head float comes from hydraulic pump at A2 through a 10 micron by-passing pressure filter to the relief valve set 600 psi and splits going to conveyor chain take-up circuit (optional) and through a 3 micron non by-passing filter, then through the pilot pressure manifold to the gathering head float valve. The pilot pressure oil is make-up oil for the gathering head cylinders.

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

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

________________________________________________________________ 5.70 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

Oil is supplied by the main pressure section of the hydraulic pump to the gathering head working section on the main control valve. By manual or remote solenoid control, the spool allows oil to enter the gathering head raise circuit. When raising the gathering head pan, oil free flows through the gathering head float valve (check valve) and splits to both cylinders.

At any time during raising the gathering head, the operator can stop the gathering head pan and the pan will hold in position.

___________________________________________________ Hydraulic A downstream check valve keeps system pressure from entering the pilot pressure lines. An adjustable needle valve allows for the bleeding off of pressure for maintenance. A gauge is incorporated into the valve block for maintenance and troubleshooting. The schematic shown in Fig. 54 is a typical gathering head circuit. Always refer to the schematic in your Bucyrus America, Inc. Parts Book for your machine.

© BUCYRUS AMERICA, INC.

Fig. 54: Gathering head circuit

Note: Solenoid designations are GHD (gathering head down) and GHU (gathering head up).

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Hydraulic ____________________________________________________ Cutter head cylinder circuit DANGER! The area under and around the raised cutter head is dangerous.

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

Oil is supplied by hydraulic pump section A1 to the cutter head working section on the main control valve. By manual or remote solenoid control, the spool allows oil to enter the cutter head cylinder circuit. The cutter head cylinder is a double-acting cylinder with load holding cartridge. There are two (2) cutter head cylinders, one on each side of the machine.

To lower the cutter head (retract cylinders), push the handle. Oil goes to the extension port of the cylinders and also pilots open the load holding cartridge allowing oil to exit the retract ports on the cylinders. The oil continues to the anti-chatter/maintenance valve block where it passes through a counterbalance valve which is set to relieve at 1,200 psi, then through the main control valve and a 10-micron bypassing return filter into the oil tank. shear down/maintenance valve (anti-chatter)

The shear down/anti chatter manifold has three primary functions: 1. It provides back pressure against the shear cylinder pistons when shearing down to prevent the machine form climbing the face (raising the machine off of the ground).

2. It provides back pressure against the shear cylinder pistons when lowering the cutter head without shearing. This allows for a smooth downward motion without allowing the load for the cutter head to run uncontrollably.

3.

It allows for bypassing of the counterbalance valve to eliminate the back pressure against the shear cylinder pistons. This provides the maximum pressure differential between the two sides of the shear cylinders which allows the machine to be raised off the ground (jack-knifed). To jack-knife the miner, the stabilizer shoe is first lowered and then the cutter head is lowered with the bypass opened. At this point, the machine can be inspected, adjustments can be made to the crawler tracks.

4.

This counterbalance valve is set at 1,200 psi.

________________________________________________________________ 5.72 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

There are two (2) port reliefs in the working section of the main control valve. Both port reliefs are set at 2,800 psi. To raise the cutter head (extend cylinders), pull the handle. Oil goes to port “P2” of the antichatter/maintenance valve free flowing thru the check valve out of port “P1” and continues to the retract port of the cylinders free flowing thru the check valve of the load holding cartridge to retract the cylinders.

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

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

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

This schematic shown is Fig. 55 is a typical cutter head cylinder raise circuit. Always refer to the schematic in your Bucyrus America, Inc. Parts Book for your machine.

© BUCYRUS AMERICA, INC.

Fig. 55: Cutter head raise circuit

Note:

Solenoid designations are CHD (cutter head down) and CHU (cutter head up).

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Hydraulic ____________________________________________________ Reduced (MCV) pilot pressure circuit - radio function main control valve The pilot pressure circuit is powered by the hydraulic pump gear section rated at 5 gpm at 600 psi. From the pump, oil passes through a 10 micron by-passing pressure filter and provides hydraulic power to the three pilot pressure circuits.

The oil continues to a manifold where the oil separates and goes thru a pressure reducing valve. Oil continues to the pilot port of the main control valve. The reduced pressure is required to prevent damage to the main control valve. This circuit supplies pilot pressure which allows the small solenoid pilot valves to shift the spools in the working sections of the main control valves.

The five (5) working sections are as follows: cutter raise, conveyor raise, conveyor swing, gathering head, and stabilizer. The pilot circuit allows the miner operator to operate the main control valve by the radio system.

When the solenoid coil is energized it shifts the spool in the main control valve, allowing oil flow to the selected function. When the solenoid coil is de-energized, the spool in the main control valve goes to the neutral position.

The schematic shown is Fig. 56 is a typical reduced pilot pressure circuit. Always refer to the schematic in your Bucyrus America, Inc. Parts Book for your machine.

________________________________________________________________ 5.74 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

The pilot pressure oil passes through a 3 micron non-bypassing filter and is controlled by a pressure regulator that is normally set to 1000 psi. When the non by-passing 3 micron filter element starts clogging with trapped particles the radio system/solenoid functions will slow down indicating it is time to change the 3 micron element. For filter element maintenance and changing schedules, see the Maintenance section in this chapter.

___________________________________________________ Hydraulic

© BUCYRUS AMERICA, INC.

Fig. 56: Reduced (MCV) pilot pressure circuit - radio function main control valve circuit

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Hydraulic ____________________________________________________ Accumulator circuit The accumulator is pre-charge with nitrogen to 400 psi. The difference between the pilot pressure of 600 psi and the pre-charge pressure of 400 psi provides a volume of oil to allow for remote operation of the fire suppression and breaker on/off control valves when the pump is not operational. The accumulator pressure should closely track the pilot circuit pressure. If the accumulator pressure drops below 450 psi, shutdown the machine and call maintenance.

The accumulator circuit is supplied from the pilot pressure manifold which is supplied by hydraulic pump section described on page 5.74.

This circuit is used for manual and automatic reset for the breaker on and off (main and tram) using hydraulic cylinders and also for the deluge fire suppression system. From the pilot pressure manifold, oil free flows thru a check valve and charges the one gallon accumulator. The check valve traps oil pressure in the circuit since the three unit solenoid manifold has normally closed cartridges. The manual control valve is blocked allowing pressure to be available when the machine pump is not running to reset the breakers and to set off the fire suppression system.

The breaker reset function can be operated by the manual breaker control valve or by radio via solenoids. The shuttle valve has two oil supply ports with one outlet port. One oil supply is from the manual breaker control valve and the other is from the solenoid valve. The outlet port goes to the cylinder to operate the breaker. There are two shuttle valves, one to turn on the breaker and one to turn the breaker off.

Breaker On (BON), the coil is energized and shifts the spool allowing oil to travel to the extend side of the main breaker cylinder and to the retract side of the tram breaker cylinders. In both cases, the BON turns on. Breaker Off (BOF), the coil is energized and shifts the spool allowing oil to travel to the retract side of the main breaker cylinder and to the extend side of the tram breaker cylinders. In both cases, the BOF turns off. If there is no radio function, the manual breaker control valve will use the accumulator pressure to supply oil for breaker reset on and off.

The remaining solenoid in the 3-unit manifold is for the deluge fire suppression system. When the solenoid coil is energized it shifts the spool, allowing oil to travel to the 2-way/2-position water valve, shifting its spool to allow water pressure to pass through it to the deluge fire spray manifolds. The water valve has a detent spool which keeps the water valve open if the battery back-up uses up its energy.

IMPORTANT! You must manually reset the 2-way, 2-position water valve to reset the deluge fire spray circuit.

________________________________________________________________ 5.76 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

WARNING! Shutdown the machine and call maintenance if the accumulator pressure drops below 450 psi.

___________________________________________________ Hydraulic IMPORTANT! The backup accumulator must maintain a minimum pressure of 500 psi for 12 minutes after the pump has been de-energized. For maintenance on the circuit, loosen the fitting SLOWLY until the pressure is released.

The schematic shown in Fig. 57 is a typical accumulator circuit. Always refer to the schematic in your Bucyrus America, Inc. Parts Book for your machine.

© BUCYRUS AMERICA, INC.

Fig. 57: Accumulator circuit

Note: See the water section for further scrubber and dust/cooling systems information and for the water circuit.

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Hydraulic ____________________________________________________ Dust-scrubber sprays hydraulic circuit The pilot hydraulic pressure circuit is powered by the hydraulic pump gear section rated at 5 gpm at 600 psi. From the pump, oil passes through a 10 micron by-passing pressure filter, relief valve, a 3 micron non-bypassing filter and pressure manifold and provides hydraulic power to three pilot pressure circuits.

The oil continues to the pilot pressure manifold where the oil separates for the dust and scrubber sprays hydraulic circuit. From the pilot pressure manifold oil flows to a 2-unit solenoid manifold which has normally closed cartridges. One cartridge is for the scrubber spray system and the other is for the dust/cooling water system.

In both cases, when the solenoid coil is de-energized, the spool in the hydraulic pilot valve shifts back to its neutral position which vents the hydraulic pilot pressure on the water control valve. This venting allows the water control valves to return to their normally closed positions.

The dust sprays automatically turn on when the cutter head starts. The dust sprays can be turned on or off manually from the radio.

The scrubber sprays automatically turn on when the scrubber motor starts. The scrubber sprays cannot be turned on or off from the radio.

The schematic shown in Fig. 58 is a typical dust-scrubber sprays circuit.

Always refer to the schematic in your Bucyrus America, Inc. Parts Book for your machine.

________________________________________________________________ 5.78 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

When the DS coil is energized it shifts the spool allowing oil to travel to the pilot operated normally closed water valve, shifting its spool to allow water pressure to pass through it to the dust/cooling water circuit.

When the SS coil is energized it shifts the spool, allowing oil to travel to the pilot operated normally closed water valve, shifting its spool to allow water pressure to pass through it to the scrubber spray circuit.

___________________________________________________ Hydraulic

© BUCYRUS AMERICA, INC.

Fig. 58: Dust and scrubber sprays hydraulic circuit

Note: See water circuit in Water section of this chapter.

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General _____________________________________________________ Continuous Miner water system overview Water is supplied to the continuous miner for the following purposes: ■

deluge water fire protection

■

cooling water for motors, transformers, etc.

■

cooling water for dust suppression

■

air cleaning via the scrubber system

■

washdown hoses

■

flow rate of 10 gpm minimum for cooling

■

total flow rate: based on customer dust plan

■

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

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

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

________________________________________________________________ 6.80 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

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

______________________________________________________ Water Water supply circuit The water pressure manifold supplies water to all the water circuits (Fig. 59). Mine water is connected to a ball valve typically mounted on the right rear corner of the machine. From the ball valve the water then passes through the ball valve with the right hand washdown hose attached. The water continues through a 150 micron bypassing filter, a flow meter, and on to A 3-unit pilot operated water valve and the water pressure manifold. There are gauges located upstream and downstream of the filter to indicate when the filter element requires maintenance. For component location see Fig. 60.

© BUCYRUS AMERICA, INC.

Fig. 59: Water supply circuit

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General _____________________________________________________ Fig. 60: Scrubber and dust-cooling component locations

23-unit RH CH spray manifold

23-unit LH spray manifold

1/2” relief valve

1/2” relief valve

4-unit throat spray manifold (LH & RH)

1/2” NPT ball valve

3/4” ball valve 3-way

2-unit side spray manifold 1/2” ball valve

2-unit side spray manifold 1/2” ball valve

2-unit side spray manifold

4-unit side spray manifold

0-1000 psi pressure gauge (Qty: 2)

1/4” flow control valve 3/4” ball valve dust/water bypass Pilot operated water valves Scrubber sprays

Mounted in sump box:1” NPT suction strainer Spray nozzle HI/4 VV-110 08 (flat) spray pattern 1” jet pump

1/2” ball valve 1” Y-strainer 1/2” female quick disconnect

1/2” female quick disconnect

________________________________________________________________ 6.82 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

4-unit throat spray manifold (LH & RH)

______________________________________________________ Water

© BUCYRUS AMERICA, INC.

Fig. 61: Deluge fire component location

3/8” spray nozzle BD-10 spray pattern (Qty: 3) 3-unit fire spray manifold

3/8” spray nozzle BD-10 spray pattern (Qty: 3) 3-unit fire spray manifold

3/8” spray nozzle BD-10 spray pattern (Qty: 3) 3-unit fire spray manifold

3/8” spray nozzle BD-10 spray pattern (Qty: 3) 3-unit fire spray manifold

3/8” spray nozzle BD-10 spray pattern (Qty: 3) 3-unit fire spray manifold

3/8” spray nozzle BD-10 spray pattern (Qty: 3) 3-unit fire spray manifold

1/2” ball valve fire activation Fire activation/ reset valve

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Water _______________________________________________________ Deluge water fire circuit The deluge fire suppression circuit (Fig. 61) can be operated by manual or remote solenoid control (see Electrical section in this chapter).

When the solenoid coil is energized, it shifts a spool, allowing hydraulic oil to travel to a 2-way, 2-position water valve. The hydraulic fluid shifts the spool, allowing the water to pass through it to the deluge fire spray manifolds. For the hydraulic portion of this circuit, see Fig. 63 in the Hydraulic section of this chapter. The water valve has a detent spool, which keeps the valve open. The 2-way, 2-position valve can be operated manually and is typically mounted on the left hand side of the machine. The valve must be manually reset to reset the fire suppression circuit.

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

For deluge water fire circuit component locations, see Fig. 62.

Fig. 62: Deluge water fire circuit

________________________________________________________________ 5.84 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

In addition, there is a ball valve used to manually operate the fire suppression circuit typically located on the right rear corner of the machine.

The valve must be manually turned off to reset the fire suppression system.

______________________________________________________ Water Scrubber sprays and sump dump circuit The scrubber spray circuit (Fig. 63) can be operated by manual or remote solenoid control (see Electrical section in this chapter). When the scrubber spray solenoid coil is energized, it shifts a spool, allowing hydraulic oil to flow to the hydraulic pilot operated normally closed water valve. The hydraulic oil shifts a spool, allowing water to pass though it to the scrubber spray circuit. For the hydraulic portion of this circuit, see Fig. 58 in the Hydraulic section of this chapter.

There is a manual ball valve that is used to bypass the pilot operated water valve so that the miner can be operated until maintenance can be performed.

© BUCYRUS AMERICA, INC.

The scrubber sprays automatically turn on when the scrubber motor starts. They cannot be turned on or off from the radio.

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

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

Fig. 63: Scrubber sprays and sump dump circuit

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Water _______________________________________________________ Dust-cooling water supply circuit The dust-cooling water circuit (Fig. 64) can be operated by manual or remote solenoid control (see Electrical section in this chapter). When the dust-cooling water solenoid coil is energized, it shifts a spool, allowing hydraulic oil to travel to the hydraulic pilot operated normally closed water valve. The water pressure manifold supplies all water to the dustcooling circuits. For the hydraulic portion of this circuit, see Fig. 58 in the Hydraulic section of this chapter.

There is a manual ball valve that is used to bypass the pilot operated water valve so that the miner can be operated until maintenance can be performed.

The dust-cooling circuit described below is for a typical Bucyrus miner containing optional bi-directional spray manifolds and side sprays. The circuit for your machine may vary depending on your dust plan and unique requirements. Always refer to the schematic in your Bucyrus America parts book for your machine.

Fig. 64: Dust-cooling water supply circuit

________________________________________________________________ 5.86 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

The dust sprays typically turn on when the cutter head starts. The sprays can be turned on or off from the radio.

______________________________________________________ Water Tram trickle circuit The tram trickle circuit (Fig. 65) can be operated by manual or remote solenoid control (see Electrical section in this chapter). When the dustcooling water solenoid coil is energized, it shifts a spool, allowing hydraulic oil to travel to the hydraulic pilot operated normally closed water valve. Water then flows through a flow control valve to left- and rightmounted crawler sprays. The sprays can be turned on or off from the radio.

The tram trickle circuit described below is for a typical Bucyrus miner containing optional bi-directional spray manifolds and side sprays. The circuit for your machine may vary depending on your dust plan and unique requirements. Always refer to the schematic in your Bucyrus America parts book for the machine.

© BUCYRUS AMERICA, INC.

Fig. 65: Tram trickle circuit

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Water _______________________________________________________ Dust-cooling machine circuit The dust-cooling machine circuit (Fig. 66) is supplied from the pressure manifold. This circuit cools the pump, tram, continuous loading arm (CLA) and cutter head motors. A portion of the CLA motor cooling water is used for the gathering head pan sprays and the (optional) gathering head side sprays. A portion of the cutter head motor cooling water is used to supply the left and right hand throat spray manifolds.

The throat spray manifolds help keep dust from flowing up the conveyor as the coal is being transported.

Bucyrus has an optional spray package available for chassis spray.

Water flows to a ball valve, used to turn off or on the (optional) chassis side sprays. With the ball valve open, water supplies three manifolds: two mounted on the left hand side of the machine (with four sprays total spraying towards the front of the machine) and three mounted on the right hand side of the machine (with two sprays total spraying towards the rear of the machine). The side sprays assist airflow direction and dust control.

The dust-cooling circuit described below is for a typical Bucyrus miner containing optional bi-directional spray manifolds and side sprays. The circuit for your machine may vary depending on your dust plan and unique requirements. Always refer to the schematic in your Bucyrus America parts book for your machine.

________________________________________________________________ 5.88 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

The cooling water continues from the cutter head motor through a diverter valve to a bi-directional spray manifold. The diverter valve allows for the selection of the spray direction through the manifold (left to right or right to left). This portion of the circuit is equipped with an atmospheric relief valve in case pressure builds up from clogged spray nozzles. A pressure gauge (optional), is used to monitor nozzle pressure.

______________________________________________________ Water

© BUCYRUS AMERICA, INC.

Fig. 66: Dust-cooling machine circuit

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Electrical ____________________________________________________ Continuous Miner electrical system overview Electrical energy is used to power the Continuous Miner. The electrical system is assembled for 950 3-phase AC voltages, at 60 Hertz (Hz) to match local mine power supplied via a trailing cable. Mine electrical power, stepped down by transformers, fed through circuit breakers and set up through electrical control circuitry, provides energy for the watercooled drive motors.

Basic principles

Schematics A schematic diagram is an illustration which shows the electrical relationship of the components and the circuits typically with standard electrical symbols (Fig. 81). A schematic diagram does not show the physical location of the components. In an electrical schematic, components are shown in their deenergized position. A set of normally open contacts (N.O.) close when the coil is energized and a set of normally closed (N.C.) open when the coil is energized.

________________________________________________________________ 5.90 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

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

___________________________________________________ Electrical

© BUCYRUS AMERICA, INC.

Fig. 67: Standard electrical symbols

______________________________________________________________ A6474X307 VASS/0 5.91

Electrical ____________________________________________________

© BUCYRUS AMERICA, INC.

Fig. 69: Electrical component layout

1. Left cutter motor 2. Right cutter motor 3. Left CLA motor 4. Right CLA motor 5. Pump motor 6. Left tram motor 7. Right tram motor 8. Emergency stop 9. Methane monitor display 10. Main controller 11. I.S. tram switch 12. Methane warning light

________________________________________________________________ 5.92 Bucyrus – Model 25M1AC Continuous Miner

___________________________________________________ Electrical Trailing cable A trailing cable (Fig. 68) with three power conductors, labeled L1, L2, L3, two (2) ground conductors (G), and a ground check conductor (GC) supplies power to the machine. A three-conductor 2/0 to 4/0 cable is used with the 950V machines.

Cables are designed with a fire-proof, tough outer jacket to withstand the constant abuse of flexing, reeling, and the exposure to sharp objects on the mine floor. They are not designed to withstand being run over by mobile equipment, especially Continuous Miners. Trailing cables exposed to moving equipment are required to be hung on the trailing cable hanger (Fig. 68) to prevent damage to insulation.

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

© BUCYRUS AMERICA, INC.

Fig. 68: Trailing cable (typical)

Trailing cable hanger

Trailing cable

Trailing cable hanger

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

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

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

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

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

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

______________________________________________________________ A6474X307 VASS/0 5.93

Electrical ____________________________________________________

© BUCYRUS AMERICA, INC.

Fig. 69: Electrical component layout (cont.)

A. B. C. D. E. F. G. H. I.

Headlights Area light Graphics display Scrubber motor Antenna Text display Fire spray Dust spray Circuit breaker reset

________________________________________________________________ 5.94 Bucyrus – Model 25M1AC Continuous Miner

___________________________________________________ Electrical Controller case—control breakers

© BUCYRUS AMERICA, INC.

Mounted on the front wall of the controller case (Fig. 70) are control breakers.

control breaker “CB4”

“CB4” is a 15A breaker for the 120VAC- supply voltage.

control breaker “CB5”

“CB5” is a 15A breaker for the 120VAC+ supply voltage.

Control breaker “CB6”

“CB6” is a 10A breaker for the 120VAC- side of the area light circuit.

control breaker “CB7”

“CB7” is a 10A breaker for the 12V0AC+ side of the area light circuit.

control breaker “CB8”

“CB8” is a 20A breaker for the 12VAC- side of the head light circuit.

control breaker “CB9”

“CB9” is a 20A breaker for the 120VAC+ side of the head light circuit.

control breaker “CB10”

“CB10” is a 5A spare breaker.

control breaker “CB11”

“CB11” is a 5A breaker on the 120VAC side of the machine controller power supply circuit.

control breaker “CB12”

“CB12” is a 5A breaker on the 120VAC- side of the solenoid circuit.

control breaker “CB13”

“CB13” is a 5A breaker on the 120VAC+ side of the solenoid circuit.

Fig. 70: Controller case

______________________________________________________________ A6474X307 VASS/0 5.95

Electrical ____________________________________________________ Operator’s case The operator’s case is located on the back right hand side of the machine. The rear wall of the operator’s case (Fig. 71) is accessed by opening the case cover and then opening the swing panel. Typically mounted on the rear wall are bridge rectifiers, methane monitor relay, and a transformer.

bridge rectifier “BR1”

The bridge rectifier for the methane monitor relay, “BR1”, converts 120VAC to DC.

bridge rectifier “BR2”

The bridge rectifier for the dust spray relay, “BR2”, converts 120VAC to DC.

bridge rectifier “BR4”

The bridge rectifier for the scrubber spray relay, “BR4”, converts 120VAC to DC.

methane monitor relay “MMR”

The methane monitor relay, “MMR”, interlocks with the cutter contactors. When “MMR” opens, the cutter contacts will open, stopping the cutters when the methane monitoring system determines there is high methane concentrations.

transformer “XFMR”

Transformer “XFMR” converts the incoming 950V to 120VAC and 12 VAC.

headlight contactor “HLR”

“HLR” is the contactor for the machine headlights.

power center trip relay “OE”

“OE” is the relay controlling the power center trip.

circuit breaker “CB1”

Circuit breaker “CB1” isolates the entire machine from power supplied via the trailing cable.

circuit breaker “CB2”

Circuit breaker “CB2” isolates the gathering head, fan and pump motor circuits.

________________________________________________________________ 5.96 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

IMPORTANT! This component location information is typical. Always verify component layout with the information in the Bucyrus parts book for your machine.

___________________________________________________ Electrical Fig. 71: Operator’s case - rear wall Methane monitor Relay “MMR”

Bridge Rectifier “BR1”

Bridge Rectifier “BR2”

Bridge Rectifier “BR4”

Transformer “XFMR” Power center trip relay “OE”

© BUCYRUS AMERICA, INC.

Headlight contactor “HLR”

Circuit breaker “CB1”

Circuit breaker “CB2”

______________________________________________________________ A6474X307 VASS/0 5.97

Electrical ____________________________________________________ Traction case The traction case (Fig. 72) is typically located on the right hand side of the machine, and is accessed by opening the controller cover and then opening the swing panel. Typically mounted on the rear wall are motor mates and a terminal block.

IMPORTANT! This component location information is typical. Always verify component layout with the information in the Bucyrus parts book for your machine.

motor mate “MMG”

Motor mate “MMG” is the current transducer for the left drive motor.

motor mate “MMH”

Motor mate “MMH” is the current transducer for the right drive motor.

overload relay “OL12”

“OL12” is the thermally-operated overload relay for the left drive motor.

overload relay “OL13”

“OL13” is the thermally-operated overload relay for the right drive motor.

control transformer “T1”

“”T1” is the control transformer that converts the incoming 950V power supply to 12V and 120V.

tram breaker “CBT”

Tram breaker “CBT” is a 1000A breaker for the tram drives.

Fig. 72: Traction case

“CBT”

“T1”

Tram drive meters

“OL13”

Motor Mate “MMG”

Motor Mate “MMH”

“OL12”

________________________________________________________________ 5.98 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

Each motor mate is triple output inductive current transducer. It takes the current from each leg of the motor and reduces it to a 4 to 20mA output that is sent to the control system.

___________________________________________________ Electrical Main controller case - rear wall The rear wall of the main controller case (Fig. 73) is accessed by opening the controller cover and then opening the swing panel. It is typically located on the left side of the machine, midway the tractor frame inside the crawler frame.

© BUCYRUS AMERICA, INC.

IMPORTANT! This component location information is typical. Always verify component layout with the information in the Bucyrus parts book for your machine. vacuum contactor “F”

Vacuum contactor “F” is the contactor for the pump motor.

vacuum contactor “A”

Vacuum contactor “A” is the contactor for the left cutter motor.

vacuum contactor “B”

Vacuum contactor “B” is the contactor for the right cutter motor.

overload relay “OL1”

“OL1” is an instantaneous overload relay for the left cutter head motor.

overload relay “OL2”

“OL2” is a thermally-operated overload relay for the left cutter head motor.

overload relay “OL3”

“OL3” is an instantaneous overload relay for right cutter head motor.

overload relay “OL4”

“OL4” is a thermally-operated overload relay for the right cutter head motor.

overload relay “OL11”

“OL11” is a thermally-operated overload relay for the pump motor.

time delay “TD2”

“TD2” is a time delay for the cutter head motor start.

______________________________________________________________ A6474X307 VASS/0 5.99

Electrical ____________________________________________________ Fig. 73: Main controller case - rear wall

“OL2”

“OL3”

“OL4”

“TD2”

Vacuum Contactor “A”

Vacuum Contactor “B”

“OL11”

Vacuum contactor “F”

________________________________________________________________ 5.100 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

“OL1”

___________________________________________________ Electrical Main controller case - inside swing panel The swing panel of the main controller case (Fig. 74) is accessed by opening the controller cover and then opening the swing panel. It is typically located on the left side of the machine, midway the tractor frame inside the crawler frame.

© BUCYRUS AMERICA, INC.

IMPORTANT! This component location information is typical. Always verify component layout with the information in the Bucyrus parts book for your machine. vacuum contactor “CF”

Vacuum contactor “CF” is the forward contactor for the left and right conveyor motors.

vacuum contactor “CR”

Vacuum contactor “CR” is the reverse contactor for the left and right conveyor motors.

vacuum contactor “E”

Vacuum contactor “E” is the contactor for the scrubber motor.

overload relay “OL5”

“OL5” is an instantaneous overload relay for conveyor forward.

overload relay “OL6”

“OL6” is a thermally-operated overload relay for conveyor forward.

overload relay “OL7”

“OL7” is an instantaneous overload relay for conveyor reverse.

overload relay “OL8”

“OL8” is a thermally-operated overload relay for conveyor reverse.

overload relay “OL10”

“OL10” is a thermally-operated overload relay for the scrubber motor.

time delay “TD4” e-stop bypass relay “ESB”

“TD4” is a time delay for the gathering head motor relay.

The e-stop bypass relay, “ESB”, bypasses the machine stop button.

Fig. 74: Main controller case - inside swing panel “OL5”

“OL7”

“ESB”

“TD4”

Vacuum Contactor “CF”

Vacuum Contactor “CR”

“OL6”

“OL8”

Vacuum Contactor “E”

“OL10”

______________________________________________________________ A6474X307 VASS/0 5.101

Electrical ____________________________________________________ Main controller case - front side swing panel The front side of the main controller case swing panel (Fig. 75) is accessed by opening the main controller case cover. Typically mounted on the rear of the swing panel are the control system components.

IMPORTANT! This component location information is typical. Always verify component layout with the information in the Bucyrus parts book for your machine.

The power supply module converts a 110VAC input to 24VDC output for the control system.

central processor

The control system software is stored on the central processor (control module).

“F3”

“F3” is a 10A fuse between the solenoid bank and the machine controller power supply.

“F4”

“F4” is a 10A fuse between the machine controller and the machine controller power supply.

“F5”

“F5” is a 5A fuse between the text display and the machine controller power supply.

“FU1”

“FU1” is a 5A fuse between the radio traction module and text display.

“FU2”

“FU2” is a 5A fuse between the radio traction module and text display.

“FU3”

“FU3” is a 5A fuse between the radio traction module and text display.

Fig. 75: Main controller case - outside swing panel

Central processor Power supply

“FU1”

“FU2”

“FU3”

“F3”

“F4”

“F5”

________________________________________________________________ 5.102 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

power supply

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

The schematic shown in Fig. 76 is typical of a power schematic. Always refer to the schematic in your Bucyrus America, Inc. parts book for your machine.

© BUCYRUS AMERICA, INC.

Fig. 76: Power circuit with control

______________________________________________________________ A6474X307 VASS/0 5.103

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

The schematic shown in Fig. 77 is a typical methane monitor circuit.

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

© BUCYRUS AMERICA, INC.

Fig. 77: Methane monitor circuit

________________________________________________________________ 5.104 Bucyrus – Model 25M1AC Continuous Miner

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

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

The schematic shown in Fig. 78 is a typical lighting circuit. Always refer to the schematic in your Bucyrus America, Inc. parts book for your machine.

© BUCYRUS AMERICA, INC.

Fig. 78: Control headlights and area lights circuit

______________________________________________________________ A6474X307 VASS/0 5.105

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

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

The schematic shown in Fig. 79 is a typical low oil circuit. Always refer to the schematic in your Bucyrus America, Inc. parts book for your machine.

© BUCYRUS AMERICA, INC.

Fig. 79: Low oil circuit

________________________________________________________________ 5.106 Bucyrus – Model 25M1AC Continuous Miner

___________________________________________________ Electrical Pump motor power circuit with control The pump motor can be started in manual by depressing the momentary switch. This completes the circuit across coil “F” and starts the pump motor. There are three thermal overloads in the pump circuit: OL11 is the thermal overload for the pump and OL12 and OL13 are the thermal overloads for the tram. This will supply three (3) phase power to the tram transformer and to the electrical tram drives. For the control circuit, when the pump contactor energizes, the “F” interlock closes. When the three (3) phase power is on the tram drives, the control contacts in the tram drives close and will complete the holding circuit for the pump motor. To stop the pump motor, depress the momentary pump stop switch. The pump motor has to be running before any other motor can be started.

© BUCYRUS AMERICA, INC.

The schematic shown in Fig. 80 is a typical pump motor power circuit.

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

______________________________________________________________ A6474X307 VASS/0 5.107

Electrical ____________________________________________________

© BUCYRUS AMERICA, INC.

Fig. 80: Pump motor circuit with control

________________________________________________________________ 5.108 Bucyrus – Model 25M1AC Continuous Miner

___________________________________________________ Electrical Cutter motor power circuit with control The pump motor must be running before the cutter motors will start.

The cutter motor is a two-hand start. To start: push the pump start and the cutter motor start momentary switch at the same time. The cutter motor can be started in manual by depressing the pump and the cutter momentary switch. This completes the circuit across coil “A” and starts the left cutter motor, as well as starting the TD2 timer for the “B” contactor right cutter motor. Both cutter motors do not start at the same time. When the Time Delay (TD2) timer times out, this completes the circuit across coil “B” and starts the right cutter motor. The holding circuit interlock “A” and “B” must be closed. There are two (2) thermal overloads and two (2) instantaneous overloads; one (1) for each motor Overload (OL)1, 2, 3 and 4. To stop the cutter motor, depress the momentary cutter stop switch.

© BUCYRUS AMERICA, INC.

The schematic shown in Fig. 81 is a typical cutter motor power circuit.

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

Fig. 81: Cutter motor circuit

______________________________________________________________ A6474X307 VASS/0 5.109

Electrical ____________________________________________________

© BUCYRUS AMERICA, INC.

Fig. 81: Cutter motor power circuit (cont.)

________________________________________________________________ 5.110 Bucyrus – Model 25M1AC Continuous Miner

___________________________________________________ Electrical Conveyor motor circuit with control The pump motor must be running before the conveyor motors will start.

The conveyor motors can be started in manual by depressing the momentary switch. This completes the circuit across coil conveyor forward (CF) and will start both conveyor motors. There are four (4) overloads in the conveyor circuit. There are two (2) thermal overloads and two (2) instantaneous overloads; one (1) for each motor OL5, 6, 7 and 8 for the control circuit when the conveyor contactor comes in the “CF” interlock closes. This completes the holding circuit. To stop the conveyor motor, depress the momentary conveyor stop switch.

The schematic shown in Fig. 82 is a typical conveyor motor circuit. Always refer to the schematic in your Bucyrus America, Inc. parts book for your machine.

© BUCYRUS AMERICA, INC.

Fig. 82: Conveyor forward and reverse motor circuits with control

______________________________________________________________ A6474X307 VASS/0 5.111

Electrical ____________________________________________________

© BUCYRUS AMERICA, INC.

Fig. 82: Conveyor forward and reverse motor circuits with control (cont.)

________________________________________________________________ 5.112 Bucyrus – Model 25M1AC Continuous Miner

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

The scrubber motor can be started in manual by depressing the momentary switch. This completes the circuit across coil “E” and starts the scrubber motor. This energizes the screen sprays for the scrubber.

There is one (1) overload in the scrubber circuit called the OL10 thermal overload. The scrubber does not have a holding circuit.

The schematic shown in Fig. 83 is a typical scrubber motor circuit. Always refer to the schematic in your Bucyrus America, Inc. parts book for your machine.

© BUCYRUS AMERICA, INC.

Fig. 83: Scrubber motor circuit with control

______________________________________________________________ A6474X307 VASS/0 5.113

Electrical ____________________________________________________

© BUCYRUS AMERICA, INC.

Fig. 83: Scrubber motor circuit with control (cont.)

________________________________________________________________ 5.114 Bucyrus – Model 25M1AC Continuous Miner

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

The schematic shown in Fig. 84 is a fire suppression circuit in radio remote. Always refer to the schematic in the Bucyrus America, Inc. parts book for your machine.

© BUCYRUS AMERICA, INC.

Fig. 84: Fire suppression in radio remote schematic

______________________________________________________________ A6474X307 VASS/0 5.115

Electrical ____________________________________________________ Shear up/down in radio remote The shear up solenoid is energized and moves the cutter boom up.

When the shear down solenoid is energized, the cutter boom is lowered. Pressing and holding the radio remote key keeps the shear up and shear down solenoid energized. The pump motor must be running in order to raise or lower the cutter boom.

The schematic shown in Fig. 85 is a typical shear up/down in radio remote circuit. Always refer to the schematic in your Bucyrus America, Inc. parts book for your machine.

© BUCYRUS AMERICA, INC.

Fig. 85: Shear up/down schematic

________________________________________________________________ 5.116 Bucyrus – Model 25M1AC Continuous Miner

_______________________________________ Mechanical assemblies Stabilizer cylinder raise/lower in radio remote The stabilizer lower solenoid is energized and moves the stabilizer down. When the stabilizer raise solenoid is energized, the stabilizer is raised. Pressing and holding the radio remote key keeps the stabilizer lower solenoid energized. The pump motor must be running in order to raise or lower the stabilizer cylinder.

The schematic shown in Fig. 86 is a typical stabilizer cylinder raise/ lower in radio remote circuit. Always refer to the schematic in the Bucyrus America, Inc. parts book for your machine.

© BUCYRUS AMERICA, INC.

Fig. 86: Stabilizer cylinder raise/lower schematic

______________________________________________________________ A6474X307 VASS/0 5.117

Electrical ____________________________________________________ Gathering pan raise/float in radio remote The gathering pan raise solenoid is energized and moves the gathering pan up. When the gathering pan float solenoid is energized, the gathering pan is floated down. Pressing and holding the radio remote key keeps the gathering pan raise solenoid energized. The pump motor must be running in order to raise or lower the gathering pan.

The schematic shown in Fig. 87 is a typical gathering pan raise/float in radio remote circuit. Always refer to the schematic in the Bucyrus America, Inc. parts book for your machine.

© BUCYRUS AMERICA, INC.

Fig. 87: Gathering pan raise/float schematic

________________________________________________________________ 5.118 Bucyrus – Model 25M1AC Continuous Miner

___________________________________________________ Electrical Conveyor left/right in radio remote The conveyor left solenoid is energized and moves the conveyor left.

When the conveyor right solenoid is energized, the conveyor is moved right. When the conveyor raise solenoid is energized, the conveyor is raised. When the conveyor lower solenoid is energized, the conveyor is lowered. Pressing and holding the radio remote key keeps the conveyor solenoid energized. The pump motor must be running in order to control the conveyor raise, lower, and swing left/right.

The schematic shown in Fig. 88 is a typical conveyor left/right in radio remote circuit. Always refer to the schematic in the Bucyrus America, Inc. parts book for your machine.

© BUCYRUS AMERICA, INC.

Fig. 88: Conveyor left/right raise lower in radio remote schematic

______________________________________________________________ A6474X307 VASS/0 5.119

Electrical ____________________________________________________ Cutter dust sprays in radio remote The cutter dust sprays are typically turned on automatically when the cutter motors are started. The control system has the possibility to turn the cutter water sprays on and off from a key on the remote console. However, this function is normally not available due to the wiring configuration of most miner electrical systems. If remote control of the water sprays is required, contact your local Bucyrus America, Inc. representative or mine personnel.

The schematic shown in Fig. 89 is a typical cutter dust sprays in radio remote circuit. Always refer to the schematic in the Bucyrus America, Inc. parts book for your machine.

© BUCYRUS AMERICA, INC.

Fig. 89: Cutter dust sprays in radio remote schematic

________________________________________________________________ 5.120 Bucyrus – Model 25M1AC Continuous Miner

___________________________________________________ Electrical Breaker on and off in radio remote The control system allows the main circuit breaker CB1, CB2, or auxiliary and tram breaker to be turned on, off, and to reset a tripped breaker using the radio remote control console. This normally requires that a battery backup version of the power supply to be installed on the machine.

The schematic shown in Fig. 90 is a typical breaker on/off in radio remote circuit. Always refer to the schematic in the Bucyrus America, Inc. parts book for your machine.

© BUCYRUS AMERICA, INC.

Fig. 90: Breaker on/off in radio remote schematic

______________________________________________________________ A6474X307 VASS/0 5.121

Electrical ____________________________________________________ Tramming The miner can be trammed manually or via the remote console. Before the tram motors will start, the pump motor must be running. While the cutters are running, reverse speed can be incremented even while the forward tram keys are being pressed.

The schematic shown in Fig. 91 is a typical tram circuit. Always refer to the schematic in the Bucyrus America, Inc. parts book for your machine.

© BUCYRUS AMERICA, INC.

Fig. 91: Power tram circuit

________________________________________________________________ 5.122 Bucyrus – Model 25M1AC Continuous Miner

_______________________________________ Mechanical assemblies

© BUCYRUS AMERICA, INC.

Fig. 91: Power tram circuit (cont.)

______________________________________________________________ A6474X307 VASS/0 5.123

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

Important notes

■

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

■

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

■

Use only suitable and approved tools for maintenance work.

■

Use only original Bucyrus spare parts when replacing components.

■

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

■

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

Before maintenance Please observe the following: ■

Shutdown the machine on level ground.

■

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

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

■

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

■

Block any and all elevated assemblies before working under them.

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

■

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

________________________________________________________________ 5.124 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

Please observe the following:

________________________________________________ Maintenance ■

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

© BUCYRUS AMERICA, INC.

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

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

■

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

■

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

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

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

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

■

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

■

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

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

■

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

______________________________________________________________ A6474X307 VASS/0 5.125

Maintenance _________________________________________________ Lubricants and fluid capacities Table 1: Lubricants and fluid capacities Location

Specification

Approximate capacity

Hydraulic oil tank Crawler Idler roller GH Assembly CLA Primary GH Assembly CLA POT Tram Drive Assembly Drum Drive Assembly, high speed (back) Drum Drive Assembly, low speed (front) Motor Lube Hoses

Spec. 100-1 Spec. 100-3 Spec. 100-15 Spec. 100-15 Spec. 100-15 Spec. 100-15

75 gals. (284 L) 1 gal (3.79 L) 1 gal (3.79 L) 2.5 gal (9.46 L) 3 gal (11.36 L) 0.5 gallon (1.89 L)

Spec. 100-15

5 gal (18.93 L)

Spec. 100-14

variable

Notes

1

IMPORTANT! As lubrication technology evolves, manufacturers continue to reformulate their products to obtain improved characteristics regarding wear, water dispersion, water absorption, environmental impact and a variety of other performance criteria. When an approved lubricant on this list has been superseded by a new formulation, it is recommended that the new formulation be tested to ensure compliance with the appropriate Bucyrus specification. At a minimum, a statement of conformance from the lubricant supplier should be obtained.

Reference Table 20 for approved lubricants and specifications.

________________________________________________________________ 5.126 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

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

________________________________________________ Maintenance Table 2: Lubrication and maintenance schedule

© BUCYRUS AMERICA, INC.

Item

Description

Places

Lubricant

Specification

1

Every Shift Cutter head lift cylinder pins

2

Lithium based grease

Spec. 100-3

2

Conveyor swing cylinder pin, front

1

Lithium based grease

Spec. 100-3

3

Conveyor swing cylinder pin, rear

1

Lithium based grease

Spec. 100-3

4

Cutter head frame pivot pin, right

1

Lithium based grease

Spec. 100-3

5

Cutter head frame pivot pin, left

1

Lithium based grease

Spec. 100-3

6

Cutter head bits (Inspect)

1

7

Conveyor roller

2

Lithium based grease

Spec. 100-3

8

Daily Gathering head hinge pin, left

1

Lithium based grease

Spec. 100-3

9

Gathering head hinge pin, right

1

Lithium based grease

Spec. 100-3

10

Crawler idler roller

2

Lithium based grease

Spec. 100-3

11

Conveyor to tractor frame pin, left

1

Lithium based grease

Spec. 100-3

12

Conveyor to tractor frame pin, right

1

Lithium based grease

Spec. 100-3

13

Stabilizer shoe pin

2

Lithium based grease

Spec. 100-3

14

Conveyor swivel pin, top

1

Lithium based grease

Spec. 100-3

15

Conveyor swivel pin, bottom

1

Lithium based grease

Spec. 100-3

16

Hood hinge pin (Inside/Outside)

2

Lithium based grease

Spec. 100-3

17

Gathering pan raise pin

4

Lithium based grease

Spec. 100-3

18

Conveyor chain take-up pin

2

Lithium based grease

Spec. 100-3

19 20

CLA head pot assembly (Check) CLA head transfer case (Check)

2 2

High demulsibility EP gear oil High demulsibility EP gear oil

Spec. 100-15 Spec. 100-15

21

Tram gear case (Check)

2

High demulsibility EP gear oil

Spec. 100-15

22

Input cutter head gear case (Check)

2

High demulsibility EP gear oil

Spec. 100-15

23

Main cutter head gear case (Check)

2

High demulsibility EP gear oil

Spec. 100-15

24

Hydraulic oil level (Check)

1

AW hydraulic oil

Spec. 100-1

25

Weekly Crawler chain (Inspect)

2

Spec. 100-8

28

Conveyor chain (Inspect)

1

Spec. 100-8

29

Footshaft

30

Fasteners (nuts, bolts, screws)

Inspect

31

Electrical cables, conduits, and glands

Inspect

32

Hydraulic/water hoses and connections

Inspect

33

Lighting

Inspect

34

Reflectors and warning tags

Inspect

35

Machine stop/E-stop switch

Inspect

36

Chain take-up locknut

2

37

Jet pump, hydraulic (Inspect)

1

See Parts Book

38

Jet pump, water (Inspect)

1

See Parts Book

39

Water filter (Change)

1

See Parts Book

2

Lithium based grease

Spec. 100-3

Lithium based grease

Spec. 100-3

______________________________________________________________ A6474X307 VASS/0 5.127

Maintenance _________________________________________________ Table 2 (continued): Lubrication and maintenance schedule Description

Places

Lubricant

Specification

40 41 42

Monthly CLA head pot assembly (Change) CLA head transfer case (Change) Input cutter head gear case (Change)

2 2 2

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

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

43 44 45

Main cutter head gear case (Change) CLAs Input cutter head gear case

2 Inspect 2

High demulsibility EP gear oil

Spec. 100-15

Sample

See Note 1

46 47

Main cutter head gear case CLA head pot assembly

2 2

Sample Sample

See Note 1 See Note 1

48 49 50

CLA head transfer case Tram gear case Main hydraulic tank

2 2 1

Sample Sample Sample

See Note 1 See Note 1 See Note 1

51 52 53

Non-bypassing pilot filter element (Change) Bypassing pilot filter element (Change) Return filter element (Change)

1 2 1

See Parts Book See Parts Book See Parts Book

Every three months 54

RH cutter motor rear bearings (Front & Rear)

2

High temperature lithium complex grease

Spec. 100-14

55

LH cutter motor front bearings (Front & Rear)

2

High temperature lithium complex grease

Spec. 100-14

56

Pump motor bearings (Front & Rear)

2

High temperature lithium complex grease

Spec. 100-14

57

Scrubber motor bearings (Front & Rear)

2

High temperature lithium complex grease

Spec. 100-14

Every six months 58

Tram gear case (Change)

2

High demulsibility EP gear oil

Spec. 100-15

59

Hydraulic oil (Change)

1

AW hydraulic oil

Spec. 100-1

60 61

Strainers (Change) Hydraulic oil filter (Change)

1 1

See Parts Book See Parts Book

62

Breather, hydraulic tank (Change)

3

See Parts Book

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

________________________________________________________________ 5.128 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

Item

________________________________________________ Maintenance Fig. 92: Lubrication chart 24, 45, 48 (check)

24, 42, 45 (check)

6

23,41,44 24,45,48 (fill)

40

20,36,49 (check)

28

50,54

21,40,47(check)

44

20,36,46 (fill) 43

21,40,47(fill) 18

10, 58 11,12

17 8,9 © BUCYRUS AMERICA, INC.

52

26 4,5

52 25,49, 58,60 22,48,57 (check) 22,48,56 (drain)

22,48,56 (fill)

28

13 60

59,37 55

53

38

51

39

39 14,15

2

35

3

19

7 ______________________________________________________________ A6474X307 VASS/0 5.129

Maintenance _________________________________________________ Specific lubrication and maintenance procedures Every shift cutter head lift cylinder pins

Lubricate the right and left cylinder pins (upper and lower) through the grease fittings and remote lube block located on each cylinder (Fig. 93). Pump approximately 3 cu. in. (50 cu. cm.) into each fitting.

Fig. 93: Cutter head cylinder pin location

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

conveyor swing cylinder pin (front and rear)

Lubricate the front and rear conveyor swing cylinder pins through the grease fittings located on each end of the cylinder (Fig. 94). Pump approximately 3 cu. in. (50 cu. cm.) into each fitting.

Fig. 94: Conveyor swing cylinder pin lubrication Conveyor swing cylinder pin grease fitting

Conveyor swing cylinder pin grease fitting

________________________________________________________________ 5.130 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

Cutter head cylinder pin (upper) (2)

________________________________________________ Maintenance cutter head frame pivot pin (left and right)

Lubricate left and right cutter head frame pivot points through the grease fittings located on the left and right front lubrication blocks (Fig. 95). Pump approximately 3 cu. in. (50 cu. cm) of grease into each fitting.

Fig. 95: Cutter head frame pivot pins

Cutter head cylinder boom pin Cutter head frame pivot pin lube block (2)

© BUCYRUS AMERICA, INC.

cutter head bits

Inspect the cutter head bits to ensure that they will rotate in their holders and for damaged or missing bits (Fig. 96). Replace bits immediately if any are missing or damaged.

Fig. 96: Cutter head bit

Bit block

conveyor roller

Cutter bit

Lubricate the conveyor roller through the two (2) grease fittings located on the shaft (Fig. 97). Pump approximately 3 cu. in. (50 cu. cm.) into each fitting.

Fig. 97: Conveyor take-up shaft lubrication

Grease fitting

Grease fitting

______________________________________________________________ A6474X307 VASS/0 5.131

Maintenance _________________________________________________ Daily gathering head hinge pin (right and hand)

Lubricate the left and right gathering head hinge pins through the grease fittings located on the left and right front lubrication blocks (Fig. 98). Pump approximately 3 cu. in. (50 cu. cm.) of grease into each fitting.

Fig. 98: Gathering head hinge pin

crawler idler roller (right and left) conveyor to tractor frame pin (left and right)

Lubricate the left and right crawler idler rollers (Fig. 99) through the grease fittings located on the outside face of the crawler idler roller.

Lubricate the left and right conveyor to tractor frame pin through the grease fittings located on the right and left front lubrication blocks (Fig. 99). Pump approximately 3 cu. in (50 cu. cm) of grease into each fitting.

Fig. 99: Crawler idler roller and conveyor to tractor frame pin lubrication

Conveyor to tractor frame pin

Crawler idler roller

________________________________________________________________ 5.132 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

Gathering head hinge pin

________________________________________________ Maintenance stabilizer shoe pin (right and left)

Lubricate the stabilizer shoe pins (right and left) through the grease fittings located on the lubrication block on the right side of the machine (Fig. 100). Pump approximately 3 cu. in (50 cu. cm) of grease into each fitting.

Fig. 100: Lubrication block - stabilizer shoe

© BUCYRUS AMERICA, INC.

Lubrication block

conveyor swivel pins (top and bottom)

Lubricate the top and bottom conveyor swivel pin located on the pins (Fig. 101). Pump approximately 3 cu. in (50 cu. cm) of grease into each fitting.

Fig. 101: Conveyor swivel pins

Conveyor swivel pin (top)

Conveyor swivel pin (typical)

______________________________________________________________ A6474X307 VASS/0 5.133

Maintenance _________________________________________________ conveyor boom pivot pins (left and right)

Lubricate the conveyor boom pivot pins (Fig. 102) through the lubrication blocks on the right hand and left hand sides of the machine. Pump approximately 3 cu. in (50 cu. cm) of grease into each fitting.

Fig. 102: Conveyor boom pivot pin

gathering head raise cylinder pins (left and right)

Lubricate the gathering head raise cylinder pins (Fig. 103) through the grease fittings located on each end of the cylinder. Pump approximately 3 cu. in (50 cu. cm) of grease into each fitting.

Fig. 103: Gathering pan raise cylinder pins Gathering head raise cylinder pin (upper)

Gathering head raise cylinder pin (lower)

conveyor chain take-up pin (left and right)

Lubricate the conveyor chain take-up pin (Fig. 104) through the grease fitting located on the pin. Pump approximately 3 cu. in (50 cu. cm) of grease into each fitting.

Fig. 104: Conveyor chain take-up pin and nut

Conveyor chain take-up pin

________________________________________________________________ 5.134 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

Conveyor boom pivot pins (2)

________________________________________________ Maintenance

CLA head pot assembly (right and left)

Level the miner and place the gathering head on grade before checking or adding lubricant. Check the oil level in the pot assembly (Fig. 105).

If oil is needed, add oil through the fill hole until oil comes out of the breather.

CLA head transfer case (right and left)

Level the miner and place the gathering head on grade before checking or adding lubricant. Check the oil level in the hydraulic transfer case (Fig. 105). If oil is needed, add oil through the fill hole until oil comes out of the breather.

© BUCYRUS AMERICA, INC.

Fig. 105: CLA head pot assembly and transfer case lubrication

Oil fill, transfer case

tram gear case (right and left)

Oil fill, pot assembly

Oil check (breather), pot assembly

Oil check (breather), transfer case

With the miner in a level position, check the oil level in both tram gear cases by looking at the sight glass located on the side of each gear case (Fig. 106). Oil should be visible in each sight glass. If oil level is low, add oil through the fill plug hole.

Fig. 106: Tram gear case oil level

Oil check

Oil fill

______________________________________________________________ A6474X307 VASS/0 5.135

Maintenance _________________________________________________ input cutter gear case

With the gathering head lowered to ground level and the cutter head boom level with ground, check the oil level in both of the input cutter gear cases by removing the check plug located on each side of the cutter head assembly (Fig. 107). Oil should flow from check plug hole when plug (s) is removed. If oil level is low, add oil through the fill plugs located on each side of the gathering head.

Fig. 107: Input cutter head gear case (s) oil level

main cutter gear case

With the cutter head boom level with the ground, and the check plug positioned at 3 or 9 o’clock, check the oil level in both of the main cutter head gear cases by removing the check plug located on the front of each gear case (Fig. 108). Oil should flow from check plug hole when plug(s) is removed. If oil level is low, add oil through the fill plug hole located on top of each gear case.

Fig. 108: Main cutter head gear case(s) oil level

Oil check plug (one per side) Oil fill plug (one per side)

________________________________________________________________ 5.136 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

Oil fill plug and check (one per side)

________________________________________________ Maintenance hydraulic oil level

With all of the machine cylinders in the fully collapsed position, check the hydraulic oil level (Fig. 109). Remove dipstick from tank and wipe clean. Insert dipstick back into tank and remove. The oil should be level with the full line indicated on dipstick. If oil level is low, add oil until full level is met.

Fig. 109: Hydraulic oil tank level Dipstick location

© BUCYRUS AMERICA, INC.

Hydraulic oil tank

Weekly crawler track tension

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

conveyor chain tension

Check the conveyor chain tension with the machine running. If adjustment is necessary, see the Conveyor chain tension adjustment procedure in this chapter.

footshaft

Lubricate the footshaft (Fig. 110) through the grease fittings located on the footshaft couplings. Pump approximately 3 cu. in (50 cu. cm) of grease into each fitting.

Fig. 110: Footshaft

Footshaft

______________________________________________________________ A6474X307 VASS/0 5.137

Maintenance _________________________________________________

electrical cables, conduits, and glands hoses and fittings

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

Loose fasteners will cause premature wear and failure to bearings, couplings, etc. Inspect and tighten as required the following fasteners: ■

cutter head gear case: hex head bolts

■

cutter head motor bolts

■

center drums: socket head capscrews

■

end drums: socket head bolts

■

tram cases: socket head capscrews

■

tram motors: hex head bolts

■

gathering head CLAs: hex head bolts

■

gathering head pots: hex head bolts

■

gathering head motors: socket head capscrews

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

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

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

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

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

■ Do not exceed working pressure of hydraulic hoses.

■ Visually inspect hoses regularly and replace if damaged.

________________________________________________________________ 5.138 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

fasteners

________________________________________________ Maintenance lighting

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

reflectors and warning tags

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

“machine stop” switches

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

chain take-up pin (right and left)

Lubricate the chain take-up pin (Fig. 111) through the grease fitting located on the nut. Pump approximately 3 cu. in (50 cu. cm) of grease into each fitting.

© BUCYRUS AMERICA, INC.

Fig. 111: Chain take-up pin

Chain pin lubrication

The jet pump and water filter are located on the back left hand side of the machine (Fig. 112). hydraulic jet pump

Inspect the hydraulic jet pump. A change may be required depending on necessity.

water jet pump

Inspect the water jet pump. A change may be required depending on necessity.

water filter

Change the water filter. A more frequent change interval may be required depending on necessity.

Fig. 112: Jet pump and water filter Water filter

Hydraulic jet pump Water jet pump

______________________________________________________________ A6474X307 VASS/0 5.139

Maintenance _________________________________________________ Monthly CLA head pot assembly

Change the oil in both CLA head pot assemblies (Fig. 113).  Level the miner, raise the gathering head pan, and secure in place.  Clean dirt and debris from around the drain plug located under the gear case.  Remove the drain plug and allow oil to completely drain from the gear case.  Clean and reinstall drain plug.  Clean dirt and debris from around the check plug and remove the plug.

 Slowly add oil through the fill plug until oil begins to flow from the check plug hole. Allow sufficient time for the oil to ravel through the gear case when filling.  Clean and reinstall the check and fill plugs.

CLA head transfer case

Change the oil in both CLA head transfer cases (Fig. 113).  Level the miner, raise the gathering head pan, and secure in place.  Clean dirt and debris from around the drain plug located under the gear case.  Remove the drain plug and allow oil to completely drain from the gear case.  Clean and reinstall drain plug.  Clean dirt and debris from around the check plug and remove the plug.  Clean dirt and debris from around the fill plug and remove the plug.  Slowly add oil through the fill plug until oil begins to flow from the check plug hole. Allow sufficient time for the oil to ravel through the gear case when filling.  Clean and reinstall the check and fill plugs.

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

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

________________________________________________________________ 5.140 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

 Clean dirt and debris from around the fill plug and remove the plug.

________________________________________________ Maintenance

© BUCYRUS AMERICA, INC.

Fig. 113: CLA pot assembly and transfer case

Oil fill, transfer case

Oil fill, pot assembly

Oil check (breather), pot assembly

Oil check (breather), transfer case

CLA head transfer case drain plug

CLA head pot drain plug

______________________________________________________________ A6474X307 VASS/0 5.141

Maintenance _________________________________________________ input cutter head gear case

Change the oil in both input cutter head gear cases (Fig.114).  Position the cutter head horizontally (flat back in a vertical position).

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

Fig. 114: Input cutter head gear case Oil fill plug (one per side)

Oil check plug

Drain plug (one per side)

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

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

________________________________________________________________ 5.142 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

 Clean and reinstall the check and fill plugs.

________________________________________________ Maintenance main cutter head gear case

Change the oil in both main cutter head gear cases (Fig. 115).  Lower the cutter head completely to the ground. Clean dirt and debris from around the drain plug, located under the gear case.  Remove the drain plug and allow oil to completely drain from the gear case.  Clean and reinstall the drain plug.  Clean dirt and debris from around the check plug and remove the plug.  Clean dirt and debris from around the fill plug and remove the plug.  Slowly add oil through the fill plug until oil begins to flow from the check plug hole. Allow sufficient time fro the oil to travel throughout the gear case when filling.

© BUCYRUS AMERICA, INC.

 Clean and reinstall the check and fill plugs.

Fig. 115: Main cutter head gear case

Oil check plug (one per side)

Oil fill plug (one per side)

CLAs

Inspect the CLAs (Fig. 116) for damage and CLA bolts for torque by moving with a slate bar. If a CLA needs replaced, see CLA removal and installation procedure in this chapter.

Fig. 116: CLAs

CLA

CLA

______________________________________________________________ A6474X307 VASS/0 5.143

Maintenance _________________________________________________ The hydraulic oil filters are located on the back right side of the machine (Fig. 117). non-bypassing pilot filter element bypassing pilot filter element return filter element

Change the non-bypassing pilot filter element. If the element is extremely dirty, a more frequent change interval may be required.

Change the bypassing pilot filter element. If the element is extremely dirty, a more frequent change interval may be required.

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

© BUCYRUS AMERICA, INC.

Fig. 117: Hydraulic oil filters

Non-bypassing pilot filter element

Bypassing pilot filter element

Return filter element

________________________________________________________________ 5.144 Bucyrus – Model 25M1AC Continuous Miner

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

Preparation prior to sample collection For each machine to be sampled, you will need a supply of sample collection bottles and identification labels (Fig.118) sufficient to sample each identified gear case (every sixty shifts).

© BUCYRUS AMERICA, INC.

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

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

Each oil sample should be taken while the oil is at normal operating temperature. If the machine has not been operating just prior to sampling, run the machine until oil temperature reaches approximate normal operating temperature. Shutdown the machine and allow 2 - 3 minutes for the oil to drain back and stabilize it’s level.

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

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

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

Following collection of all oil samples, record the specific brand and product name of the lubricant that has been installed in each gear case.

Recommended gear cases to be sampled: ■

Input cutter head gear case (left and right)

■

Main cutter head gear case (left and right)

______________________________________________________________ A6474X307 VASS/0 5.145

Maintenance _________________________________________________ ■

Input gathering head gear case (left and right)

■

Main gathering head gear case (left and right)

■

Tram gear case (left and right)

■

Main hydraulic oil tank

Fig. 118: Oil sampling procedure Oil fill plug

Place end of siphon tube approximately half way into sump

Note: Hold sample pump and bottle below oil level

________________________________________________________________ 5.146 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

Typical siphon pump and bottle

Oil level

________________________________________________ Maintenance Every three months IMPORTANT! For motor bearings that require high temperature lithium complex grease, Bucyrus provides a special “button” style lubrication fitting (Fig. 120) to prevent the accidental use of multi-purpose lithium complex grease at these locations. cutter motor bearings

Lubricate the left and right cutter head motor bearings (Fig. 123) with high temperature lithium complex grease through the grease fittings located on each side of the cutter head assembly . To lubricate the motors:  Remove the cover to access the motor.  Inspect the grease fittings on the exit side of the front and rear motor bearing.

© BUCYRUS AMERICA, INC.

 If the exit side motor bearing ports are equipped with a spring loaded relief fitting (as shown in Fig. 119): 

Lubricate both motor bearings using the “button” fittings (Fig. 119) until new grease appears out of the relief port on the exit side of the bearing.



Operate the motor for five minutes.



Inspect for any grease leakage in the area around the bearing.

If the grease fitting on the exit side of the motor bearing is fitted with a plug: 

Remove the plug.



Lubricate both motor bearings using the “button” fitting (Fig. 119) until new grease appears out of the exit side of the bearing.



Operate the motor for five minutes.



Inspect for any grease leakage in the area around the bearing.



Replace the plug.

NOTICE! Incorrect grease or over greasing of the electric motor may cause serious damage to the motor. Follow the greasing procedure outlined above.

IMPORTANT! For motor bearings that require high temperature lithium complex grease, Bucyrus provides a special “button” style lubrication fitting (Fig. 120) to prevent the accidental use of multi-purpose lithium complex grease at these locations.

______________________________________________________________ A6474X307 VASS/0 5.147

Maintenance _________________________________________________ Fig. 119: Cutter motor bearing lubrication Relief fitting

Relief fitting Spring loaded grease relief fitting Relief port

Lubricate the pump motor (Fig. 120) with high temperature lithium complex grease through the two (2)grease fittings located the right side of the machine . To lubricate the motors:  Remove the cover to access the motor.  Inspect the grease fittings on the exit side of the front and rear motor bearing.  If the exit side motor bearing ports are equipped with a spring loaded relief fitting (as shown in Fig. 120): 

Lubricate both motor bearings using the “button” fittings (Fig. 120) until new grease appears out of the relief port on the exit side of the bearing.



Operate the motor for five minutes.



Inspect for any grease leakage in the area around the bearing.

If the grease fitting on the exit side of the motor bearing is fitted with a plug: 

Remove the plug.



Lubricate both motor bearings using the “button” fitting (Fig. 120) until new grease appears out of the exit side of the bearing.



Operate the motor for five minutes.



Inspect for any grease leakage in the area around the bearing.



Replace the plug.

NOTICE! Incorrect grease or over greasing of the electric motor may cause serious damage to the motor. Follow the greasing procedure outlined above.

________________________________________________________________ 5.148 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

pump motor bearings

________________________________________________ Maintenance Fig. 120: Pump motor bearings

Pump motor (located behind cover)

© BUCYRUS AMERICA, INC.

IMPORTANT! For motor bearings that require high temperature lithium complex grease, Bucyrus provides a special “button” style lubrication fitting (Fig. 123) to prevent the accidental use o f multi-purpose lithium complex grease at these locations. scrubber motor bearings

Lubricate the scrubber motor bearings (Fig. 121) with high temperature lithium complex grease through the grease fittings located on the scrubber side of the machine. To lubricate the motors:  Remove the cover to access the motor.  Remove grease plug (s) on exit side of bearing (s).  Lubricate bearing using “button” fitting until new grease appears out of open port on exit side of bearing (s).  Operate motor (s) for five (5) minutes.  Replace grease plug (s) in all port (s).

NOTICE! Incorrect grease or over greasing of the electric motor may cause serious damage to the motor. Follow the greasing procedure outlined in previous instructions.

Fig. 121: Scrubber motor bearings

Scrubber motor (located under cover)

______________________________________________________________ A6474X307 VASS/0 5.149

Maintenance _________________________________________________ Every six months tram gear cases

Change the oil in both tram gear cases (Fig. 122).  Remove the two drain plugs and allow oil to completely drain from the gear case. One drain plug is located under the check and fill plugs, and one drain plug is underneath the reach gears.  Clean and reinstall the drain plugs.  Remove the fill plug located on top of the gear case.  Add oil through the fill plug hole until oil is visible in the sight glass.

When filling, allow sufficient time for the oil to travel throughout the gear case.

Fig. 122: Tram gear case

Oil check (breather)

© BUCYRUS AMERICA, INC.

Oil fill

Secondary oil drain

________________________________________________________________ 5.150 Bucyrus – Model 25M1AC Continuous Miner

________________________________________________ Maintenance hydraulic oil & filter, suction strainer, breather

Change the oil in the hydraulic oil tank (Fig. 123).  Clean all dirt and debris from around the fill cap and the drain plug.  Remove the drain plug and allow the oil tank to completely drain.  Clean and remove the drain plug.  Replace oil filter.  Replace breather.  Manually add oil until the fill pump picks it up.

WARNING! The hydraulic oil fill pump will be damaged if it is run dry.

© BUCYRUS AMERICA, INC.

 Fill the tank with oil using the power fill pump until the oil level reaches the full level as indicated on the dipstick. To activate the power fill:  Engage the conveyor down function.  Open the ball valve.  After filling, start the machine and engage all cylinders for the full length of travel (full extend and retract) in order to purge the hydraulic system of air.  Recheck the oil level on the dipstick. Add more oil as needed.

Fig. 123: Hydraulic oil tank Dipstick location

Hydraulic oil tank

______________________________________________________________ A6474X307 VASS/0 5.151

Adjustment procedures ________________________________________ Setting hydraulic pressures ■

Always refer to the hydraulic schematic in the Bucyrus America, Inc. parts book supplied with your miner.

■

Most relief valves are set to factory specifications and should require no further adjustment. If a problem occurs which requires the reliefs to be adjusted, make certain the correct procedures are followed and all work is performed by a qualified person.

■

Remember when adjusting relief valves that turning the adjusting screw in (clockwise) will increase the pressure setting.

WARNING! Use extreme caution when performing test procedures and making adjustments. Unless noted in the procedures, all controls are to be in the neutral position.

■

main flow - primary pressure circuit (all functions of the main control valve can be read from this gauge),

■

pilot pressure circuit,

■

accumulator,

■

conveyor chain take-up,

■

anti-chatter/maintenance (shear down) valve for cutter head,

■

gathering head float valve, and

■

the reduce pilot pressure circuits.

There will be occasions when relief valves, or other pressure control valves, must be set or adjusted. Setting relief valve pressure is necessary when a relief valve is replaced with a new unit or when an existing relief valve needs to be adjusted, for example, during the course of troubleshooting a hydraulic system fault. This section describes the proper procedure for setting the relief valves.

________________________________________________________________ 5.152 Bucyrus – Model 25M1AC Continuous Miner

© Bucyrus America, Inc.

The miner is equipped with seven pressure gauges, typically mounted in a gauge panel, to aid in setting relief pressures. The gauges are for:

_______________________________________ Adjustment procedures IMPORTANT! Always use the proper tools when adjusting valve cartridges.

IMPORTANT! Do not start any motors - CLA, cutter head, pump, or traction motors - until all pressures are set. Start the pump motor as directed.

Load holding valve adjustment The load holding valve is factory preset and should not be field adjusted.

Always refer to your parts manual when ordering load holding valves for the cutter or conveyor cylinders.

© BUCYRUS AMERICA, INC.

Never rely on the load holding valve as a means of supporting the cutter boom or conveyor boom while making repairs. Always support the cutter boom and conveyor boom with adequate material before working around or underneath the cutter or conveyor.

WARNING! Never rely on the load holding valve as a means of supporting the cutter or conveyor boom while making repairs. Severe injury or death could result.

Adjustment procedures should start with the pilot pressure circuit because this system is a “closed center circuit” and will build pressure as soon as the pump is started. The main flow-primary pressure circuit is an “open-center circuit” and no pressure is present in this circuit until a function is activated.

Reference Pilot and Main flow-primary pressure circuits and Abbreviation and terms in the Hydraulic section of this chapter.

______________________________________________________________ A6474X307 VASS/0 5.153

Adjustment procedures ________________________________________ Pilot pump circuit relief valve adjustments The following procedure is for start up of new and rebuilt machines.

IMPORTANT! Reference the Hydraulic section in this chapter for individual circuit information. Always refer to the hydraulic schematic in your Bucyrus America, Inc. parts manual for your miner.

WARNING! Two people are required to adjust pressure settings. One person will make the adjustments while the second person must remain at the “E-STOP” at all times during the adjustment procedure.

Failure to do so may result in serious injury or death.

 2. Start the pump motor (see Startup procedure in this chapter) and adjust the pilot pressure relief valve.  Loosen the nut on the valve cartridge and, using an Allen wrench, turn the screw in (clockwise) to increase pressure or out (counter-clockwise) to decrease pressure. Refer to the hydraulic schematic for pressure setting.

IMPORTANT! Before making any further adjustments, verify that the hydraulic oil is at operating temperature.  3. Adjust the reduced pilot pressure valve.  Turn the cartridge in (clockwise) until the pressure reading is 350 psi.  While holding the cartridge in place, tighten the nut to lock the spool in place. Double check the pressure reading to ensure that the cartridge was not turned while tightening the nut.  4. Readjust the pilot pressure relief valve, is necessary, to 600 psi.

Relief valve replacement  Pilot relief valve replacement: Set the pilot relief to 600 psi, per Step 3, making sure that the conveyor chain take-up knob is closed (turn clockwise to close).  Reduced pilot pressure valve replacement: See Steps 1 and 3.

________________________________________________________________ 5.154 Bucyrus – Model 25M1AC Continuous Miner

© Bucyrus America, Inc.

 1. Reduced pilot pressure circuit: loosen the nut on the pressure reducing valve cartridge and turn the screw out (counterclockwise) using an Allen wrench to prevent over pressuring the gauge on this circuit.

_______________________________________ Adjustment procedures Main control valve working port relief adjustment Each valve bank section, with the exception of the gathering head, has two (2) working port reliefs. When the handle is pulled (spool in), oil is directed to the work port and relief closest to the handle; this is “A” port. When the handle is pushed in (spool out), oil is directed to the work port and relief farthest from the handle; this is ‘B” port.

© BUCYRUS AMERICA, INC.

WARNING! Always allow cylinder functions to bottom out (stop moving) before adjusting any pressure. Pressure adjustments will only be accurate with the cylinder in this condition.

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Adjustment procedures ________________________________________ Main control valve adjustment IMPORTANT! The main relief is set higher than the port reliefs and will only relieve if a spike occurs in the system or if the port relief does not function properly. This provides protection of the main pump section, A1.

CAUTION! Do not adjust the main relief over 3,000 psi. Destruction of the valve bank and the main pump could result.

CAUTION! Always be alert for any unintended machine movement.

WARNING! Two people are required to adjust pressure settings. One person will make the adjustments while the second person must remain at the “Machine stop/E-STOP” at all times during the adjustment procedure. Failure to do so may result in serious injury or death.

Main relief adjustment  Remove the protective cap on the front port relief of the cutter head working section and loosen the nut on the adjusting screw. Turn the adjusting screw in all the way.  Loosen the nut on the main relief cartridge. Turn the main relief adjusting screw two turns clockwise.

WARNING! Keep body parts clear of machine while in raised position or serious injury could result.

________________________________________________________________ 5.156 Bucyrus – Model 25M1AC Continuous Miner

© Bucyrus America, Inc.

IMPORTANT! Reference the Hydraulic section in this chapter for individual circuit information. Always refer to the hydraulic schematic in your Bucyrus America, Inc. parts manual for your miner.

_______________________________________ Adjustment procedures Port relief valve adjustment Port relief valves are functional when operating the circuit in which they are installed. As the particular function is activated and the pressure reaches the adjusted setting, the port relief will relieve excessive pressure to the tank cavity within the valve bank, preventing damage to the circuit.

WARNING! Always allow function to bottom out and stop moving before adjusting any pressure.

If the correct pressure reading is not obtained as noted in Items 1 through 5 below, the port relief for that function must be adjusted.

The adjustment procedure for each port relief is the same and is:

© BUCYRUS AMERICA, INC.

 Remove the protective cap on the port relief and loosen the nut on the adjusting screw.  Turn the port relief screw in (clockwise) to increase pressure and out (counter-clockwise) to decrease pressure.  Once the correct pressure reading is obtained, return the function to the neutral position, hold the screw in place, and tighten the lock nut. Check the pressure reading to ensure that the screw did not turn while the lock nut was being tightened.

Pressure readings: 1. Stabilizer shoe port relief  Activate the stabilizer shoe raise circuit to fully raise the stabilizer shoe. The main control valve pressure gauge should read 1,200 psi.  Activate the stabilizer shoe lower circuit to fully lower the stabilizer shoe. The main control valve pressure gauge should read 2,500 psi.

2. Cutter head port relief  Activate the cutter head raise circuit to fully raise the cutter head. The main control pressure gauge should read 2,800 psi.  Activate the cutter head lower circuit to fully lower the cutter head and raise the front of the machine off the ground. The main control pressure gauge should read 2,800 psi.

WARNING! Keep body parts clear of machine while in raised position or serious injury could result.

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Adjustment procedures ________________________________________ 3. Conveyor raise/lower port relief  Activate the conveyor raise circuit to fully raise the conveyor.

The main control valve pressure gauge should read 1,800 psi.  Activate the conveyor lower circuit to fully lower the conveyor.

The main control valve pressure gauge should read 1,400 psi.

Note: Be sure that the ball valve is closed on the tank oil fill part of this circuit.

4. Conveyor swing port relief  Activate the conveyor swing left circuit to fully swing the conveyor to the left. The main control valve pressure gauge should read 1,800 psi.  Activate the conveyor swing right circuit to fully swing the conveyor to the right. The main control valve pressure gauge should read 1,800 psi.

 Activate the gathering head raise circuit to fully raise the gathering head. The main control valve pressure gauge should read 1,700 psi.  If 1,700 psi is not obtainable, check that the relief in the gathering head float valve that is stamped “CR” is set to 1,800 psi (see Gathering head raise/hold/float-lower circuit in the Hydraulic section of this chapter).

________________________________________________________________ 5.158 Bucyrus – Model 25M1AC Continuous Miner

© Bucyrus America, Inc.

5. Gathering head port relief

_______________________________________ Adjustment procedures Tram track adjustment  1. Lower the conveyor tail section until it is level with the floor.  2. Raise the gathering head and cutter head and block both assemblies following standard blocking procedures.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all blocking devices.  3. Lower the gathering head and cutter head onto the blocking so that the front end of the miner lifts off the floor.  4. Extend the stabilizer completely so that the rear end of the miner lifts off the floor.

© BUCYRUS AMERICA, INC.

 5. Securely block under the machine. The machine must be securely supported off the ground with the tram track free to turn.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load of all blocking devices.  6. Raise the stabilizer, gathering head, and cutter head assemblies so that the weight of the miner rests on the blocking.  7. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine lockout/tagout regulations.

WARNING! Follow all Federal and mine lockout/tagout regulations and procedures. Failure to do so could result in machine damage or serious injury or death to personnel.  8. Double check the tractor frame support blocking now that the weight of the tractor frame is completely upon it.  9. Evaluate the tram track for proper tension (Fig. 124). The tram track is at the proper tension when it hangs approximately 2 1/2” to 3 1/2” from the bottom wear shoes when the tractor frame is blocked off the floor. Using this evaluation, determine whether step 13, 14, or 15 provides the appropriate subprocedure to correct improper track tension.

Fig. 124: Tram track adjustment Bottom of tractor wear shoe

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

Top of tram track

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Adjustment procedures ________________________________________  10. Remove the hex head capscrews and lock washers that secure the front rub rail to the tractor frame (Fig. 125) and open the front rub rail cover.

Fig. 125: Rub rail removal Capscrew and lock washer

View A

Tram rub rail

Capscrew and lock washer View A

 12. Locate the front idler take-up jack grease fitting and attach the grease gun to the fitting.  13. If the tram track tension is too tight, readjust the idler position using the following steps: ■

Pump grease into the take-up jack to extend the cylinder and remove pusher plate pressure on the idler shims.

■

Remove one or more idler adjustment shims from the idler slide channel.

■

Open the pressure release valve for the front idler take-up jack and allow the jack to contract. The pusher plate will slide backwards until it is stopped by the remaining idler shims.

■

Pump grease into the idler take-up jack to extend the cylinder, move the idler assembly forward and tighten the tram track until it is at the correct tension. The tram track is at the proper tension when it hangs 2 1/2” to 3 1/2” from the bottom wear shoes when the tractor frame is blocked off the floor.

WARNING! Keep body parts clear of machine while in raised position or serious injury could result.

________________________________________________________________ 5.160 Bucyrus – Model 25M1AC Continuous Miner

© Bucyrus America, Inc.

 11. Remove the cover plate to allow access to the idler assembly.

_______________________________________ Adjustment procedures

© BUCYRUS AMERICA, INC.

 14. If the tram track is too loose, readjust the idler position using the following steps: ■

Pump grease into the idler take-up jack to extend the cylinder, move the idler assembly forward and tighten the tram track until it is at the correct location. The tram track is at the proper tension when it hangs 2 1/2” to 3 1/2” from the bottom wear shoes when the tractor frame is blocked off the floor.

■

Insert shims (Fig. 126) into the idler slide channel until the space between the tractor frame and the pusher plate is filled.

■

Open the pressure release valve for the front idler take-up jack and allow the cylinder to contract. The idler adjustment shims will keep the idler stationary and the track tensioned.

■

Evaluate the resulting track tension and repeat these steps until the track reaches proper tension.

CAUTION! Shims must be inserted completely into the idler slide channel. A shim that is not correctly seated on the idler slide channel’s inside surface provides uneven support that can cause idler slant. A slanted idler can cause uneven wear and stress on the tram track and can cause improper operation of or damage to the tram system.

IMPORTANT! Check that the shims are correctly seated on the idler slide channel’s inside surface by looking at the channel’s inside surface from the opposite side of the miner through the space between the gathering head and the idler assembly.

Fig. 126: Tram track adjustment

Pressure relief valve

Take-up cylinder

Spacer Plate (can be turned 180°)

Pusher plate

Shims Idler assembly

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Adjustment procedures ________________________________________  15. If the tram track tension is still too loose when the entire 5” shim set is inserted into the idler slide channel, re-adjust the idler position after removing a tram track link using the following steps:  The spacer plate can be turned 180° (Fig. 126). This will allow for approximately 3 more inches of adjustment.  Pump grease into the take-up jack to extend the cylinder and remove the pusher plate pressure on the idler shims.  Remove all of the idler adjustment shims from the idler slide channel.  Open the pressure release valve for the front idler take-up jack and allow the cylinder to contract.  The tram track tension should now be reduced and separation of the tram track will be easier.

 Using the hammer and punch, remove the four roll pins of the two tram track pins (Fig. 127) that secure the tram track link to the track.  Using the hammer and punch, remove the tram track pins to disconnect the link from the track. Remove the disconnected link.  Store the tram track link, one of the tram track pins and two of the roll pins in a safe place.  Connect the two ends of the tram track and using the hammer and punch, secure the two end links together with the remaining tram track pin.  Using the hammer and punch, secure the tram track pin between the two links with the remaining two roll pins.  Pump grease into the idler take-up jack to extend the cylinder, move the idler assembly forward and tighten the tram track until it is at the correct tension. The tram track is at the proper tension when it hangs approximately 2 1/1” to 3 1/2” from the bottom wear shoes when the tractor frame is blocked off the floor.  Insert shims into the idler slide channel until the space between the tractor frame and the pusher plate is filled.  Open the pressure release valve for the front idler take-up jack and allow the cylinder to contract. The idler adjustment shims will keep the idler stationary and the track tensioned.  The idler adjustment shims will keep the idler stationary and the track tensioned.  Evaluate the resulting track tension and repeat until the track reaches proper tension. ________________________________________________________________ 5.162 Bucyrus – Model 25M1AC Continuous Miner

© Bucyrus America, Inc.

 Locate a tram track link near the tram idler.

_______________________________________ Adjustment procedures Fig. 127: Tram track adjustment

Track retention pin Pad

© BUCYRUS AMERICA, INC.

Lock pin

 15. When the tram track has been adjusted to the proper tension, remove the grease gun from the idler take-up jack grease fitting.  16. Open the pressure release in order to take pressure off of the take-up cylinder.  17. Close the front rub rail cover and secure the front rub rail to the tractor frame with hex head capscrews and lock washers.  18. Connect the trailing cable to energize the miner.  19. Raise the tractor frame off the blocking by lowering the stabilizer and gathering head and cutter head assemblies.  20. Carefully remove the support blocking from under the tractor frame.  21. Lower the tractor frame onto the floor by raising the stabilizer and gathering head and cutter head assemblies.  22. Carefully remove the blocking from underneath the raised stabilizer, gathering head, and cutter head assemblies.

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Adjustment procedures ________________________________________ Tail shim adjustment As the conveyor wears the tail section may sag relative to the conveyor front section. The conveyor has been designed to allow correction of the sag by adding shims.  1. Lower the cutter head and gathering head assemblies until they touch the floor.  2. Position the conveyor tail section directly behind the miner and raise it to its highest position.  3. Insert blocking under the tail section and lower the tail onto the blocking. The conveyor should be at an angle with the rear end of the tail section slightly higher than the front.

 4. Insert blocking between the top of the tractor frame and the bottom of the conveyor, leaving about 2” of space between the blocking and the conveyor bottom.  5. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine lockout/tagout regulations.

WARNING! Follow all Federal and mine lockout/tagout regulations and procedures. Failure to do so could result in machine damage or serious injury or death to personnel. 

6. Loosen the hex head capscrews that secure the shims between the shim retainer and the conveyor lower pivot plate (Fig. 128).

Fig. 128: Shim removal Hex head capscrews

Lower pivot plate

Shim retainer

Shims

________________________________________________________________ 5.164 Bucyrus – Model 25M1AC Continuous Miner

© Bucyrus America, Inc.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all blocking devices.

_______________________________________ Adjustment procedures  7. Connect the trailing cable to energize the miner.

WARNING! The following steps releases the shims, which will fall free. Watch out for falling shims when loosening the capscrews.  8.

Slowly lower the conveyor slightly so that the front section rests on the frame support blocking. The slotted shims will now fall free.

 9.

Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine lockout/tagout regulations.

WARNING! Follow all Federal and mine lockout/tagout regulations and procedures. Failure to do so could result in machine damage or serious injury or death to personnel.

© BUCYRUS AMERICA, INC.

 10. Replace the removed shims (Fig. 129) and add the number of shims required to level the conveyor front and tail sections.  11. Tighten the hex head capscrews.

Fig. 129: Tail shim adjustment Hex head capscrews

Shim retainer

Lower pivot plate

Shims

 12. Connect the trailing cable to energize the miner.  13. Raise the conveyor tail from the blocking.  14. Remove both sets of blocking and lower the conveyor tail until it is level with the floor.  15. Check the gap and alignment (Fig. 130) at the juncture of the conveyor front and tail sections for alignment. If the sections are not horizontally aligned, then add or subtract shims as required.

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Adjustment procedures ________________________________________ Fig. 130: Tail shim adjustment Correct gap and alignment Conveyor tail section

Conveyor front section

Add shims Conveyor tail section

Conveyor front section

Remove shims Conveyor front section

 16. Re-insert the blocking between the top of the tractor frame and the bottom of the conveyor following mine standard blocking procedures.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all blocking devices.  17. Securely retighten the hex head capscrews.

Chain tension adjustment - hydraulic take-up With the hydraulic chain take-up, the only adjustment is to the conveyor chain take-up valve. If the valve needs adjusted, see Conveyor chain take-up valve adjustment procedure in this chapter.

________________________________________________________________ 5.166 Bucyrus – Model 25M1AC Continuous Miner

© Bucyrus America, Inc.

Conveyor tail section

____________________________________ Replacement of wear parts Instructions on the replacement of wear parts It is essential that wear parts are replaced before they reach the lowest wear limit. Inspect the wear parts at regular intervals.

CAUTION! Because these maintenance techniques are specialized, they should be performed only be qualified personnel.

Cutter head (boom) assembly The cutter head assembly (Fig. 131) can be removed as an assembly or in individual components.

Fig. 131: Cutter head assembly Cutter boom

© BUCYRUS AMERICA, INC.

Shear cylinder

Cutter boom pivot

cutter head assembly removal

Drum drive gear case

Shear cylinder clevis pin

Drum drive torque limiting clutch

Drum drive motor

End drum

To remove the cutter head assembly (Fig. 132):  1. Attach an appropriate lifting device to the boom assembly.

Take up the slack in the lift assembly so that the weight is supported as the assembly is unpinned from the miner.

WARNING! You could be seriously injured or even killed by falling loads. Observe the safe working load limits of lifting and blocking devices and keep a safe distance from suspended loads.  2. Lower the gathering head and the cutter head to the floor and position the conveyor tail section level with floor.  3. Disconnect and lock out the electrical power to the miner. Follow all applicable Federal and mine regulations regarding lockout/tagout procedures.

______________________________________________________________ A6474X307 VASS/0 5.167

Replacement of wear parts _____________________________________ WARNING! Follow all Federal and mine regulations for lockout/tagout. Failure to do so may result in serious injury or death.  4. Disconnect the power cables and water hoses from the cutter motors (see Cutter motor removal procedure in this chapter).

Be sure to tape up the power cables since electrical power will be connected to the miner.  5. Disconnect the water hoses to the dust suppression sprays.  6. Remove the 2 boom pivot pins (see Boom pivot pin removal procedure in this chapter - note that there are two different procedures; one for straight pins and one for tapered (McSweeney) pins).  7. Connect electrical power to the miner.

 9. Block the boom and shear cylinders to keep them stationary during their pin removal.

WARNING! You could be seriously injured or even killed by falling loads. Observe the safe working load limits of lifting or blocking devices and keep a safe distance from suspended loads.  10. Disconnect power to the miner. Follow all applicable Federal and mine regulations regarding lockout/tagout procedures.

WARNING! Follow all Federal and mine regulations for lockout/tagout. Failure to do so may result in serious injury or death.  11. Remove the shear cylinder boom clevis pins (see Shear cylinder removal procedure in this chapter).  12. Connect electrical power to the miner.  13. Retract the shear cylinders to pull their bearings free from the boom clevises.  14. Disconnect power to the miner. Follow all applicable Federal and mine regulations regarding lockout/tagout procedures.  15. Raise the rear of the boom assembly until it is above the top edge of the gathering head backboard.  16. Slowly tram the mine backwards until the cutter boom pivot points clear the front of the gathering head.

________________________________________________________________ 5.168 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

 8. Extend the shear cylinders to push the boom pivots out of their tractor frame clevises.

____________________________________ Replacement of wear parts Fig. 132: Cutter head assembly removal Shear cylinder

Shear cylinder clevis pin

Cutter boom

Cutter boom pivot

cutter head assembly installation

To install the cutter head assembly (Fig. 132)  1.

© BUCYRUS AMERICA, INC.



Slowly tram the miner forward toward the raised end of the boom until the pivot pins clear the gathering head backboard.

2. Lower the boom pivot points until the shear cylinders can reach their boom clevises. Block the boom to keep it in a secure position.

 3. Extend the shear cylinders until their rod end bearings can be inserted into the cutter boom clevises.  4. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations regarding lockout/tagout procedures.

WARNING! Follow all Federal and mine regulations regarding lockout/tagout procedures. Failure to do so may result in serious injury or death.

WARNING! Do not test the alignment of the shear cylinder rod end bearings and the cutter boom clevis using your fingers. Shifting of the aligned pieces could cause serious injury.  5. Position the right cylinder’s rod end bearing in the boom clevis.

IMPORTANT! The pin should be inserted so that its retaining channel remains outside the bushing.  6. Insert the rod end pin through the aligned clevis bushings and rod end bearing.

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Replacement of wear parts _____________________________________  7.

Insert the pin retaining plate and secure to the boom clevis with hex head capscrews and lock washers.

 8.

Repeat steps 4 through 7 on the left shear cylinder.

 9.

Connect the trailing cable to energize the miner.

 10. Once the shear cylinders are secured to the cutter boom, remove the boom blocking to allow the cylinders to move the boom.  11. Contract the shear cylinders to pull the cutter boom pivot points into position in the tractor frame boom pivot clevises.

 12. Install both cutter boom pivot pins (see Boom pivot pin procedure - note that there are two procedures: one for straight boom pivot pins and one for tapered (McSweeney) pins).  13. Replace the motor cooling water and scrubber spray water hoses onto the cutter head boom.  14. Replace the electrical power cables onto the cutter head boom.

________________________________________________________________ 5.170 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

IMPORTANT! In addition to the shear cylinders, the stabilizer and gathering head can also be used to adjust the cutter boom’s position to allow easier insertion of the cutter boom pivot pins.

____________________________________ Replacement of wear parts Boom pivot pin removal and installation boom pivot pin removal

To remove the boom pivot pin:  1. Lower the conveyor tail section until it is level with the floor and gathering head and cutter head until they rest on the floor.  2. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations regarding lockout/tagout procedures.

WARNING! Follow all Federal and mine regulations regarding lockout/tagout procedures. Failure to do so may result in serious injury or death.  3. Locate the miner’s front rub rail and remove the hex head capscrew and lock washer that secures the rub rail to the tractor frame.

© BUCYRUS AMERICA, INC.

 4. Open the front rub rail (Fig. 133).

Fig. 133: Front rub rail Capscrew and lock washer

View A

Tram rub rail

Capscrew and lock washer View A

 5. Locate the front idler take-up jack bracket assembly (Fig. 134), which is mounted directly to the rear of the idler shim channel.  6. Pull the flip pin from the half link to release the take-up jack bracket from the tractor frame.  7. Lower the end of the bracket until it clears the half link and pull the bracket straight out to remove it from the tractor frame.

IMPORTANT! Pressure from the cutter boom onto the pivot pin can make its removal very difficult. The shear cylinders can be used to find the boom position that puts the least pressure on the pin.

CAUTION! When the pivot pin pull point is found, block the cutter boom to prevent it from dropping or moving when the pivot pin is removed.

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Replacement of wear parts _____________________________________ Fig. 134: Half link

Tale-up jack bracket Half link

 8. Locate the end of the boom pivot pin in the area from which the take-up jack bracket was removed.

To remove the boom pivot pin:  9.

Remove the hex head capscrews and lockwashers that secure the boom pivot pin retaining plate to the tractor frame.

 10. Remove the pin retaining plate and its support block.  11. Insert a slide hammer adapter into the threaded hole in the end of the boom pivot pin.

IMPORTANT! Pressure from the cutter boom onto the boom pivot pin can make its removal very difficult. The shear cylinders can be used to find the boom position that puts the least pressure onto the pin. This position can be determined by striking the pin, slightly contracting or extending the shear cylinder, then striking the pin again and comparing the “ring”; as boom pressure on the pin decreases, the “ring” of the pin when it is struck becomes lower. When the “ring” of the pin becomes short and low, pin removal is much easier.

CAUTION! Use extreme caution when adjusting the boom with the shear cylinder to find the pivot pin’s pull point.  12. When the pivot pin’s pull point is found, block the cutter boom to keep it from dropping or moving when the pin is pulled.  13. Attach the slide hammer to its adapter and pull the boom pivot pin.

________________________________________________________________ 5.172 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

Flip pin

____________________________________ Replacement of wear parts boom pivot pin installation

To install the boom pivot pin:  1. Position the boom pivot pin so that the end with the two flats (the end without the adapter) is inserted first. The single flat of the pin’s opposite end must face the four retaining plate holes.

IMPORTANT! On the back of the tractor frame clevis there is a welded strap that keeps the boom pivot pin from rotating. One of the flats of the boom pivot pin must parallel this strap or the pin cannot be completely inserted.  2. Use the hammer to insert the boom pivot pin through the aligned tractor frame clevis and boom pivot bushings.

© BUCYRUS AMERICA, INC.

IMPORTANT! If it is extremely difficult to insert the boom pivot pin through the aligned tractor frame clevis and boom pivot bushings, extend or contract the shear cylinders to improve the alignment between the clevis and boom.

CAUTION! Use extreme caution when adjusting the clevis and boom alignment with the shear cylinders.  3. Replace the support block over the four threaded holes in the tractor frame.  4. Place the retaining plate onto the support block. The end of the retaining plate L-extension should be positioned against the flat of the boom pivot pin.  5. Insert and tighten the hex head capscrews lockwashers to secure the boom pivot pin retaining plate to the tractor frame.

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Replacement of wear parts _____________________________________ Shear cylinder removal and installation shear cylinder removal

To remove the shear cylinder:  1.

Lower the gathering head until it touches the floor and lower the conveyor tail section until it is level with the floor. Advance the conveyor chain so that its flights do not block the shear cylinder piston end pin access plates on the conveyor bed.

 2.

Raise the cutter head assembly until it reaches its highest point. Place blocking underneath the cutter head. Lower the assembly onto the blocking at a level where the shear cylinder is partially but not fully contracted.

 3.

Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine lockout/tagout regulations.

WARNING! Follow all Federal and mine lockout/tagout regulations and procedures. Failure to do so could result in machine damage or serious injury or death to personnel.

CAUTION! The shear cylinder is very heavy. Verify its weight can be supported.

WARNING! Replacement of the shear cylinder involves working around a raised cutter head assembly. Never work under any raised assembly without proper blocking. Always block between the raised assembly and the tractor frame in addition to between the raised assembly and the floor.

WARNING! This procedure involves disconnecting the hydraulic hoses. Always use caution when working with or around hydraulic systems because they can be under extremely high pressures.  4. Locate the shear cylinder guard, if equipped.  5. If there is a guard, then using pliers, remove the two cotter pins from the hinge pin at the front of the guard. Remove the hinge pin to detach the guard from the boom plate collar.

________________________________________________________________ 5.174 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all blocking devices. Do not stand near the blocked cutter head.

____________________________________ Replacement of wear parts

 6.

On the boom clevis of the shear cylinder’s rod end, locate the rod end pin and its retaining bracket.

 7. Remove the hex head capscrews and lock washers that secure the pin retaining plate to the cutter boom.  8. Remove the retaining plate.  9. Insert the slide hammer’s adapter into the threaded hole in the end of the pin.  10. Attach the adapter to the slide hammer and pull the pin from the clevis bushings.  11. Connect the trailing cable to energize the miner.

© BUCYRUS AMERICA, INC.

WARNING! Stand clear of the blocked cutter head assembly during shear cylinder contraction.  12. Slowly contract the shear cylinder until the rod end comes free from its clevis.  13. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine lockout/tagout regulations.

WARNING! Follow all Federal and mine lockout/tagout regulations and procedures. Failure to do so could result in machine damage or serious injury or death to personnel.  14. Raise and lower the shear cylinder control lever to release any pressure from the shear cylinder.

WARNING! The next steps disconnect the shear cylinder from the tractor frame. The shear cylinder is extremely heavy. Be prepared to support its weight before performing the following steps.  15. Locate the shear cylinder’s piston end pin and pin retaining plate.  16. Remove the two hex head capscrews and lockwashers that secure the pin retaining plate to the frame.  17. Remove the pin retaining plate.  18. Locate the shear cylinder piston end pin access plate on the conveyor bed.  19. Remove the hex head capscrew and lock washer that secures the access plate to the conveyor bed.

______________________________________________________________ A6474X307 VASS/0 5.175

Replacement of wear parts _____________________________________  20. Remove the access plate (Fig. 136).

Fig. 136: Shear cylinder access plate and pin

Access plate

 21. Locate the pin.  22. Insert the slide hammer adapter into the threaded hole in the end of the pin.  23. Attach the adapter to the slide hammer and pull the pin.  24. Disconnect, tag, and cap the hydraulic hoses going to the cylinder.

WARNING! Never disconnect a hydraulic hose if the circuit is pressurized or if there is a load on the circuit. If a hose is disconnected while the circuit is pressurized or a load is on it, the load will fall, causing damage to the machine or serious injury or death to personnel.  25. Remove the hydraulic fittings from the shear cylinder and store in a clean place.  26. Disconnect the grease hose from the grease fitting on the piston end of the shear cylinder. Plug the hose end to keep it clean.  27. Remove the grease fitting from the piston end of the shear cylinder.  28. The shear cylinder is now free and can be removed.

________________________________________________________________ 5.176 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

Pin

____________________________________ Replacement of wear parts shear cylinder installation

To install the shear cylinder:  1. Position the shear cylinder piston end close to its frame clevis.

IMPORTANT! The following steps may require opening unsecured top covers.  2. Insert the grease fitting into the piston end of shear cylinder.  3. Attach the grease hose to the grease fitting.  4. Insert the hydraulic fittings into the piston end of the cylinder.  5. Reconnect hydraulic hoses to the cylinder.

© BUCYRUS AMERICA, INC.



6. Place the shear cylinder’s piston end into its frame clevis.

 7. Insert the shear cylinder piston end pin from the access opening on the conveyor bed into the aligned tractor frame clevis and shear cylinder piston end. The end of the pin with the retaining channel should be inserted first.  8. Tap on the pin with a hammer until its retaining channel emerges from the bushing on the other side of the clevis.  9. Insert the pin retaining plate in the pin’s channel to secure the pin in the clevis.  10. Insert and tighten the hex head capscrews and lock washers that secure the pin retaining plate to the frame clevis.  11. Replace the shear cylinder piston end pin access plate.  12. Insert and tighten the hex head capscrew and lock washer to secure the access plate to the conveyor bed.  13. Connect the trailing cable to energize the miner.

WARNING! Stand clear of the shear cylinder and the blocked cutter head assembly during extension of the shear cylinder.  14. Slowly extend the shear cylinder’s rod end so that it can be inserted into the boom clevis.  15. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine lockout/tagout regulations.

WARNING! Follow all Federal and mine lockout/tagout regulations and procedures. Failure to do so could result in machine damage or serious injury or death to personnel.

______________________________________________________________ A6474X307 VASS/0 5.177

Replacement of wear parts _____________________________________  16. Position the shear cylinder’s rod end bearing in the boom clevis.

IMPORTANT! The pin should be inserted so that its retaining channel remains outside the bushings.  17. Gently tapping on the pin with a hammer, insert the rod end pin through the aligned clevis bushings and rod end bearing.  18. Insert the pin retaining plate in the pin’s channel to secure the pin in the clevis.  19. Insert and tighten the hex head capscrews and lock washers to secure the pin retaining plate to the boom clevis.

 23. Insert the hinge pin through the jack guard and boom plate collar.  24. Using the pliers, insert and flare the two cotter pins through the cylinder guard hinge pin to secure the jack guard.

________________________________________________________________ 5.178 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

 22. Replace the shear cylinder guard assembly (optional) into the boom plate collar.

____________________________________ Replacement of wear parts Center cutter drum center cutter drum removal

To remove the center cutter drum: WARNING! Replacement of the cutter head center drum involves working around a raised cutter head assembly. Never work under any raised assembly without proper blocking. Always block between the raised assembly and the tractor frame in addition to between the raised assembly and the floor.

WARNING! This procedure involves disconnecting and reconnecting the miner’s trailing cable. Always be aware of whether or not the miner is energized. Never perform maintenance on an energized miner.

Fig. 137: Center cutter drum removal/installation (typical shown)

© BUCYRUS AMERICA, INC.

Center drum

Drum seam

Strap

Capscrews Alignment key (square ends)

Retainer (strut bolts) Capscrews Strap

______________________________________________________________ A6474X307 VASS/0 5.179

Replacement of wear parts _____________________________________  1. Lower the gathering head completely until its touches the floor.

Lower the conveyor tail assembly until it is level with the floor.  2. Rotate the cutter head slowly until one of the center drum seams (Fig. 137) appears directly in front and one appears directly in rear of the cutter head.  3. Lower the cutter head assembly until it touches the floor.  4.

Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine lockout/tagout regulations.

WARNING! Follow all Federal and mine lockout/tagout regulations and procedures. Failure to do so could result in machine damage or serious injury or death to personnel.

DANGER! Never work under any raised assembly without proper blocking.  5. Remove the socket head capscrews securing the front seam of the center drum.  6. Remove the socket head capscrews securing the rear seam of the center drum.  7. Collect the retaining plates for the center drum’s capscrews.

Store the retaining plates in a safe place for a center drum reassembly.  8. Attach chains to the upper half of the center drum. The chains should be capable of supporting the entire weight of the upper half of the center drum.  9. Using the pry bar and other necessary force, break the seal between the center drum so that the bottom half is free from the top half.  10. Attach the chain falls to the ceiling bolts.  11. Connect the chain falls to the chains on the upper half of the center drum.

________________________________________________________________ 5.180 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

CAUTION! Make sure the lifting device is capable of lifting the drum weight.

Use care when handling the cutter drum.

____________________________________ Replacement of wear parts  12. Use the chain falls to lift the upper half of the center drum off the cutter head assembly. The cutter head and the lower half of the center drum should remain on the floor.

WARNING! Serious injury or death can result from falling loads. Observe the safe working load limits of lifting devices and keep a safe distance from suspended loads.  13. Connect trailing cable energize the miner.  14. Slowly raise the cutter head assembly until it is completely clear of the lower half of the center drum.  15. Slowly tram the miner backwards away from the suspended upper half and the resting lower half of the center until the cutter head assembly is completely clear of both of these pieces.

© BUCYRUS AMERICA, INC.

To install the center cutter drum (Fig. 137): WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of lifting devices and keep a safe distance from suspended loads. center cutter drum installation

 1. Slowly lower the cutter head assembly into the bottom half of the center drum. The bottom drum drive keys should fit into the interior of the lower half of the center drum.

WARNING! Stand clear of the cutter head assembly and the unsecured upper half of the center drum while lowering it.  2. Using the chain falls, slowly lower the upper half of the center drum onto the cutter head assembly. The top drum drive keys should fit into the underside interior of the upper half of the center drum.  3. Disconnect the chains that supported the upper half of the center drum from the chain falls.  4. Remove the chains from the upper half of the center drum.

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Replacement of wear parts _____________________________________  5. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine lockout/tagout regulations.

WARNING! Follow all Federal and mine lockout/tagout regulations and procedures. Failure to do so could result in machine damage or serious injury or death to personnel.  6. Insert the socket head capscrews into the holes in the top half of the drum through the alignment keys and through the bottom half of the drum. Use the following steps to equally distribute the torque over the center drum (Fig. 138):

 Alternating from front to back and moving from right to left, repeat this threading process on the other nine pairs of capscrews and nine retaining plates.  When all capscrews have been inserted into their retaining plates, start with the paired capscrews on the right of the front seam of the center drum and torque.  Proceed to the paired capscrews on the back right seam of the center drum and torque.  Alternating from front to back and moving from right to left, torque the eight remaining pairs of capscrews into their retaining plates.  7.

Double check that all bolts have been properly torqued.

Fig. 138: Bolt torqueing order

________________________________________________________________ 5.182 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

 Starting with the pair of capscrews at the right front of the center drum, place a retaining plate under the bottom half of the drum where the capscrews emerge and thread the capscrews into the retaining plate.

____________________________________ Replacement of wear parts End cutter drum end cutter drum removal

To remove the end cutter drum:  1. Lower the gathering head completely until it touches the floor.

Lower the conveyor tail assembly until it is level with the floor.  2. Raise the cutter head assembly to its highest position. Place blocking underneath the cutter head assembly and lower the cutter head assembly onto the blocking.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of lifting devices and keep a safe distance from suspended loads.

© BUCYRUS AMERICA, INC.

 3. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine lockout/tagout regulations.

WARNING! Follow all Federal and mine lockout/tagout regulations and procedures. Failure to do so could result in machine damage or serious injury or death to personnel. 

4. Drain the gear case oil before removing the drums.

 5. Remove the lock tabs tack welded to the capscrews using a cutting torch.

Fig. 139: Lock tabs tack welded to capscrews

Lock tab welded in place

Oil drain plug

Access to center drum input shaft

 6. Remove the long capscrews and nuts on the two alignment dowels which secure the end drum to the cutter drum drive assembly.  7. Remove plug and center drum input shaft.  8. Remove the drum by sliding it off the hub.  9. Remove the drum alignment key (Fig. 140) and store for reinstallation.

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Replacement of wear parts _____________________________________ Fig. 140: Drum alignment key

Drum alignment key

end cutter drum installation

To install the end cutter drum:  1.

Locate the timing arrows (Fig 141) on the intermediate drum and the end drum about to be installed. The end drum must be installed so that its timing arrow is directly adjacent to the intermediate drum timing arrow.

Fig. 141: Intermediate drum timing arrows

Timing arrow on intermediate drum

Timing arrow on intermediate drum

 2.

Insert drum alignment key.

 3.

Slide the end drum onto the cutter drum drive gear case.

 4.

Install the plug and center drum input shaft. Add oil as necessary.

 5.

Tighten the long capscrews and nuts onto the two alignment dowels which secure the end drum to the cutter drum drive assembly.

 6.

Torque the capscrews to 900 lb.-ft. Tack weld the lock tabs.

________________________________________________________________ 5.184 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

WARNING! You could be seriously injured by falling loads. Use extreme caution when working near suspended loads.

____________________________________ Replacement of wear parts Drum drive motor drum drive motor removal

To remove the drum drive motor:  1. Lower the gathering head completely until it touches the floor.

Lower the conveyor tail assembly until it is level with the floor.  2. Raise the cutter head assembly to its highest position. Place blocking underneath the cutter head assembly. Lower the cutter head assembly WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all blocking devices. Do not stand near the blocked cutter head.

© BUCYRUS AMERICA, INC.

 3.

Disconnect the two cooling water hoses from the top manifold.

Plug the hose ends to keep them clean.

WARNING! Follow all Federal and mine lockout/tagout regulations and procedures. Failure to do so could result in machine damage or serious injury or death to personnel.

Fig. 142: Drum drive motor

Drum drive motor

______________________________________________________________ A6474X307 VASS/0 5.185

Replacement of wear parts _____________________________________  4. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine lockout/tagout regulations. Disconnect the two cooling water hoses from the top manifold. Plug the hose ends to keep them clean.  5. Remove the hex head bolts and lock washers that secure the manifold.  6. Remove the two manifolds to expose the top of the motor. Two o-rings on the top and bottom will be visible. Secure o-rings for use in re-installation.  7. Remove the flat bar connecting the hex head capscrews and lockwashers that secure the side motor cover.  8. Remove the cover (Fig. 143) to expose the side of the motor and the motor’s junction box.

Fig. 143: Cover removal Hex head bolts (4)

Flat bar

Manifold

Capscrews (8)

________________________________________________________________ 5.186 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

WARNING! You could be seriously injured or killed by falling loads. Observe the working load limits of lifting and blocking devices.

____________________________________ Replacement of wear parts

 9. Remove the cutter motor shaft.  10. Place blocking under the motor to keep it supported when it becomes free from the cutter boom.  11. Remove the hex head caps crews and lockwashers that secure the junction box cover (Fig. 144).  12. Remove the cover and O-ring.  13. Locate the three taped power connections.  14. Strip off the three layers of tape covering these lug connections.

© BUCYRUS AMERICA, INC.

IMPORTANT! Before detaching these lugs, mark the wires to facilitate reconnection during motor installation.  15. Tag the lugs for correct reconnection then remove the hex head capscrew, flat washer, lock washer and hex head nut that secure the three power cable lugs to the three motor lugs.  16. Remove the socket head capscrews and lockwashers that secure the stuffing box’s half-moon clamp to the junction box.  17. Remove the clamp and slide the stuffing box out of the junction box. The power cable should be completely disconnected from the motor.

WARNING! While this power cable is detached from the motor, the trailing cable should not be reconnected to energize the miner. Damage to the miner, personal injury or death could result.  18. To prevent damage to the power cable lugs and gland assembly, cover the power cable and secure it to the miner in a safe location.  19. To protect the motor’s electrical connections, replace the motor junction box cover and secure it using hex head capscrews and lock washers.

______________________________________________________________ A6474X307 VASS/0 5.187

Replacement of wear parts _____________________________________ WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all lifting devices.  20. Remove the four socket head capscrews that secure the cutter drive motor to the cutter gear case (Fig. 144).  21. Remove motor and remove bottom manifold. Secure o-rings ( 2 ea.). Manifolds (top and bottom) do not come on exchange motors.  22. Remove plates on exchange motor (installed to cooling ports) and re-install on motor removed.

Fig. 144: Drum drive motor Manifold

© BUCYRUS AMERICA, INC.

Hex head bolts (4)

Capscrews (8)

________________________________________________________________ 5.188 Bucyrus – Model 25M1AC Continuous Miner

____________________________________ Replacement of wear parts drum drive motor installation

To install the drum drive motor: WARNING! Federal law requires that mining equipment electrical connections must be inspected by a certified electrician before the equipment can be operated.

WARNING! This procedure involves attaching an electrical power cable to the cutter head drum drive motor. The trailing cable must be disconnected to safely perform this operation or serious injury or death will result.

WARNING! You can be seriously injured or killed by a falling load. Follow the safe working load limits of all blocking devices.

© BUCYRUS AMERICA, INC.

 1. Slide the motor into the gear case.  2. Insert the four bolts through the motor mounting holes and hand tighten them into the boom’s threaded motor mounting holes.  3. Torque the four bolts to approximately 1,800 ft-lbs (see bolt installation procedure in this chapter) to secure the drive motor to the boom.  4. Connect the cooling water hoses to the motor. Check to make sure motor and hose ends are clean before connecting them to the motor.  5. Connect the motor and power cable leads.  6. Insert o-rings and capscrews onto the motor junction box cover.  7. Replace the retaining ring, the plug and the o-ring. Engage the drive shaft with the gear case and install the shaft cover.  8. Insert the capscrews and lockwashers that secure the cover for the drive shear shaft.  9. Replace the brackets and covers that protect the drum drive motor.  10. Following installation, isolate and jog the new motor to check for correct rotation.

______________________________________________________________ A6474X307 VASS/0 5.189

Replacement of wear parts _____________________________________ Drum drive gear case removal and installation drum drive gear case removal

To remove the drum drive gear case:  1. Remove the cutter head center drum (See Center cutter drum removal procedure in this chapter).  2. Remove the covers, water spray manifolds, hosing and cutter motor power leads.  3. Remove the cutter head end drum (See End cutter drum removal procedure in this chapter).  4. Carefully lower the cutter head assembly (now with the cutter drum drive gear case exposed) onto blocking.

 5. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine lockout/tagout regulations.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.  6. Remove the strapping from the capscrews securing the gear case to the boom using a cutting torch.  7. Remove the sixteen hex head capscrews (Fig. 145) that secure the cutter drum drive gear case to the cutter drum.

Fig. 145: Capscrews

Capscrews

 8. Remove the cutter motor.  9. Connect electrical power to the miner.  10. Slowly tram the miner in reverse away from the blocked gear case.  11. Remove the two keys and store for installation.

________________________________________________________________ 5.190 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

WARNING! You could be seriously injured or killed by falling loads. Always observe the safe working load limits of blocking devices.

____________________________________ Replacement of wear parts drum drive gear case installation

To install the drum drive gear case:  1.

Securely block the gear case so that the miner’s boom can be trammed forward into position behind it.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all blocking devices.  2.

Install the gear case’s two alignment keys.

 3. Connect the trailing cable to energize the miner.  4. Slowly tram the miner in forward toward the blocked gear case.

WARNING! Use extreme caution when tramming the miner forward to position the boom face against the gear case.

© BUCYRUS AMERICA, INC.

 5. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine lockout/tagout regulations.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.  6. Install the cutter motor.  7. Install the hex head capscrews into the cutter drum drive gear case mounting brace and into the threaded holes in the cutter boom face.  8. Using a torque wrench with 20 to 1 multiplier, tighten all twentyone hex head capscrews to 1,900 ft-lb.  9. Install the strapping (Fig. 146) onto the capscrews securing the gear case to the boom.

Fig. 146: Capscrew strapping Strapping

Strapping

 10. Install the cutter motor power leads, hosing, water spray manifolds and covers.  11. Install the cutter drums. ______________________________________________________________ A6474X307 VASS/0 5.191

Replacement of wear parts _____________________________________ Gathering head assembly The gathering head assembly (Fig. 147) consists of the gathering pan, the continuous loading arms (CLAs), lift cylinders, and drive motors.

Fig. 147: Gathering head assembly CLA key

Lift cylinder location

Gear case (under CLA) Continuous loading arms (CLA) (2)

gathering head assembly removal

To remove the gathering head assembly  1. Lower the conveyor tail section until it is level with the floor.

Lower the gathering head until it rests on the floor. Place blocking under the rear of the gathering head to stabilize its position during and after removal of the pivot pins and disconnection of the lift cylinders.  2. Raise the cutter head to its highest point and place blocking underneath it. Lower the cutter head onto the blocking.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of blocking devices.  3. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.

________________________________________________________________ 5.192 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

Foot shaft location

____________________________________ Replacement of wear parts  4. Double check that the cutter head is securely blocked.  5. Separate the conveyor chain and remove the foot shaft (see Foot shaft removal procedure in this chapter).  6. Remove the hex head capscrews and lock washers that secure each of the front rub rails to the tractor frame and open both front rub rails.  7. Remove the electrical power cables from the gathering head.  8. Disconnect, tag, and cap the motor cooling water and scrubber spray water hoses from the gathering head.

© BUCYRUS AMERICA, INC.

WARNING! You could be seriously injured or killed by falling loads. Do not remove the gathering head pivot pins unless the gathering head is securely blocked into a stationary position. Use extreme caution when removing the pivot pins.  9. Remove the hex head capscrews and lockwashers that secure the right gathering head pivot pin retaining plate to the tractor frame (Fig. 148).  10. Remove the hex head capscrews and lock washers that secure the pin retaining plate to the gathering head pivot pin and remove the retaining plate.

Fig. 148: Gathering head pivot pin Hex head capscrews (retaining plate to tractor frame)

Pivot pin retaining plate

Gathering head pivot pin

Hex head capscrews (retaining plate to pivot pin)

______________________________________________________________ A6474X307 VASS/0 5.193

Replacement of wear parts _____________________________________  11. Using a slide hammer, pull the pivot pin.  12. Repeat steps 9 through 11 for the left gathering head pivot pin.

WARNING! You can be seriously injured or killed by falling loads. Do not disconnect the gathering head cylinder unless the gathering head is securely blocked. Use extreme caution when disconnecting the gathering head lift cylinder.  13. Remove the hex head capscrews and lock washers that secure the piston pin retaining bar on the right gathering head lift cylinder to the gathering head side panel and remove the retaining bar (Fig. 149).  14. Repeat step 13 for the left gathering head lift cylinder.

Fig. 149: Gathering head lift cylinder piston pin retaining bar

Lock washer

Retaining bar

Gathering head lift cylinder Hex head capscrew

 15. Connect the trailing cable to energizer the miner.

WARNING! Stand clear of the blocked cutter head and gathering head assemblies during the contraction of the gathering head lift cylinders.  16. Slowly contract the lift cylinders until the piston ends come free from their gathering head clevises.

CAUTION! When separating the gathering head from the tractor frame, ensure that the disconnected ends of the conveyor chain smoothly slide out of the gathering head.  17. Lift the cutter head off the blocking and slowly tram the miner in reverse until the cutter head clears the backboard of the gathering head. ________________________________________________________________

5.194

Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

Piston pin

____________________________________ Replacement of wear parts gathering head assembly installation

To install the gathering head assembly:  1. Position the gathering head assembly at the front of the tractor frame. Block up the rear of the gathering head so that it’s pivot points are at the level of the tractor frame clevises.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of blocking devices.

CAUTION! When tramming the miner toward the gathering head, be careful that the conveyor chain and gathering head lift cylinders do not become pinched between the tractor frame and the gathering head.  2. Raise the cutter head assembly to its highest point.

© BUCYRUS AMERICA, INC.

 3. Slowly tram the miner forward until it is close to the gathering head head assembly.  4. Thread the lower end of the conveyor chain into the gathering head assembly return pan so that the end appears on the footshaft return plate. Place the upper end of the conveyor chain down the front of the gathering head entrance pan.  5. Place blocking underneath the cutter head and lower the cutter head onto the blocking.  6. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel. 

7. Connect the trailing cable to energize the miner.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of blocking and lifting devices and stand clear of the blocked cutter head and the gathering head during the gathering head lift extension. 

8. Extend the gathering head lift cylinders so that the piston end bearings can be inserted into the gathering head lift cylinder clevises.

 9.

Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel. ______________________________________________________________ A6474X307

VASS/0

5.195

Replacement of wear parts _____________________________________  10. Insert the piston end bearing of the right gathering head lift cylinder into the gathering head clevis.  11. Using the hammer, insert the piston end pin through the aligned clevis bushings and the rod end bearing.

IMPORTANT! Insert the pin far enough to avoid obstructing the placement of the pin retaining bar.  12. Place the pin retaining bar over the end of the pin and insert and tighten the two hex head capscrews and lock washers that secure the piston pin retaining bar to the gathering head side panel.  13. Repeat steps 10 through 12 on the left gathering head lift cylinder.

 14. Use the gathering head lift cylinders and tractor frame stabilizer to align the tractor frame clevis and the gathering head pivot points to make inserting pivot pins easier.  15. Gently tap the right gathering head pivot pin through the aligned tractor frame clevis and gathering head pivot bushings.

IMPORTANT! The pin must be inserted far enough so that it does not obstruct positioning of the retaining plate flat against the tractor frame.  16. Place the pivot pin retaining plate so that edge with two cutouts located in the corners is positioned against the backup strip.

The edge of the plate with two cutouts and a hole for the pin’s grease fitting must be positioned over the pivot pin.  17. Insert and tighten the two hex head capscrews and lock washers to secure the pivot pin retaining plate to the gathering head pivot pin.  18. Insert and tighten the hex head capscrews and lock washers to secure the pivot pin retaining plate to the tractor frame.  19. Repeat steps 16 through 18 for the left gathering head pivot pin.  20. Replace the motor cooling water and scrubber spray water hoses onto the gathering head assembly.  21. Replace the electrical power cables onto the gathering head assembly.  22. Close the front rub rails and insert and tighten a hex head capscrew and lock washer to secure the front rub rail closed against the tractor frame.  23. Replace the foot shaft into the gathering head (see Foot shaft removal and installation procedure in this chapter) and reconnect the conveyor chain. ________________________________________________________________

5.196

Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

CAUTION! Use caution when using the lift cylinders and stabilizer to adjust the alignment of the clevis and pivot pins.

____________________________________ Replacement of wear parts Gathering head drive motor removal and installation gathering head drive motor removal

To remove the gathering head drive motor:  1. Lower the gathering head completely until it touches the floor.

Lower the conveyor tail assembly until it is level with the floor.  2. Lower the cutter head completely until it touches the floor.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of blocking devices.  3. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

© BUCYRUS AMERICA, INC.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.  4. Take side cover off at conveyor motor; clean the debris from around the motor.  5. Remove the four allen bolts.  6. If necessary, remove the CLA to allow access to the motor mounting bolts. Only remove the CLA if the bolts cannot be removed any other way.  7. Locate the side cover of the gathering head motor and remove the hex head capscrews and lock washers that secure the side cover to the gathering head assembly.  8. Remove the cover to expose the end of the motor.

Fig. 150: Upper deck cover Upper deck cover

______________________________________________________________ A6474X307 VASS/0 5.197

Replacement of wear parts _____________________________________  9. Remove the square-headed pipe plug on the end of the gathering head motor.  10. Remove the retaining ring that secures the shaft end plug inside the motor housing (Fig. 151).  11. Using a slide hammer, pull the drive shaft end plug out.  12. Pull the motor shaft from the motor and store in safe place.

Fig. 151: Drive shaft and end plug removal

O-ring

Retainer ring Shaft

 13. Use the adjustable wrench to replace the pipe plug into the end of the motor. Remove water hosing from motor and cap, and move to sides.  14. Remove the hex head capscrews and lock washers that secure the motor junction box cover.  15. Remove the cover and its o-ring.  16. Locate the three taped power connections inside the junction box and strip the tap covering each lug connection.  17. Tag each connection and remove the hex head capscrew, flat washer, lock washer, and hex head nut that secures each of the power cable lugs.  18. Remove the socket head capscrews and lock washers that secure the stuffing box’s half-moon clamp to the junction box.  19. Remove the clamp and slide the stuffing box out of the junction box. The power cable should be completely disconnected from the motor.

WARNING! While the power cable is detached from the motor, the trailing cable should not be reconnected to the miner. Damage to the machine or injury or death to personnel could result.

________________________________________________________________ 5.198 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

Drive shaft end plug

____________________________________ Replacement of wear parts  20. To prevent damage to the power cable lugs, stuffing box, and gland assembly, cover and secure the power cable to the miner in a safe location.  21. Replace the junction box o-ring and cover and secure with the hex head capscrews and lock washers to protect the motor’s electrical connections.  22. Tag, disconnect, and cap the two cooling water hoses (with elbow and adapter) from the two motor cooling water fittings on the gear case end of the motor.  23. Remove the two motor cooling water fittings from the motor and store in a clean place.

© BUCYRUS AMERICA, INC.

 24. Plug the two motor cooling water ports to keep them clean.

WARNING! The next steps disconnect the gathering head drive motor from the adapter that links it to the gathering head gear case. The gathering head drive motor is extremely heavy. Be prepared to support this weight before performing the following steps.  25. Remove the socket head capscrews that secure the motor to the gear case adapter plate.  26. The gathering head drive motor should now be detached from the gear case and able to be removed from the gathering head assembly through the motor side cover opening. gathering head drive motor installation

To install the gathering head drive motor:  1. Insert the gear case to motor seal between the adapter plate and the gear case (Fig. 152). When the motor is inserted, the seal should be located between the surfaces of the motor and the gear case.  2. Insert the gathering head motor through the slide cover opening, attachment bolt holes first. The junction box of the motor should be positioned toward the front of the gathering head.

Fig. 152: Gear case to motor seal installation Gear case to motor seal

Gear case adapter plate

Motor

______________________________________________________________ A6474X307 VASS/0 5.199

 3.

Position the motor against the gear case adapter plate and align the four attachment bolt holes on the gear case side of the motor with the four holes on the corners of the adapter plate.

 4.

Apply Loctite 242 (blue) to the four socket head capscrews.

 5.

Insert and tighten the socket head capscrews to secure the motor to the gear case adapter plate.

 6.

Using an adjustable wrench, insert the two motor cooling water fittings into the gathering head drive motor’s cooling water ports, which are located on the gear case end of the motor.

 7.

Attach the two motor cooling water hoses (with elbow and adapter) to the fitting.

 8.

Remove the hex head capscrews and lock washers that secure the junction box cover.

 9.

Remove the cover and its o-ring.

 10. Insert the three lugs of the power cable (with gland and stuffing box already installed) into the motor’s junction box.  11. Replace the stuffing box’s half-moon clamp in its channel to secure the stuffing box in the junction box.  12. Insert and tighten the two socket head capscrews and lock washers to secure clamp to the junction box.  13. Locate the motor’s lug connections inside the junction box and match the motor lug connections to the corresponding power cable lugs.  14. Attach the first motor lug to its corresponding power cable lug by inserting a hex head capscrew through the power cable lug, through the motor lug, through a flat washer, and through a lock washer. Secure the capscrew with a hex nut.  15. Repeat this step with the other two power cable and motor lugged connections.  16. When all three connections have been secured, wrap each of the three connections with a layer of rubber tape, then a layer of electrical (black) tape, and finally a layer of glass tape.  17. Replace the junction box o-ring and junction box cover and secure the cover with hex head capscrews and lock washers to secure the junction box cover.

________________________________________________________________ 5.200 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

Replacement of wear parts _____________________________________

____________________________________ Replacement of wear parts  18. Remove the pipe plug from the end of the motor (Fig. 153).  19. Slide the drive shaft through the gathering head motor and into the gathering head gear case (the drive shaft end without the threaded hole should be inserted first). The shaft may require some adjustment so that its end fits into the gear case.  20. Install the o-ring into the channel on the shaft end plug.  21. Insert the drive shaft end plug into position in the center of the motor.  22. Insert the retaining ring to secure the shaft end plug inside the motor housing.  23. Replace the pipe plug into the end of the motor.

© BUCYRUS AMERICA, INC.

Fig. 153: Drive shaft installation

O-ring Retainer ring

Pipe plug

Drive shaft Drive shaft end plug

 24. Reconnect water hosing.  25. Replace the gathering head motor side access cover. Secure the cover to the gathering head by inserting and tightening the hex head capscrews.  26. Replace the upper deck cover (if removed) and secure to the gathering head by inserting and tightening the hex head capscrews.  27. If removed, install the CLA over the motor (see CLA removal and installation procedure in this chapter).

______________________________________________________________ A6474X307 VASS/0 5.201

Replacement of wear parts _____________________________________ Gathering head gearcase removal and installation gathering head gear case removal

To remove the gathering head gear case:  1. Lower the conveyor tail section until it is level with the floor.

Lower the gathering head until it touches the floor.  2. Raise the cutter head assembly to its highest position. Place blocking underneath the cutter head assembly. Lower the cutter head assembly onto the blocking.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of blocking devices.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.  4. Remove the gathering head motor’s side cover by removing the hex head capscrews and lock washers that secure the side cover to the gathering head assembly.  5. Remove the cover to expose the end of the motor.  6. Remove the square-headed pipe plug on the end of the gathering head motor.  7. Remove the retaining ring that secures the shaft end plug inside the motor housing (Fig. 154).  8. Using a slide hammer, pull out the drive shaft end plug.  9. Pull the drive shaft from the motor and store in a safe place.  10. Replace the pipe plug into the end of the motor.

Fig. 154: Motor shaft removal

Drive shaft end plug

O-ring

Retainer ring Drive shaft

________________________________________________________________ 5.202 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

 3. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

____________________________________ Replacement of wear parts  11. Remove the CLA to expose the gathering head gear case (see CLA removal and installation procedure in this chapter).  12. Remove the hex head capscrews and lock washers that secure the upper deck cover (Fig. 155) to the gathering head assembly. Remove the upper deck cover to expose the gear case and the drive shaft end of the motor.  13. Remove the hex head capscrews and lock washers that secure the lower deck cover (Fig. 155) to the gathering head assembly and remove the lower deck.

Fig. 155: Deck covers

© BUCYRUS AMERICA, INC.

Upper deck cover

Lower deck cover

 14. Loosen tension on the conveyor chain as much as possible (see Conveyor chain adjustment in the Adjustment procedures section of this chapter).  15. Separate the conveyor chain and remove the gathering head foot shaft (see the Foot shaft removal and installation procedure in this chapter).  16. Connect the trailing cable to energize the miner.  17. Raise the gathering head to its highest position. Place blocking underneath the gathering head and lower the gathering head onto the blocking.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of blocking devices.  18. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel. ______________________________________________________________ A6474X307

VASS/0

5.203

Replacement of wear parts _____________________________________  19. Remove the drain plugs from the underside of the gathering head gear case and completely drain the gear case lubricant.  20. Replace the drain plugs into the underside of the gear case.  21. Connect the trailing cable to energize the miner.  22. Raise the gathering head off the blocking, remove the blocking, and lower the gathering head until it touches the floor.  23. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.

 25. Remove the socket head capscrews (Fig. 156) that secure the motor to the gear case adapter plate.  26. Remove the motor and clean out the cavity.  27. Remove the hex head capscrews that secure the gathering head gear case pot to the mounting plate.  28. Remove eight wedge bolts and remove four wedge blocks.  29. The gathering head gear case is now unattached and can be removed from its position in the gathering head.

Fig. 156: Gear case removal Plugs

Lubrication lines

Socket head capscrews (gear case to adapter plate)

Adapter plate

Hex head capscrews (gear case to mounting plate)

________________________________________________________________ 5.204 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

 24. Disconnect, tag, and cap the four lubrication connections from the gathering head gear case.

____________________________________ Replacement of wear parts gathering head gear case removal

To install the gathering head gear case:  1. Insert a new gear case-to-motor seal between the adapter plate and the gear case (Fig. 157). When the gear case is inserted into the gathering head and the transfer case is positioned against the gathering head motor, the seal should be located between the surfaces of the motor and the gear case.  2. Carefully insert the gathering head gear case into position in the gathering head assembly.  3. Insert and tighten the hex head capscrews, lock washers and wedges to secure the gear case pot to its mounting plate.

Fig. 157: Gear case mounting

© BUCYRUS AMERICA, INC.

Gear case adapter plate

Gear caseto-motor seal

Hex head capscrews

 4.

Install the motor and align the four holes on the corners of the adapter plate with the four attachment bolt holes on the gear case side of the motor.

 5.

Apply Loctite 242 (blue) to the four socket head capscrews.

 6.

Insert and tighten the four socket head capscrews to secure the gear case adapter plate to the motor.

 7.

Attach the four lubrication connections to the gathering head gear case.

 8.

Attach the rose gun to the lower ports located adjacent to the gathering head side cover and fill the gathering head gear case to the proper level with lubricant. Check the gear case lubricant level.

IMPORTANT! The bottom ports on the high speed input cases are the fill lines.

The top ports on the high speed input cases are the check lines.  9.

Examine the gathering head gear case in various places for signs of leaking lubricant that identify improper installation or gear case damage.

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Replacement of wear parts _____________________________________  10. Install the gathering head foot shaft and reconnect the conveyor chain (see Foot shaft installation procedure in this chapter).  11. Tighten the conveyor chain to the proper tension (see Con veyor chain adjustment in the Adjustment procedures section of this chapter).

IMPORTANT! Improper conveyor chain tension can lead to excessive wear, mechanical problems, and miner downtime. Always keep the conveyor chain at proper tension.  12. Replace the lower deck cover (Fig. 158) onto the gathering head assembly and secure to the gathering head assembly by inserting and tightening the hex head capscrews and washers.

© BUCYRUS AMERICA, INC.

 13. Replace the upper deck cover (Fig. 158) onto the gathering head assembly and secure by inserting and tightening the hex head capscrews and washers.

Fig. 158: Deck covers

Upper deck cover

Lower deck cover

 14. Install the CLA onto the gathering head gear case turntable (see CLA removal and installation procedure in this chapter).  15.. Remove the pipe plug from the end of the motor.  16. Slide the drive shaft through the gathering head motor and into the gathering head gear case (the drive shaft end without the threaded hole should be inserted first.) The shaft may require some adjustment so that its end fits into the gear case.

________________________________________________________________ 5.206 Bucyrus – Model 25M1AC Continuous Miner

____________________________________ Replacement of wear parts  17. Install the o-ring into the channel on the shaft end plug (Fig. 159).  18. Insert the drive shaft end plug into position in the center of the motor.  19. Insert the retaining ring to secure the shaft end plug inside the motor housing.

Fig. 159: Drive shaft installation

© BUCYRUS AMERICA, INC.

Retainer ring

O-ring

Pipe plug

Drive shaft Drive shaft end plug

 20. Replace the pipe plug into the end of the motor.  21. Install fittings and re-hose water supply.  22. Replace the side cover onto the gathering head assembly.  23. Insert and tighten the hex head capscrews and lock washers to secure the side cover to the gathering head assembly.

______________________________________________________________ A6474X307 VASS/0 5.207

Replacement of wear parts _____________________________________ Gathering head foot shaft removal and installation gathering head foot shaft removal

To remove the gathering head foot shaft:  1. Lower the gathering head until it touches the floor.  2. Position the conveyor tail section directly behind the miner so that it is level with the floor.  3. Raise the cutter head assembly to its highest position. Place blocking underneath the cutter head assembly and lower the cutter head assembly onto the blocking.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of blocking devices.

 5. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.  6. Loosen tension on the conveyor chain as much as possible (see Conveyor chain adjustment procedure in the Adjustment procedures section of this chapter).  7. With conveyor chain tension removed, remove the connecting link pins and the connecting link.  8. The conveyor chain should now be separated. Move the two pieces of the conveyor chain out of the way to allow for easier removal of the gathering head foot shaft.  9.

Remove the hex head capscrews and lock washers that secure the foot shaft cover to the gathering head and remove the foot shaft cover.

 10. Locate the two collars on the foot shaft and remove the hex head capscrews that secure each of the collars to the foot shaft. When the capscrews are removed, the flex lock nuts will fall free from the other side of the collar. Retrieve these nut and hand tighten them onto their capscrews for safe keeping. Remove both collars from the foot shaft.

________________________________________________________________ 5.208 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

 4. Slowly advance the conveyor chain until a connecting link appears on the gathering head entrance pan.

____________________________________ Replacement of wear parts  11. Slide the foot shaft couplings (Fig. 160) from the ends of the foot shaft toward the sprocket in the center. Once the couplings have been moved, the foot shaft is disconnected from the gear case bevel pinions.  12. The foot shaft can now be removed from the gathering head.

Fig. 160: Foot shaft removal Hex head capscrews

Gear case bevel pinion

Flex lock nuts

© BUCYRUS AMERICA, INC.

Foot shaft collar Foot shaft coupling

gathering head foot shaft installation

To install the gathering head foot shaft:  1. Slide a coupling onto each end of the foot shaft (Fig. 160).  2

Inspect the snap rings on both output shaft seal retainers.

 3. Insert the gathering head foot shaft into position between the two gathering head gear case bevel pinions.

IMPORTANT! Position the foot shaft so its sprocket will engage the conveyor chain links when the chain is reconnected.  4. Align the foot shaft splines with the bevel pinions’ splines.  5. Slide the right coupling over the foot shaft spline onto the bevel pinion splines until it touches the gear case seal carrier. Repeat with the left coupling.  6. Place a collar onto each end of the foot shaft so that the collars keep the couplings secure against the gear case seal carriers, bridged between the foot shaft and bevel pinion.  7. Insert and tighten the hex head capscrews through both halves of each collar and into the flex lock nuts to secure the collars to the foot shaft.  8. Replace the foot shaft cover.  9. Insert and tighten the hex head capscrews and lock washers to secure the foot shaft cover to the gathering head.

______________________________________________________________ A6474X307 VASS/0 5.209

Replacement of wear parts _____________________________________  10. Reattach the two ends of the conveyor chain by replacing the connecting link. Secure the link.  11. Tighten the conveyor chain to the proper tension (see Conveyor chain adjustment procedure in the Adjustment procedure section of this chapter).

© BUCYRUS AMERICA, INC.

IMPORTANT! Improper conveyor chain tension can lead to excessive wear, mechanical problems, and miner downtime. Always keep the conveyor chain at proper tension.

________________________________________________________________ 5.210 Bucyrus – Model 25M1AC Continuous Miner

____________________________________ Replacement of wear parts Gathering head lift cylinder removal and installation gathering head lift cylinder removal

To remove a gathering head lift cylinder:  1. Lower the conveyor tail section so that it is level with the floor.  2. Completely raise the cutter head and gathering head assemblies.  3. Place blocking under the cutter head and gathering head assemblies and lower the assemblies onto the blocking.

WARNING! You can be seriously injured or killed by falling loads. Observe the safe working load limits of all blocking devices.

© BUCYRUS AMERICA, INC.

 4. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.  5. Remove the hex head capscrews and lock washers that secure the lift cylinder piston pin retaining bar to the gathering head side panel and then remove the retaining bar (Fig. 161).

Fig. 161: Gather head lift cylinder piston pin retaining bar Piston pin

Lock washer

Retaining bar Gathering head lift cylinder Hex head capscrew

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Replacement of wear parts _____________________________________  6. Use a slide hammer to pull the pin from the clevis bushings.  7. Connect the trailing cable to energize the miner.

WARNING! Stand clear of the blocked cutterhead and gathering head assemblies during gathering head lift cylinder contraction.  8. Slowly contract the lift cylinder until the piston end comes free from its clevis.  9. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

 10. Check the blocking that supports the cutter head and gathering head assemblies.  11. Move the gathering head lift cylinder control lever up and down to release any pressure from the gathering head lift cylinders.  12. Disconnect and plug the hydraulic hose from the gathering head lift cylinder’s hydraulic fitting.  13. Remove the hydraulic fitting from the gathering head lift cylinder and store it in a clean place.  14. Attach a lifting device to the gathering head lift cylinder. Take up any slack in the lift device so that the weight of the cylinder rests on the left device.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all lifting devices and stay clear of suspended loads.  15. Remove the two hex head capscrews and lock washers that secure the pin retaining plate on the gathering head lift cylinder to the tractor frame and remove the retaining plate.  16. Using a slide hammer, remove the rod end pin from the frame clevis bushing. The cylinder should now be able to be removed from the miner.

________________________________________________________________ 5.212 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.

____________________________________ Replacement of wear parts gathering head lift cylinder installation

To install the lift cylinder:  1. Insert the piston end bearing of the gathering head lift cylinder into the gathering head assembly clevis.  2. Insert the piston end through the aligned clevis bushings and piston end bearing.

WARNING! This procedure involves the alignment of hydraulic cylinder end bearings within their clevises to allow for insertion of the retaining pins. DO not test this alignment using your fingers. Shifting of the aligned pieces could cause serious injury.  3. Place the pin retaining bar over the piston end pin and secure to the gathering head side panel with hex head capscrews and lock washers.

© BUCYRUS AMERICA, INC.

 4. Insert the hydraulic fitting into the gathering head lift cylinder hydraulic port.  5. Attach the hydraulic hose to the gathering head cylinder hydraulic fitting.  6. Connect the trailing cable to energize the miner.

WARNING! Stand clear of the blocked cutterhead and gathering head assemblies during the gathering head lift cylinder extension.  7. Slowly extend the cylinder so that its rod end bearing can be inserted into the gathering head cylinder frame clevis.  8. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.  9. Position the gathering head cylinder rod and bearing into the gathering head cylinder frame clevis.  10. Insert the rod end pin into the aligned clevis bushings and rod end of the cylinder.

IMPORTANT! The pin should be inserted so that its retaining channel remains outside of the bushings.  11. Insert the pin retaining plate in the pin’s channel to secure the pin in the clevis.  12. Insert and tighten the two hex head capscrews and lock washers that secure the pin retaining plate to the tractor frame. ______________________________________________________________ A6474X307 VASS/0 5.213

Replacement of wear parts _____________________________________ CLA removal and installation Fig. 162: Continuous loading arms (CLAs) Continuous loading arm (CLA)

Hog rings

CLA removal

Socket head capscrews

To remove a CLA:  1. Lower the conveyor tail section until it is level with the floor.

Lower the gathering head until it touches the floor.  2. Raise the cutter head assembly to its highest position. Place blocking under the cutter head assembly. Lower the cutter head assembly onto the blocking.

WARNING! You can be seriously injured or killed by falling loads. Observe the safe working load limits of all blocking devices.  3. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.  4. Remove the hog rings (Fig. 163) from around each of the CLA’s socket head capscrews.  5. Remove the socket head capscrews located where the arms meet the CLA hub.  6. Remove the capscrews located in the center of the CLA hub.

The CLA should now be free and able to be removed.

________________________________________________________________ 5.214 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

CLA tip

____________________________________ Replacement of wear parts  7. Remove the four CLA alignment keys (Fig. 166) from the exposed gathering head gear case turntable and store the keys in a safe place.

Fig. 163: CLA alignment key removal

Alignment key

© BUCYRUS AMERICA, INC.

Inner hub

CLA installation

To install the CLA:  1.

On the CLA exterior, mark the bolt hole (outer set of three holes) located directly adjacent to a key cut-out.

 2.

Place an alignment dowel (Fig. 164) in the gathering head gear case turntable bolt hole (outer set of three holes) that is directly adjacent to a key cut-out.

 3.

Place the four keys into their cutouts on the gathering head gear case turntable.

Fig. 164: Alignment dowel placement Alignment dowel placement location Alignment key

Inner hub

Gear case turn table

______________________________________________________________ A6474X307 VASS/0 5.215

Replacement of wear parts _____________________________________  4. Place the CLA onto the gear case turntable so that the dowel extends through the marked CLA hole. Adjust the CLA as necessary to fit the turntable keys into the CLA cut-outs.  5. Insert two socket head capscrews into the CLA outer holes not blocked by the dowel.  6

Remove the alignment dowel and insert the last socket head capscrew into the CLA hole.

 7. Tighten the three capscrews to secure the CLA to the gear case turntable.  8. Use the hammer to install three hog rings into the counterbore around each of the three outer socket head capscrews of the CLA. The rings should be tapped down until they are below the chamfer of the socket head capscrews.

 9. Insert the socket head capscrews into CLA hub bolt holes and tighten.  10. Use the hammer to install hog rings into the counterbore around each of the socket head capscrews of the CLA hub (Fig. 165). The rings should be tapped down until they are below the chamfer of the socket head capscrews.

Fig. 165: Hog ring installation

Capscrew chamfer

Hog ring

Hog ring

Bottom of hog ring counterbore

________________________________________________________________ 5.216 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

IMPORTANT! Hog rings should be installed so that their sharp points are directed clockwise.

____________________________________ Replacement of wear parts Continuous loading arm tip replacement  1. Lower the conveyor tail section until it is level with the floor.

Lower the gathering head until it touches the floor.  2. Raise the cutter head assembly to its highest position. Place blocking under the cutter head assembly, both on the floor and on the gathering head. Lower the cutter head assembly onto the blocking.

WARNING! You can be seriously injured or killed by falling loads. Observe the safe working load limits of all blocking devices.

© BUCYRUS AMERICA, INC.

 3. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.  4. Locate the CLA tip which requires replacement.  5. Remove the hex head capscrews that secure the tip to the CLA.  6. Use force as necessary to remove the tip from the CLA..  7. Slide the new tip onto the CLA..  8. Insert and tighten the hex head capscrews through the tip and the CLA.

______________________________________________________________ A6474X307 VASS/0 5.217

Replacement of wear parts _____________________________________ Tram motor removal and installation tram motor removal

To remove the tram motor:  1. Lower the conveyor tail section until it is level with the floor.  2. Lower the gathering head and cutter head assemblies until they touch the floor.  3. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.

 5. Remove the tram rub rail to expose the tram gear case and locate the tram drive motor inside the gear case (Fig. 166).

Fig. 166: Tram drive motor location

Tram drive motor

 6. Remove the hex head capscrews and hi-collar lock washers that secure the input shaft access cover to the motor housing.

Note that the cooling water hose support clamp is secured by one of the capscrews.  7. Remove the input shaft access cover and its o-ring.  8. Remove the retaining ring that secures the shaft plug in position.  9. Remove the shaft plug with o-ring that secures the input shaft in the motor.

________________________________________________________________ 5.218 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

 4. Remove the two rub ail pins that secure the tram rub rail to the two rub rail sections adjacent to it.

____________________________________ Replacement of wear parts  10. Pull the input shaft from the motor and store in a safe place.  11. Replace the input shaft access cover on the motor housing and secure the cover with the hex head capscrews and hi-collar lock washers.  12. Tag, disconnect, and cap the cooling water hoses or fittings from the cooling water fittings located on the top left and right corners of the tram motor.  13. Remove the cooling water fittings from the bottom left and right corners of the tram motor and store in a safe place.  14. Remove the hex head capscrews and disc lock washers that secure the tram motor bracket to the tram case.  15. Remove the socket head set screws that secure the tram motor bracket to the tram motor.

© BUCYRUS AMERICA, INC.

 16. Remove the tram motor bracket from the tram motor.  17. Carefully slide the tram motor out from the tram case until the motor’s electrical connection and hand hole cover are accessible.  18. Remove the socket head capscrews and hi-collar lockwashers that secure the hand hole cover to the motor housing.  19. Remove the hand hole cover and its o-ring from the motor housing.  20. Remove the socket head capscrews and lock washers that secure the stuffing box's half moon clamp to the junction box.  21. Remove the clamp and slide the stuffing box out of the junction box. The power cable should be completely disconnected from the motor.

______________________________________________________________ A6474X307 VASS/0 5.219

Replacement of wear parts _____________________________________ WARNING! Do not reconnect the trailing cable to the miner while the power cable is detached from the motor. Serious injury or death or damage to the machine may result.  22. To prevent damage to the power cable lugs and gland assembly, cover the power cable and secure it to the miner in a safe location. Bucyrus also recommends replacing motor gear case input seals for all motors.  23. To protect the motor’s electrical connections, replace the motor hand hole cover and o-ring and secure using the socket head capscrews and hi-collar lock washers.  24. Carefully remove the tram motor from the tram case and slide onto blocking. Clean out tram motor housing.

 26. Clean out tram motor housing.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all blocking devices. tram motor installation

To install the tram motor:  1. Replace the seal on the motor adapter plate, which is positioned against the primary planetary (Fig. 167).  2. Install fittings and install tram motor bypass hose on the rear of motor.  3. Slide the tram motor into the tram case, leaving the motor’s hand hole cover and stuffing box accessible outside the tram case.

Fig. 167: Tram motor installation

Tram case Tram motor

Drain plug

Motor-toadapter seal

________________________________________________________________ 5.220 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

 25. Remove the tram motor cooling water bypass hose that connects the two cooling water fittings on the rear of the tram motor and store in a safe place.

____________________________________ Replacement of wear parts  4. Remove the socket head capscrews and hi-collar lock washers that secure the hand hole cover to the motor housing.  5. Remove the hand hole cover and its o-ring.  6. Insert the four lugs of the power cable (with gland and stuffing box already installed) into the tram motor’s junction box.  7. Replace the stuffing box’s half-moon clamp in its channel to secure the stuffing box in the junction box.  8. Tighten the socket head capscrews to secure the clamp to the junction box.  9. Match the power cable lugs to the corresponding terminal strip posts and secure each lug to the corresponding post with a flat washer, lock washer, and hex nut.

© BUCYRUS AMERICA, INC.

 10. Replace the motor hand hole cover and o-ring, and secure it with socket head capscrews and hi-collar lockwashers.  11. Carefully slide the tram motor into position in the tram case.

The end of the motor must be completely flush against the primary planetary adapter plate.  12. Position the tram motor bracket against the motor. The lower half of the bracket must be flush against the motor and upper bracket must be flush against the tram case. Reposition the tram motor until the bracket can be properly positioned.  13. Insert and tighten the socket head capscrews to secure the tram motor bracket to the tram motor.  14. Insert and tighten the hex head capscrews and disc lock washers to secure the tram motor bracket to the tram case.  15. Insert the two cooling water fittings into the cooling water ports located on the top left and right corners of the tram motor.  16. Attach the cooling water hoses to the two cooling water fittings located on the top left and right corners of the tram motor.  17. Remove the hex head capscrews and hi-collar lock washers that secure the input shaft access cover to the motor housing.  18. Remove the input shaft access cover and its O-ring.

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Replacement of wear parts _____________________________________

 19. Slide the input shaft through the tram motor and into the tram planetary primary gear (the input shaft end without the threaded hole should be inserted first). The shaft may require some adjusting so that its splined end fits into the gear.  20. When the drive shaft is correctly positioned in the motor, install the o-ring onto the input shaft plug and then insert the plug into the motor.  21. Insert the retaining ring to secure the input shaft plug inside the tram motor.

 23. Replace the tram rub rail between the two adjacent rub rails and secure it with the two rub rail pins.

________________________________________________________________ 5.222 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

 22. Replace the input shaft access cover and its O-ring on the motor housing. When replacing the input shaft access cover and its capscrews, carefully insert the tram motor cooling water bypass hose into the bypass hose clamp. The clamp is secured to the tram motor by the access cover’s lower capscrew. Secure the cover with hex head capscrews and hi-collar lock washers.

____________________________________ Replacement of wear parts Tram primary planetary gear removal and installation primary planetary gear removal

To remove the primary planetary gear:  1. Lower the conveyor tail section until it is level with the floor.  2. Lower the gathering head and cutter head assemblies until they touch the floor.  3. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.

© BUCYRUS AMERICA, INC.

 4. Remove the two rub rail pins that secure the tram rub rail to the two rub rail sections adjacent to it and remove the tram rub rail to expose the tram gear case.  5. Remove the tram motor (see Tram motor removal and installation procedure in this chapter).  6. Remove the socket head capscrews that secure the motor adapter plate to the primary gear ring (and also secure the primary planetary carrier assembly to the tram case) (Fig. 168).  7. Remove the motor adapter plate from the tram case.  8. Carefully slide the primary planetary carrier assembly out of the primary gear ring and remove the assembly from the tram case.  9. Carefully slide the primary gear ring out of the tram case.

Fig. 168: Tram primary gear removal Tram case Motor adapter plate

Socket head capscrews

Primary planetary gear ring Primary planetary carrier assembly

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Replacement of wear parts _____________________________________ primary planetary gear installation

To install the tram primary planetary gear:  1. Insert alignment dowels into four of the sixteen capscrew holes in the tram case (Fig. 169).  2. To facilitate gear ring insertion, mark the mounting holes of the primary planetary gear ring that corresponds to the holes in which dowels were placed.  3. Slide the primary planetary gear ring onto the alignment dowels so the dowels appear through the marked holes.

Fig. 169: Alignment dowels and gear ring mounting Alignment dowels

Tram case

Tram drive pinion gear

Mounting marks (match with alignment dowels)

 4. Carefully insert the primary planetary gear assembly into the gear ring, ensuring that the extension of the sun gear faces out from the centerline of the miner and that the internal gear teeth of the primary carrier are seated securely onto the tram drive pinion gear.  5. Place the two adapter plate dowels into two 1” holes on the bottom left and right corners of the adapter plate.  6. Orient the adapter plate with the adapter dowels along the bottom edge.  7. Slide the adapter plate onto the four alignment dowels.  8. Insert and tighten twelve socket head capscrews into the holes in the adapter plate not blocked by the alignment dowels.  9. Remove the four alignment dowels and insert and tighten the final four socket head capscrews to secure the adapter plate and gear ring to the tram case.

________________________________________________________________ 5.224 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

Primary planetary gear ring

____________________________________ Replacement of wear parts  10. Torque the sixteen socket head capscrews to the appropriate amount (see Torque tables in Chapter 6 of this manual).  11. Install the tram motor in the tram case (see Tram motor removal and installation procedure in this chapter).  12. Replace the tram rub rail between the two adjacent rub rails and secure it with the two rub rail pins.

© BUCYRUS AMERICA, INC.

 13. Refill the tram gear case with oil.

______________________________________________________________ A6474X307 VASS/0 5.225

Replacement of wear parts _____________________________________ Tram secondary planetary gear removal/installation secondary planetary gear removal

To remove the tram secondary planetary gear:  1. Lower the conveyor tail section until it is level with the floor.  2. Lower the gathering head and cutter head assemblies until they touch the floor.

3. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.

 5. Remove the plug from the bottom of the tram secondary planetary gear cover and drain the lubricant from the gear case.  6. Replace the oil drain plug in the gear cover (Fig. 170).  7. Remove the sixteen socket head capscrews that secure the secondary planetary gear cover to the tram case and carefully remove the secondary planetary gear cover.

Fig. 170: Tram secondary planetary gear cover and drain plug

Tram secondary planetary gear cover

Socket head capscrews

Drain plug

________________________________________________________________ 5.226 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

 4. Remove the two rub rail pins that secure the tram rub rail to the two rub rail sections adjacent to it and remove the tram rub rail.

____________________________________ Replacement of wear parts WARNING! The next step removes the secondary planetary gear ring from the secondary planetary gear assembly. The secondary planetary gear ring is extremely heavy. Be prepared to support its weight before removing it from the secondary planetary assembly.  8. Carefully slide the secondary planetary gear ring off the secondary planetary gear assembly.  9. Insert eight hex head capscrews into the sprocket bearing carrier to secure it to the tram case.  10. Carefully pull the secondary tram drive shaft from the gear and sprocket and store in a safe place.  11. Carefully slide the secondary planetary assembly out of the sprocket bearing carrier.

© BUCYRUS AMERICA, INC.

Fig. 171: Secondary planetary assembly removal Ring gear

Secondary planetary gear assembly

Thrust washer

Hex head capscrew

Secondary planetary gear assembly

Secondary tram drive shaft

Sprocket bearing carrier

Secondary planetary gear assembly

______________________________________________________________ A6474X307 VASS/0 5.227

Replacement of wear parts _____________________________________ secondary planetary gear removal

To install the tram secondary planetary gear:  1. Carefully insert the secondary planetary gear assembly into the sprocket bearing carrier (Fig. 172), ensuring that the splined extension of the planetary carrier seats securely in the interior teeth of the sprocket.

Fig. 172: Planetary carrier installation Sprocket bearing carrier

Sprocket teeth Secondary planetary gear assembly

 2. Slide the secondary tram drive shaft through the secondary planetary gear assembly and into the tram drive sprocket and reach gear set (the drive shaft end without the threaded hole should be inserted first). The shaft may require some adjustment so that the end fits into the reach gears.  3. Insert four alignment dowels into the holes in the sprocket bearing carrier not blocked by the eight hex head capscrews (Fig. 173).  4. To facilitate gear ring insertion, mark the mounting holes of the secondary planetary gear ring that corresponds to the holes in which the dowels were placed.  5. Remove the eight hex head capscrews that secure the sprocket bearing carrier to the tram.

Fig. 173: Gear ring installation Sprocket bearing carrier

Secondary planetary gear assembly Gear ring

Thrust washer Hex head capscrews Alignment marks

Alignment dowels

________________________________________________________________ 5.228 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

Splined extension

____________________________________ Replacement of wear parts  6. Apply silicon sealant to the ring gear.  7. Carefully slide the secondary planetary gear ring onto the four alignment dowels so that the dowels appear through the marked holes. The planetary gear teeth should slide smoothly and securely into the gear teeth should slide smoothly and securely into the gear ring teeth.  8. Place the thrust water into the secondary planetary carrier directly behind the secondary tram drive shaft. The side of the thrust washer with the inscribed circles should face away from the drive shaft.  9. Apply silicon sealant to the cover.

© BUCYRUS AMERICA, INC.

 10. To facilitate gear cover replacement, mark the mounting holes of the secondary planetary gear cover that corresponds to the holes in which alignment dowels are placed.  11. Slide the secondary planetary gear case cover onto the alignment dowels so that the dowels appear through the marked holes.

IMPORTANT! The flat edge of the cover located adjacent to the lubrication fitting is the top of the cover. Orient the cover so that the lubricant level check plug is on the motor side of the cover and the drain plug is on the bottom.  12. Insert and tighten the twelve socket head capscrews into the holes in the gear case cover not blocked by the alignment dowels.  13. Remove the four alignment dowels.  14. Insert and tighten the remaining four socket head capscrews to secure the cover, the gear ring, and the sprocket bearing carrier to the tram case.  15. Using a torque wrench, torque all sixteen socket head capscrews to the proper torque (see Torque tables in Chapter 6 of this manual).  16. Using the lubrication fitting at the top of the gear cover (Fig. 174), fill the secondary planetary gear case to the proper level with lubricant.  17. Examine the secondary planetary gear case in various places for signs of leaking lubricant that identify improper installation or gear case damage.

______________________________________________________________ A6474X307 VASS/0 5.229

Replacement of wear parts _____________________________________ Fig. 174: Gear case fill and check plugs

Fill plug

Check plug

© BUCYRUS AMERICA, INC.

 18. Replace the tram rub rail between the two adjacent rub rails and secure it with the two rub rail pins.

________________________________________________________________ 5.230 Bucyrus – Model 25M1AC Continuous Miner

____________________________________ Replacement of wear parts Tram case removal and installation tram case removal

To remove the tram case:  1. Lower the conveyor tail section until it is level with the floor.  2. Raise the gathering head and cutter head and place a small stack of blocking under these two assemblies.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all blocking devices.  3. Lower the gathering head and cutter head onto the blocking so that the front end of the miner lifts off the floor.

© BUCYRUS AMERICA, INC.

 4. Extend the stabilizer completely so that the rear end of the miner lifts off of the floor.  5. Place blocking in multiple locations under the miner tram track.

When the miner is lowered, the tram track should be secured between the blocking and the tractor frame.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all blocking devices.  6. Raise the stabilizer and the gathering head and cutter head assemblies so the weight of the miner rests on the blocking.  7. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.  8. Remove the two rub rail pins that secure the tram rub rail to the two rub rail sections adjacent to it and remove the tram rub rail to expose the tram case.  9. Remove the hex head capscrew and lock washer that secure the front rub rail to the tractor frame and open the front rub rail cover.  10. Attach the grease gun to the front idler take-up cylinder fitting (Fig. 175) and pump grease into the take-up cylinder to extend the cylinder and remove pusher plate pressure on the idler shims.

______________________________________________________________ A6474X307 VASS/0 5.231

Replacement of wear parts _____________________________________  11. Remove all the idler adjustment shims and store the shims in a safe place.  12. Open the pressure release valve for the front idler take-up jack and allow the cylinder to contract.

Fig. 175: Idler take-up cylinder Idler take-up cylinder

Pressure release valve

Idler adjustment shims

 13. Locate a tram track link near the track entry opening at the bottom of the tram case (Fig. 176) and, using a hammer and punch, remove the two roll pins that secure the tram track pin between the links. Store the roll pins in a safe place.  14. Using the hammer and punch, remove the tram track pin to disconnect the links and separate the track. Store the track pin in a safe place.

Fig. 176: Tram track removal

Roll pins

Separate track here

Tram track pin

________________________________________________________________ 5.232 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

Grease fitting

____________________________________ Replacement of wear parts  15. Attach guide wires to the end of the tram track that passes through the tram case.  16. Connect the trailing cable to energize the miner.  17. Use the tram motor to slowly rotate the sprocket so that the end of the tram track that passes through the case is pulled up through the case and rolls off the sprocket.  18. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.

© BUCYRUS AMERICA, INC.

 19. Pull on the tram track from the front of the miner (near the idler) so that the free end of the tram track is pulled clear of the tram case exit opening.  20. Remove the tram motor (see Tram motor removal and installation procedure in this chapter).  21. Remove the bolts and washers from the sprocket and motor sides of the tram case.  22. Place a stack of blocking in front of the tram case onto which the case can be removed.

WARNING! The next step removes the tram case from the tractor frame. The tram case (with sprocket and reach gears) is extremely heavy. Be prepared to support the tram case before removing it from the tractor frame.

WARNING! Ensure that the electrical cables and cooling water hoses for the tram motor are free from the tram cases before attempting to remove the tram case from the tractor frame.  23. Carefully slide the tram case out from the tractor frame and onto the blocking.

WARNING! You can be seriously injured or killed by falling loads. Observe the safe working load limits of all blocking devices.  24. Pull the tram track guide wires out of the tram case exit opening and secure the wires to the tractor frame.

______________________________________________________________ A6474X307 VASS/0 5.233

Replacement of wear parts _____________________________________ tram case installation

To install the tram case:  1. Block up the tram case adjacent to its tractor frame position at a level that makes it easy to slide the case into the tractor frame.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all blocking devices.  2. Thread the guide wires through the tram case exit opening, between the sprocket gears, and out the tram case entry opening.  3. Slide the tram case into position in the tractor frame.

WARNING! Before attempting to slide the tram case into the tractor frame, ensure that the tram motor electrical and water connections are out of the way. Failure to do so may result in damage to the electrical and water connections.  4. Slide the tram case into position in the tractor frame.  5. Install the bolts that secure the motor side of the tram case to the tractor frame.  6. Install the bolts that secure the sprocket side of the tram case to the tractor frame.  7. Replace the tram motor (see Tram motor removal and installation procedure in this chapter).  8. While feeding the tram track from the front of the miner (near the idler), pull on the tram track guide wires until a link of the tram track engages the sprocket.  9. Connect the trailing cable to energize the miner.

WARNING! Stand clear of the miner when using the motor to pull the tram track through the tram case.  10. Use the tram motor to slowly rotate the sprocket and pull the tram track through the case until the end appears out the bottom.

WARNING! Double check that the links of the tram track are correctly seated onto the tram drive sprocket. Improper engagement of the tram track links onto the sprocket can cause serious mechanical damage. ________________________________________________________________

5.234

Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

IMPORTANT! The guide wires will be used to pull the tram track links onto the tram case sprocket after the tram case is installed.

____________________________________ Replacement of wear parts  11. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.  12. Remove the guide wires from the tram track.  13. Connect the two ends of the tram track and using the hammer and punch, insert the track pin to secure the two track links together.  14. Using the hammer and punch, insert the two roll pins into the track pin to secure the pin in the links.

© BUCYRUS AMERICA, INC.

 15. Adjust the tram track tension (see Tram track adjustment procedure in the Adjustment procedures section of this chapter).  16. Close the front rub rail cover and replace the hex head capscrews and lock washers that secure the front rub rail to the tractor frame.  17. Replace the tram rub rail between the two adjacent rub rails and secure it with the two rub rail pins.  18. Connect the trailing cable to energize the miner.  19. Remove blocking.  20. Fill gear case to proper level with lubricant.

WARNING! You could be seriously injured or killed by falling loads. Follow mine procedure to remove blocking devices and use caution.

______________________________________________________________ A6474X307 VASS/0 5.235

Replacement of wear parts _____________________________________ Tram reach gear set removal and installation tram case removal

To remove the tram reach gear set:  1. Lower the conveyor tail section until it is level with the floor.  2. Raise the gathering head and cutter head assemblies and place a small stack of blocking under each.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of blocking devices.  3. Lower the gathering head and cutter head onto the blocking so that the front end of the miner lifts off the floor.

 5. Place blocking in multiple locations under the miner tram track to securely support the tractor frame off the floor.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of blocking devices.  6. Raise the stabilizer and the gathering head and cutter head assemblies so the weight of the miner rests on the blocking.

When the tractor frame is lowered, the tram track should be secured between the blocking and the tractor frame.  7. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.  8. Double-check the tractor frame support blocking now that the weight of the tractor frame is completely upon it.  9. Remove the two rub rail pins that secure the tram rub rail to the two rub rail sections adjacent to it and remove the tram rub rail to expose the tram case.  10. Remove the tram case (see Tram case removal and installation procedure in this chapter).  11. Remove the plug from the motor end of the reach gear case bottom and drain the lubricant from the gear case.  12. When the lubricant has been completely drained, replace the plug.

________________________________________________________________ 5.236 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

 4. Extend the stabilizer completely so that the rear end of the miner lifts off the floor.

____________________________________ Replacement of wear parts  13. Remove the hex head capscrews and lock washers (Fig. 177) that secure the reach gear case cover to the gear case and remove the cover.

Fig. 177: Reach gear case cover removal Hex head capscrews Lock washers Reach gear case cover

© BUCYRUS AMERICA, INC.

Reach gear case

Rear side of tram case

Drain plug

 14. Locate the cap bearing carrier that secures the tram drive pinion inside the reach gear case.  15. Using retaining ring pliers, remove the retaining ring located outside the cap bearing carrier on the tram drive pinion (Fig. 178).  16. Using the wire cutters, cut and remove the wire securing the cap bearing carrier capscrews in position.  17. Remove the four drilled head capscrews and lock washers that secure the cap bearing carrier to the tram case and remove the cap bearing carrier.

Fig. 178: Cap bearing carrier removal Drilled head capscrews

Cap bearing carrier

Retaining ring

Tram drive pinion

______________________________________________________________ A6474X307 VASS/0 5.237

Replacement of wear parts _____________________________________  18. Remove the three steel shims and the bearing found under the shims (Fig. 179).  19. Carefully pull the tram drive pinion out of the reach gear case through the cap bearing carrier opening.

Fig. 179: Tram drive pinion removal Bearing carrier opening Cap bearing carrier

Bearing cup and cone set

Shims

 20. Cut and remove the wire securing the idler shaft capscrews in position.  21. Remove the drilled hex head capscrews that secure the idler shaft cap to the tram case and remove the idler shaft and three steel shims located under the cap.  22. Carefully slide the idler shaft out of the reach gear case through the idler shaft cap opening.  23. Remove the idler reach gear through the top opening of the reach gear case (Fig. 180).  24. Remove the bearing cup and cone sets from the center indentions of the idler reach gear.

________________________________________________________________ 5.238 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

Tram drive pinion

____________________________________ Replacement of wear parts Fig. 180: Idler reach gear and idler shaft removal Idler reach gear

Bearing cup and cone set Reach gear case

Rear side of tram case

Shims

Hex head capscrews

© BUCYRUS AMERICA, INC.

Idler shaft cap

 25. Remove the hex head capscrews and lock washers that secure the sprocket reach gear bearing cap to the reach gear case (Fig. 181).  26. Remove the bearing cap and the three steel shims under the cap.  27. Remove the bearing cone and cup set from the end of the splined sleeve.  28. Carefully slide the splined sleeve out of the sprocket reach gear.  29. Remove the sprocket reach gear through the top opening of the reach gear case.

Fig. 181: Sprocket reach gear removal Sprocket reach gear Splined sleeve Shims

Bearing cup and cone set Reach gear case

Sprocket reach gear bearing cap

Hex head capscrews

______________________________________________________________ A6474X307 VASS/0 5.239

Replacement of wear parts _____________________________________  30. Remove the second splined sleeve bearing cone and cup set from the rear of the reach gear case, located behind the sprocket reach gear. tram reach gear set installation

To install the tram reach gear set:  1. Insert one of the bearing cup and cone sets (cone side facing out) into the cut-out inside the reach gear case adjacent to the tram case sprocket (Fig. 182).

Fig. 182: Bearing cup and cone set installation

 2. Insert the sprocket reach gear into the top of the reach gear case and position it against the bearing cup and cone set adjacent to the tram case sprocket (Fig. 183).

Fig. 183: Sprocket reach gear installation

Sprocket reach gear set

 3. Insert the splined sleeve into the reach gear case (Fig. 184), through the sprocket reach gear and through the bearing cup and cone set until it is positioned against the tram sprocket.  4. Slide the second bearing cup and cone set (cup side facing out) onto the end of the splined sleeve.  5. Replace the three steel shims over the bearing set.  6. Replace the sprocket reach bearing cap.  7. Insert and tighten the hex head capscrews and lock washers to secure the sprocket reach gear bearing cap to the reach gear case.

________________________________________________________________ 5.240 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

Bearing cup and cone set

____________________________________ Replacement of wear parts Fig. 184: Splined sleeve and bearing cap installation Sprocket reach gear Splined sleeve Shims

Bearing cup and cone set

© BUCYRUS AMERICA, INC.

Reach gear case

Sprocket reach gear bearing cap

Hex head capscrews

 8. Insert two cup and cone bearing sets into the central cut-outs on either side of the idler reach gear (Fig. 185). The cone side of the bearing sets should face out of the gear on both sides.  9. Insert the idler reach gear through the top opening of the reach gear case and position it against the sprocket reach gear, ensuring that the gear teeth securely mesh.  10. Insert the idler shaft through the bearing sets in the idler reach gear until it is positioned against the tractor frame.  11. Replace the three steel shims over the idler shaft.  12. Replace the idler shaft cap.

Fig. 185: Idler reach gear and idler shaft installation Idler reach gear

Bearing cup and cone set Reach gear case

Rear side of tram case

Shims

Hex head capscrews

Idler shaft cap

______________________________________________________________ A6474X307 VASS/0 5.241

Replacement of wear parts _____________________________________  13. Insert and tighten the ten drilled hex head capscrews to secure the idler shaft cap.  14. Insert the tram drive pinion through the cap bearing carrier opening (located on the inside of the tram case tram motor bay) into the reach gear case. Ensure that the teeth of the pinion securely mesh with the idler reach hear teeth.  15. Replace the pinion bearing.  16. Replace the three steel shims over the pinion bearing.  17. Replace the cap bearing carrier over the pinion end.  18 Insert and tighten the drilled hex head capscrews and lock washers to secure the cap bearing carrier to the tram case.

 20. Double check that the tram drive pinion, idler reach gear and sprocket reach gear teeth are properly meshed and the gears rotate smoothly.  21. Tighten the sprocket reach gear bearing cap capscrews to correct torque (see Torque tables in Chapter 6 of this manual).  22. Tighten the idler shaft cap capscrews to correct torque (see Torque tables in Chapter 6 of this manual).  23. Lock wire the idler shaft cap capscrews to secure their positions.  24. Tighten the tram drive pinion cap bearing carrier capscrews to correct torque (see Torque tables in Chapter 6 of this manual).  25. Lock wire the tram drive pinion cap bearing carrier capscrews to secure their positions.  26. Replace the reach gear case cover onto the top of the reach gear case.  27. Insert and tighten fourteen hex head capscrews and lock washers to secure the reach gear case cover to the gear case.  28. Remove the plug from the sprocket side of the reach gear case cover.  29. Fill the reach gear case to the proper level with lubricant (Spec.

100-14).  30. Replace the fill plug.  31. Replace the tram case into the tractor frame (see Tram case removal and installation procedure in this chapter).

________________________________________________________________ 5.242 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

 19. Install the retaining ring on the tram drive pinion.

____________________________________ Replacement of wear parts IMPORTANT! The re-installation procedure for the tram case includes reinstallation of the primary and secondary planetary gears and the tram motor, and reconnection of the tram track.  32. Replace the tram rub rail between the two adjacent rub rails and secure it with the two rub rail pins.  33. Reconnect the trailing cable to energize the miner.  34. Raise the tractor frame by lowering the stabilizer and the gathering head and cutter head assemblies.  35. Carefully remove the support blocking from under the tractor frame.

© BUCYRUS AMERICA, INC.

 36. Lower the tractor frame onto the floor by raising the stabilizer and the gathering head and cutter head assemblies.

______________________________________________________________ A6474X307 VASS/0 5.243

Replacement of wear parts _____________________________________ Tram sprocket removal and installation tram sprocket removal

To remove the tram sprocket:  1. Lower the conveyor tail section until it is level with the floor.  2. Raise the gathering head and cutter head and place a small stack of blocking under these two assemblies.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all blocking devices.  3. Lower the gathering head and cutter head onto the blocking so that the front end of the miner lifts off the floor.

 5. Place blocking in multiple locations under the miner tram track.

When the miner is lowered, the tram track should be secured between the blocking and the tractor frame.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all blocking devices.  6. Raise the stabilizer and the gathering head and cutter head assemblies so the weight of the miner rests on the blocking.  7. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.  8. Double check the tractor frame support blocking now that the weight of the tractor frame is completely upon it.  9. Remove the two rub rail pins that secure the tram rub rail to the two rub rail sections adjacent to it and remove the tram rub rail to expose the tram case.  10. Remove the hex head capscrew and lock washer that secures the front rub rail to the tractor frame and open the cover.  11. Attach the grease gun to the fitting on the grease take-up cylinder (Fig. 186) and pump grease to extend the cylinder and remove pusher plate pressure on the idler shims.

________________________________________________________________ 5.244 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

 4. Extend the stabilizer completely so that the rear end of the miner lifts off the floor.

____________________________________ Replacement of wear parts  12.

Remove all the idler adjustment shims and store the shims in a safe place.

 13.

Open the pressure release valve for the front idler take-up jack and allow the cylinder to contract.

Fig. 186: Idler adjustment shim removal Idler take-up cylinder

Pressure release valve

© BUCYRUS AMERICA, INC.

Grease fitting

Idler adjustment shims

 14. Locate a tram track link near the track entry opening at the bottom of the tram case (Fig. 187) and, using the hammer and punch, remove the two roll pins that secure the tram track pin between the links. Store the roll pins in a safe place.  15. Using the hammer and punch, remove the tram track pin to disconnect the links and separate the track. Store the track pin in a safe place.

Fig. 187: Tram track removal

Roll pins

Separate track here Tram track pin

______________________________________________________________ A6474X307 VASS/0 5.245

Replacement of wear parts _____________________________________  16. Attach guide wires to the end of the tram track that passes through the tram case.  17. Connect the trailing cable to energize the miner.  18. Use the tram motor to slowly rotate the sprocket so that the end of the tram track that passes through the case is pulled up through the case and rolls off the sprocket.  19. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.

WARNING! Ensure that the end of the tram track is out of the tram case exit opening before attempting to remove the tram case from the tractor frame.  21. Remove the plug from the bottom of the cover and drain the lubricant from the gear case (Fig. 188).  22. Replace the oil drain plug in the gear cover.  23. Remove the Secondary planetary gear assembly (see Secondary planetary gear assembly removal and installation procedure in this chapter).

Fig. 188: Tram secondary planetary gear cover and drain plug

Tram secondary planetary gear cover

Socket head capscrews

Drain plug

________________________________________________________________ 5.246 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

 20. Pull on the tram track from the front of the miner (near the idler) so that the free end of the tram track is pulled clear of the tram case exit opening.

____________________________________ Replacement of wear parts  24. Remove the bearing carrier (Fig. 189).

Fig. 189: Sprocket bearing carrier removal

Bearing/seal sleeve assembly

Sprocket

© BUCYRUS AMERICA, INC.

Sprocket bearing carrier

WARNING! The next step removes the sprocket from the tram case. The sprocket is extremely heavy. Be prepared to support its weight before removing it from the tram case.  25. Remove the sprocket from the tram case (Fig. 190).  26. Remove the bearing/seal sleeve assembly from the rear of the sprocket bay of the tram case.

Fig. 190: Tram sprocket removal Bearing/seal sleeve assembly Tram case

Sprocket

______________________________________________________________ A6474X307 VASS/0 5.247

Replacement of wear parts _____________________________________ tram sprocket installation

To install the tram sprocket:  1. Bucyrus recommends ordering a pre-assembled sprocket. If you choose to order a pre-assembled sprocket, go directly to step 16. Consult your Bucyrus service representative to order a pre-assembled sprocket.  2. Install a spherical bearing into one of the bearing sleeves (Fig. 191).  3. Install the o-ring into the outside channel of the bearing sleeve.

IMPORTANT! When the bearing sleeve is inserted into position, the o-ring forms a seal between the sleeve and the piece that holds it.  4. Install a Duo-Cone seal into the seal sleeve (see Duo-cone seal installation notes in this chapter). The rubber side of the seal should face toward the sleeve; the metal ring of the seal should face outward.

Spherical bearing Seal sleeve

Duo-cone seal

O-ring Bearing sleeve

Metal ring

Rubber seal

 5. Insert the seal sleeve into the bearing sleeve.  6. Insert and tighten the three set screw into the bearing sleeve to secure the seal sleeve in the bearing sleeve.  7. Insert the bearing/seal sleeve assembly into position at the rear of the sprocket bay of the tram case.  8. Install the two Duo-Cone seals into the channel in each end of the sprocket. The rubber side of the seals should face into the sprocket channel; the metal rings of the Duo-Cone seals should face outward.  9. Insert the end of the sprocket into the seal sleeve so that it seats into the spherical bearing. Push the sprocket until the metal rings of the Duo-Cone seals are securely against each other.  10. Install the other spherical bearing into the remaining bearing sleeve.

________________________________________________________________ 5.248 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

Fig. 191: Bearing/seal sleeve assembly

____________________________________ Replacement of wear parts  11. Install the o-ring into the outside channel of the bearing sleeve.  12. Install a Duo-Cone seal into the remaining seal sleeve. The rubber side of the seal should face toward the sleeve; the metal ring of the seal should be facing outward.  13. Insert the seal sleeve into the bearing sleeve.  14. Insert and tighten the three set screws into the bearing sleeve to secure the seal sleeve in position.  15. Slide the bearing/seal sleeve assembly onto the end of the sprocket. Push the sleeve assembly until the end of the sprocket seats into the spherical bearing and the metal rings of the Duo-Cone seals are securely against each other.  16. Install the assembled sprocket assembly.

© BUCYRUS AMERICA, INC.

 17. Replace the bearing carrier over the bearing sleeve and end of the bearing sleeve and end of the sprocket.  18. Apply anti-seize to all the bearing fits on the sprocket, then use the planetary shaft to support the weight of the sprocket during installation. Start the sprocket bearing in evenly, then install the bearing carrier and start the front bearing in evenly.  19. Install the Secondary planetary gear assembly (see the Secondary planetary gear assembly removal and installation procedure in this chapter).  20. While feeding the tram track from the front of the miner (near the idler), pull on the tram track guide wires until a link of the tram track engages the sprocket.  21. Connect the trailing cable to energize the miner.

WARNING! Stand clear of the miner when using the motor to pull the tram track through the tram case.  22. Use the tram motor to slowly rotate the sprocket and pull the tram track through the case until the end appears out the bottom.

WARNING! Double check that the links of the tram track are correctly seated onto the tram drive sprocket. Improper engagement of the tram track links onto the sprocket can cause serious mechanical damage.  23. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.  24. Remove the guide wires from the tram track. ______________________________________________________________ A6474X307 VASS/0 5.249

Replacement of wear parts _____________________________________  25. Connect the two ends of the tram track and using the hammer and punch, insert the track pin to secure the two track links together.  26. Using the hammer and punch, insert the two roll pins into the track pin to secure the pin in the links.  27. Adjust the tram track tension (see Tram track adjustment procedure in the Adjustment procedures section of this chapter).  28. Close the front rub rail cover and replace the hex head capscrews and lock washers that secure the front rub rail to the tractor frame.  29. Replace the tram rub rail between the two adjacent rub rails and secure it with the two rub rail pins.  30. Connect the trailing cable to energize the miner.

WARNING! You could be seriously injured or killed by falling loads. Follow mine procedure to remove blocking devices and use caution.

________________________________________________________________ 5.250 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

 31. Remove blocking.

____________________________________ Replacement of wear parts Tram track front idler removal and installation tram track front idler removal

To remove the tram track front idler:  1. Raise the gathering head and cutter head assemblies to their highest points and place blocking underneath. Lower the assemblies onto the blocking. The gathering head and cutter head must be blocked high enough to allow the idler assembly to be removed from the tractor frame’s idler slide channel.

WARNING! You can be seriously injured or killed by falling loads. Observe the safe working load limits of all blocking devices.

© BUCYRUS AMERICA, INC.

 2. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.  3. Remove the hex head capscrew and lock washer that secure the front rub rail to the tractor frame and open the front rub rail cover.  4. Attach the grease gun to the front idler take-up cylinder fitting (Fig. 192) and pump grease into the take-up cylinder to extend the cylinder and remove pusher plate pressure on the idler shims.  5. Remove all the idler adjustment shims and store the shims in a safe place.  6. Open the pressure release valve for the front idler take-up jack and allow the cylinder to contract.

Fig. 192: Idler take-up cylinder

Pressure release valve

Idler take-up cylinder

Grease fitting

Idler adjustment shims

______________________________________________________________ A6474X307 VASS/0 5.251

Replacement of wear parts _____________________________________  7. Locate a tram track link near the near the idler and remove roll pins and link pin.  8. Using the hammer and punch, remove the tram track pin to disconnect the links and separate the track. Store the track pin in a safe place.

Fig. 193: Tram track removal

Roll pins

Separate track here

 9. Slide the front idler assembly out of the idler slide channel (Fig. 194).

Fig. 194: Front idler assembly removal

Pressure relief valve

Take-up cylinder

Idler slide channel Front idler assembly

________________________________________________________________ 5.252 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

Tram track pin

____________________________________ Replacement of wear parts  10. Slide the pusher plate and the spacer pusher out of the idler slide channel to inspect for damage (Fig. 195).

Fig. 1985 Pusher plate removal Take-up cylinder

Spacer pusher

Pressure relief valve

© BUCYRUS AMERICA, INC.

Pusher plate

Idler slide channel

tram track front idler installation

To install the tram track front idler:  1. Insert the pusher spacer (Fig. 196) into the tractor frame’s idler slide channel so that it rests on the slide block support and is positioned against the take-up jack.  2. Ensuring that the channel guides face away from the take-up jack, insert the pusher plate into the idler slide channel until it touches the pusher spacer.

Fig. 196: Pusher plate installation Take-up cylinder

Pusher spacer

Pressure relief valve Pusher plate

Idler slide channel

______________________________________________________________ A6474X307 VASS/0 5.253

Replacement of wear parts _____________________________________  3. Insert the block slides of the front idler assembly (Fig. 197) into the idler slide channel. The relief valve of the slide blocks must be oriented toward the front of the miner. The grease fittings must be oriented to the outside of the miner.  4. Push the front idler assembly into the slide channel until the block slides are against the pusher plate channel guides.

Fig. 197: Front idler installation Take-up cylinder

Idler slide channel Pusher plate channel Block slide

Relief

 5. Connect the two ends of the tram track and using the hammer and punch, insert the track pin to secure the two track links together.  6. Using the hammer and punch, insert the two roll pins into the track pin to secure the pin in the links.  7. Adjust the tram track tension (see Tram track adjustment procedure in the Adjustment procedures section of this chapter).  8. Close the front rub rail cover and replace the hex head capscrews and lock washers that secure the front rub rail to the tractor frame.

________________________________________________________________ 5.254 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

Front idler assembly

Pressure relief valve

____________________________________ Replacement of wear parts Front idler take-up cylinder removal and installation front idler cylinder removal

To remove the front idler take-up cylinder  1. Lower the conveyor tail section until it is level with the floor.  2. Lower the gathering head and cutter head until these two assemblies touch the floor.  3. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.

© BUCYRUS AMERICA, INC.

 4. Remove the hex head capscrew and lock washer that secures the front rub rail to the tractor frame and open the front rub rail cover.  5. If installed, remove the hex head capscrews that secure the fill plate to the frame and remove the fill plate. The cylinder may have to be collapsed before the fill plate can be removed.  6. Locate the front idler take-up cylinder bracket assembly (Fig. 198) which is mounted to the rear of the idler shim channel.

Fig. 198: Front idler take-up cylinder bracket Bracket assembly

Idler shim channel

______________________________________________________________ A6474X307 VASS/0 5.255

Replacement of wear parts _____________________________________  7. Pull the flip pin (Fig. 199) from the half link to release the takeup cylinder bracket from the tractor frame.  8. Lower the end of the bracket until it clears the half link and pull the bracket straight out to remove it from the tractor frame. If necessary, collapse the take-up cylinder.

Fig. 199: Front idler take-up cylinder removal Idler take-up cylinder assembly

Flip pin

front idler cylinder installation

Flip pin

Tractor frame

To install the front idler take-up cylinder:  1.

Replace the take-up cylinder bracket assembly into the tractor frame and secure it by inserting the flip pin through the half link.

 2.

Replace the fill plate and secure with capscrews.

 3.

Close the front rub rail cover and secure to the tractor frame with a hex head capscrew and lock washer to secure the front rub rail to the tractor frame.

________________________________________________________________ 5.256 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

Bracket assembly

____________________________________ Replacement of wear parts Hydraulic pump removal  1. Lower the conveyor tail section until it is level with the floor.  2. Lower the gathering head and cutterhead assemblies until they rest on the floor.  3. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.

There are two alternative locations and instructions for the removal of the hydraulic pump: in front of the demister box or behind the operator’s case.

© BUCYRUS AMERICA, INC.

When located in front of the demister box:  4. Locate the rub rail directly behind the tram case on the scrubber exhaust side of the miner (Fig. 200). Remove the two rub rail pins that secure the rub rail to the two rub rail sections adjacent to it and remove the rub rail.

Fig. 200: Pump located behind demister Hydraulic pump

Scrubber exhaust Rub rail

 5. Locate the hydraulic pump and motor assembly (Fig. 200).  6. Using the adjustable wrench, disconnect the inlet hose from the pump. Plug the hose end to keep it clean.  7. Using the adjustable wrench, disconnect the pilot and valve hoses from the pump fittings. Plug the hose ends to keep them clean.

______________________________________________________________ A6474X307 VASS/0 5.257

Replacement of wear parts _____________________________________  8. Remove the hose fittings from the pump and store in a safe place.  9. Remove all hex head capscrews and lockwashers that secure the pump assembly to the motor assembly and save for reinstallation.  10. Carefully remove the pump assembly by sliding it out of the pump motor.

When located behind the operator’s case:  4. Locate the rub rail directly behind the tram case on the operator’s side of the miner. Remove the two rub rail pins that secure the rub rail to the two rub rail sections adjacent to it and remove the rub rail.  5. Locate the hydraulic pump and motor assembly.

 7. Using the adjustable wrench, disconnect the pilot and valve hoses from the pump fittings. Plug the hose ends to keep them clean.

________________________________________________________________ 5.258 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

 6. Using the adjustable wrench, disconnect the inlet hose from the pump. Plug the hose end to keep it clean.

____________________________________ Replacement of wear parts Hydraulic pump installation  1. Slide the pump assembly into the pump motor (Fig. 201).  2. Insert and tighten, all hex head capscrews and lockwashers to secure the pump assembly to the motor.

Fig. 201: Hydraulic pump installation Motor

© BUCYRUS AMERICA, INC.

Hex head capscrew

Pump

Lockwasher

 3. Insert the hydraulic hose fittings into the pump assembly and tighten.  4. Attach and tighten the exit pilot and valve hoses to the pump fittings.  5. Attach the inlet hose to the pump.  6. Replace the rub rail between the two adjacent rub rails and secure it with the two rub rail pins.  7. Check the hydraulic fluid level.  8. Jog pump motor on and off a few times to prime the pump before starting.

______________________________________________________________ A6474X307 VASS/0 5.259

Replacement of wear parts _____________________________________ Hydraulic pump motor removal  1. Lower the conveyor tail section it is level with the floor.  2. Lower the gathering head and cutter head until they touch the floor. 

3. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel. 

4. Remove the hydraulic pump (see Hydraulic pump removal procedure in this chapter).



6. Remove the two hex head capscrews and lockwashers that secure the pump stand to the tractor frame and remove the pump stand.

Fig. 202: Hydraulic pump stand removal Hex head capscrew (2) Pump stand

Motor

Hex head capscrew (2)

________________________________________________________________ 5.260 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

 5. Remove the two hex head capscrews that secures the motor to the pump stand (Fig. 202).

____________________________________ Replacement of wear parts  7. Tag, disconnect, and cap the two cooling water hoses from the cooling water fittings on the pump motor.  8. Remove the cooling water fittings from the top left and right surface of the pump motor and store in a safe place.  9. Carefully slide the hydraulic pump motor out of the tractor frame enough to open the motor junction box.  10. Remove the cover and its o-ring from the motor’s junction box by removing four hex head capscrews and lockwashers.  11. Locate the three taped power connections inside the junction box.  12. Strip off the three layers of tape covering each of the three lug connections inside the junction box.

© BUCYRUS AMERICA, INC.

 13. Tag the three lugs to facilitate reconnection during motor installation.  14. Remove the hex head capscrew, flat washer, lockwasher, and hex head nut that secures the three power cable lugs to the three motor lugs.  15. Remove the two socket head capscrews and lockwashers that secure the stuffing box’s half-moon clamp to the junction box.  16. Remove the clamp and slide the stuffing box out of the junction box. The power cable should be completely disconnected from the motor.  17. To prevent damage to the power cable lugs and gland assembly, cover the power cable and secure it to the miner in a safe location.  18. To protect the motor’s electrical connections, replace the motor junction box cover and secure it using four hex head capscrews and lockwashers.

WARNING! The hydraulic pump motor is now detached from the tractor frame and can be removed. The hydraulic pump motor is extremely heavy. Prepare to support its weight before removing it from the tractor frame.

______________________________________________________________ A6474X307 VASS/0 5.261

Replacement of wear parts _____________________________________ Hydraulic pump motor installation  1. Slide the hydraulic pump motor into position in the tractor frame.  2. Remove the four hex head capscrews and lockwashers that secure the junction box cover and remove the cover and its oring.  3. Insert the three lugs of the power cable (with gland and stuffing box already installed) into the motor’s junction box.  4. Replace the stuffing box’s half-moon clamp in its channel to secure the stuffing box in the junction box.

 6. Inside the junction box, locate the motor’s lug connections.

Match the motor lug connections to the corresponding power cable lugs (refer to the wiring diagram supplied in your Bucyrus America, Inc. parts manual).  7. Attach the first motor lug to its corresponding power cable lug by inserting a hex head capscrew through the motor lug, through the power cable lug, through a flat washer, and through a lockwasher. Secure the capscrew with a hex nut.

Repeat this step for the other two lugged connections.  8. When all three connections have been secured, wrap each of the three connections with a layer of rubber tape, then a layer of black tape and finally a layer of glass tape.  9. Replace the junction box O-ring and cover.  10. Insert the four hex head capscrews and lockwashers to secure the junction box cover and tighten.  11. Insert the two motor cooling water fittings into the pump motor cooling water ports.  12. Attach the two motor cooling water hoses to the fittings.  13. Position the pump stand against the motor and attach to the motor with two hex head capscrews.  14. Insert and tighten the two hex head capscrews and lockwashers to secure the pump stand to the tractor frame.  15. Install the hydraulic pump (see hydraulic pump installation procedure in this chapter).

________________________________________________________________ 5.262 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

 5. Tighten the two socket head capscrews to secure the clamp to the junction box.

____________________________________ Replacement of wear parts Scrubber fan/motor removal  1. Lower the conveyor tail section until it is level with the floor.  2. Lower the gathering head and cutter head assemblies until they rest on the floor.  3. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.  4. Locate the rub rail on the fan exhaust side at the rear of the miner (Fig. 203) and remove the pin that secures the rear rub rail to the rail adjacent to it. Open both rub rails.

© BUCYRUS AMERICA, INC.

Fig. 203: Scrubber fan/motor location

Scrubber fan/motor

 5. Remove the four capscrews and lockwashers that secure the rub rail hinge post to the tractor frame and remove the post.  6. Locate the scrubber fan motor junction box and remove the four hex head capscrews and lockwashers that secure the junction box cover. Remove the cover and o-ring.  7. Locate the three taped power connections inside the junction box.  8. Strip off the three layers of tape covering each of the three lug connections inside the junction box.  9. Tag the three lugs to facilitate reconnection during motor installation.

______________________________________________________________ A6474X307 VASS/0 5.263

Replacement of wear parts _____________________________________

 10. Remove the hex head capscrew, flat washer, lockwasher, and hex head nut that secures the three power cable lugs to the three motor lugs.  11. Remove the two socket head capscrews and lockwashers that secure the stuffing box’s half-moon clamp to the junction box.  12. Remove the clamp and slide the stuffing box out of the junction box. The power cable should be completely disconnected from the motor.  13. To prevent damage to the power cable lugs and gland assembly, cover the power cable and secure it to the miner in a safe location.

 15 Remove the twelve hex head capscrews and lock-washers to secure the scrubber fan/motor assembly to the tractor frame.

WARNING! The scrubber fan/motor is now detached from the tractor frame and can be removed. The hydraulic pump motor is extremely heavy. Prepare to support its weight before removing it from the tractor frame.  16. Carefully slide the scrubber fan/motor out of the tractor frame.

________________________________________________________________ 5.264 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

 14. To protect the motor’s electrical connections, replace the motor junction box cover and secure it using four hex head capscrews and lockwashers.

____________________________________ Replacement of wear parts Scrubber fan/motor installation  1. Carefully insert the scrubber fan/motor assembly into the tractor frame so the motor face is toward the scrubber’s mist eliminator box.  2. Orient the scrubber fan/motor so the motor drain is directly at the bottom of the assembly. Ensure that the scrubber fan/motor is positioned correctly for airflow out the rear vent of the miner.  3. Insert and tighten the twelve hex head capscrews and lockwashers to secure the scrubber fan/motor assembly to the tractor frame.  4. Remove the four hex head capscrews and lockwashers that secure the junction box cover and remove the cover and its oring.

© BUCYRUS AMERICA, INC.

 5. Insert the three lugs of the power cable (with gland and stuffing box already installed) into the motor’s junction box.  6. Replace the stuffing box’s half-moon clamp in its channel to secure the stuffing box in the junction box.  7. Tighten the two socket head capscrews to secure the clamp to the junction box.  8. Inside the junction box, locate the motor’s lug connections.

Match the motor lug connections to the corresponding power cable lugs (refer to the wiring diagram supplied in your Bucyrus America, Inc. parts manual).  9. Attach the first motor lug to its corresponding power cable lug by inserting a hex head capscrew through the motor lug, through the power cable lug, through a flat washer, and through a lockwasher. Secure the capscrew with a hex nut.

Repeat this step for the other two lugged connections.  10. When all three connections have been secured, wrap each of the three connections with a layer of rubber tape, then a layer of black tape and finally a layer of glass tape.  11. Replace the junction box O-ring (optional) and cover.  12. Insert the four hex head capscrews and lockwashers to secure the junction box cover and tighten.  13. Replace the rub rail hinge post.  14. Insert and tighten the four hex head capscrews and lockwashers to secure the rub rail hinge post to the tractor frame.  15. Close both rub rails and secure with the rub rail pin.

______________________________________________________________ A6474X307 VASS/0 5.265

Replacement of wear parts _____________________________________ Stabilizer cylinder removal WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all blocking devices.  1. Raise the conveyor tail assembly to its highest position.  2. Raise the cutter head and gathering head assemblies. Place a small stack of blocking under the cutter head and gathering head assemblies.

 4. Completely extend the stabilizer so that the rear of the tractor frame lifts off the floor. Place blocking under the rear of the tractor frame. Raise the stabilizer slightly so that the tractor frame lowers onto the blocking.  5. Place blocking under the conveyor tail assembly and lower the tail assembly onto the blocking.  6. Extend the stabilizer so that it touches the floor. The stabilizer should not support any miner weight.  7. Double check that the tractor frame and the conveyor tail are securely blocked.  8. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel. 

9. Locate the rod end bearing pin of the stabilizer cylinder (Fig. 204). Remove the socket head capscrew that passes through the rod end bearing pin and retaining collar and remove the pin securing the stabilizer cylinder rod end bearing in its clevis.

 10.

Connect the trailing cable to energize the miner.

________________________________________________________________ 5.266 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

 3. Lower the cutter head and gathering head assemblies onto the blocking so that the front of the tractor frame lifts off the floor.

Place blocking under the front of the tractor frame. Raise the cutter head and gathering head assemblies slightly so that the tractor frame lowers onto the blocking.

____________________________________ Replacement of wear parts Fig. 204: Stabilizer cylinder rod end bearing Retaining collar

Rod end, right stabilizer cylinder

Bearing pin

Nut Socket head capscrew

© BUCYRUS AMERICA, INC.

 11. Contract the stabilizer cylinder. The rod end bearing of the cylinder should remove itself from its stabilizer shoe clevis.

WARNING! Stand clear of the blocked tractor frame during contraction of the stabilizer cylinder.  12. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.  13.

Raise and lower the stabilizer cylinder lever to release any pressure from the conveyor lift cylinder.

WARNING! The next steps require crawling under the block supported conveyor tail section. Verify that this tail section is adequately secured before proceeding.  14. Tag, disconnect, and cap the hydraulic hoses from the stabilizer cylinder’s fittings.  15. Remove the hydraulic fittings from the stabilizer cylinder and store in a clean place.

WARNING! Each stabilizer cylinder is extremely heavy. The next steps will remove the cylinder from its tractor frame mounting. Be prepared to support the weight from its tractor frame mounting. Be prepared to support the weight of the cylinder when it becomes free from the mounting.

______________________________________________________________ A6474X307 VASS/0 5.267

Replacement of wear parts _____________________________________  16. Locate the bearing pin that secures the stabilizer cylinder to its tractor frame mounting.  17. Remove the two cotter pins that secure the bearing pin inside the stabilizer cylinder’s piston bearing and tractor frame mounting.

© BUCYRUS AMERICA, INC.

 18. Slide the washers off both ends of the pin and Remove the pin from the cylinder’s piston end bearing and tractor frame mounting. The cylinder is now free and can be removed.

________________________________________________________________ 5.268 Bucyrus – Model 25M1AC Continuous Miner

____________________________________ Replacement of wear parts Swivel pin assembly removal Reference Fig. 205:  1. Lower the cutter head and gathering head assemblies until they touch the ground.  2. Position the conveyor tail section to the extreme right or left of the miner so that the chain is drawn to one side as far as possible and the conveyor swivel pin is exposed.  3. Lower the conveyor tail section until it is level with the floor.  4. Insert blocking between the conveyor tail section and the floor.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all blocking devices.

© BUCYRUS AMERICA, INC.



5. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.

Fig. 205: Conveyor swivel Dowel pin

Grease fitting

Set screw

Swivel pin

Socket head capscrews

Retainer

View A-A ______________________________________________________________ A6474X307 VASS/0 5.269

Replacement of wear parts _____________________________________  6. Remove the socket head capscrews from the upper swivel pin.  7. Remove the center setscrew from the center of the upper conveyor swivel pin.  8. Use a slide hammer to remove the upper conveyor swivel pin.  9. Remove the center setscrew from the center of the lower conveyor swivel pin.  10. Remove the socket head capscrews from the lower conveyor swivel pin.  11. Use a slide hammer to remove the lower conveyor swivel pin.  12. Reach into the conveyor chain return channel and retrieve both upper and lower swivel pin retainers.

Reference Fig. 206:  1. Working first on the upper swivel pin assembly, insert the dowel pin, center setscrew, and the grease fitting into the swivel pin.  2. Lower the swivel pin into the hole in the conveyor bed making sure the dowel pin is positioned in the notch and the top of the swivel pin is flush with the top surface of the conveyor bed.  3. Holding the swivel pin retainer with the flanged side downward, reach into the conveyor chain return channel and fit the swivel pin retainer into the hole.  4. Insert the socket head capscrews and tighten.  5. Working on the lower swivel pin assembly, insert the dowel pin, center setscrew and the grease fitting into the swivel pin.  6. Lift the swivel pin into the hole in the lower side of the conveyor making sure the dowel pin is positioned in the notch and the lower side of the swivel pin is flush with the lower surface.  7. Holding the swivel pin retainer with the flanged side upward, reach into the conveyor chain return channel and fit the swivel pin retainer into the hole.  8. Insert the socket head capscrews and tighten.

________________________________________________________________ 5.270 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

Swivel pin assembly installation

____________________________________ Replacement of wear parts Tail roller removal Reference Fig. 206:  1. Lower the gathering head and cutter head assemblies until they rest on the floor.  2. Slowly advance the conveyor chain until a connecting link moves onto the conveyor tail section slide pan.  3. Using the procedure outlined in Chain Tension, Loosen tension on the conveyor chain as much as possible (see Conveyor chain adjustment procedure I n this chapter).  4. Lower the conveyor tail section onto blocking so it is level with the floor.

© BUCYRUS AMERICA, INC.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all blocking devices. 

5. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.  6. With conveyor chain tension removed, remove the retaining rings, or “T” pins, from the connecting link.  7. Remove the connecting link and its strap. The conveyor chain should now be separated. Move the two pieces of the conveyor chain out of the way to allow for easier removal of the conveyor tail roller assembly. 

8. Remove the socket head capscrews that secure the tail roller assembly to the slide pan.



9. Remove the tail roller assembly from its location in the slide pan.

______________________________________________________________ A6474X307 VASS/0 5.271

Replacement of wear parts _____________________________________ Fig. 206: Tail roller

Tail roller

Socket head capscrew

 1. Insert the tail roller assembly into the proper location in the slide pan (Fig. 206).  2. Insert and tighten the socket head capscrews through the holes in the tail roller shaft and into the threaded holes in the slide pan (Fig. 206).  3. Reattach the two ends of the conveyor chain by replacing the connecting link.  4. Secure the connecting link by replacing the side strap and the retaining rings onto the ends of its pins.  5. Tighten the conveyor chain to the proper tension (see Conveyor chain adjustment procedure in this chapter).

IMPORTANT! Improper conveyor chain tension can lead to excessive wear, mechanical problems and miner downtime. Always keep the conveyor chain at the proper tension.

________________________________________________________________ 5.272 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

Tail roller installation

____________________________________ Replacement of wear parts Chain replacement  1. Lower the cutter head and gathering head assemblies until they touch the ground.  2. Position the conveyor tail section directly behind the miner and raise it. Insert the blocking under the tail section and lower the tail section onto the blocking.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all blocking devices. 

3. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

© BUCYRUS AMERICA, INC.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.  4. Loosen the tension of the conveyor chain as much as possible (see Conveyor chain adjustment procedure in this chapter).  5. Remove the two retaining rings from a connecting link located near the rear of the conveyor bed.  6. Remove the connecting link. The chain is now separated.  7. Connect the come-along to the end of the chain on the conveyor bed.  8. Connect the new chain to the end of the lower chain and allow the new chain to extend behind the miner on the floor.  9. Use the come along to pull the old chain out of the miner. The new chain will follow the old through the conveyor return channel around the gathering head foot shaft and out onto the conveyor tail section.  10. When the entire length of old chain has been pulled through the miner and the replacement chain is in position, disconnect the old chain from the new and remove the come along.  11. Connect both ends of the new chain by replacing the connecting link, pins and retaining rings.  12. Tighten the conveyor chain (see Conveyor chain adjustment procedure in this chapter).

______________________________________________________________ A6474X307 VASS/0 5.273

Troubleshooting ______________________________________________ Troubleshooting procedures The following section lists possible problems encountered when servicing the Continuous Miner and can aid in locating and correcting these problems.

This section covers basic components, with each listed in a troublecause-remedy format.

WARNING! Some procedures must be carried out with the cover of the electrical controller removed and some procedures require the controller to be energized during the tests. It is extremely important that you take all necessary precautions to prevent accidental electrical shock while working within the controller. An MSHA-certified electrician must supervise and inspect all work performed.

■

Before removing the controller cover, remove power from the system by disconnecting the trailing cable. Follow all mine, local, State, and Federal lockout/tagout procedures.

■

Use insulated gloves and tools where possible.

■

All connections must be tight and care must be taken to pre vent bolts, nuts, washers and other small metal fasteners from being dropped or lost inside the controller. These lost fasteners could cause electrical shorts inside the controller.

For procedures that DO require that the controller be energized while the cover is off: ■

At no time should you reach inside the controller while it is energized. If it becomes necessary to make adjustments or to replace parts inside the controller, the machine circuit breaker must be turned to the “OFF” position. Once the circuit breaker is in the “OFF” position, adjustments or parts replacements can be made.

■

Use insulated gloves and tools where possible.

■

All connections must be tight and care must be taken to pre vent bolts, nuts, washers and other small metal fasteners from being dropped or lost inside the controller. These lost fasteners could cause electrical shorts inside the controller.

________________________________________________________________ 5.274 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

For maintenance procedures and tests that DO NOT require the controller to be energized, these precautions include:

___________________________________________________ Hydraulic WARNING! Never disconnect a hydraulic hose if the circuit is pressurized or there is a load on the circuit. If a hose is disconnected while the cylinder is supporting a load, the load will fall.

Typical hydraulic problems

© BUCYRUS AMERICA, INC.

The most common causes for improper function are: ■

contaminated oil or poor oil quality

■

low or insufficient oil in the system

■

using the wrong type of oil or wrong viscosity grade

■

air in the hydraulic system

■

internal or external leakage of the hydraulic system

■

improper mechanical adjustments, such as reliefs

■

mechanical or structural damage leading to component failure

■

components by-passing (internal leaking or inability to hold pressure) which leads to erosion of bushings, valve spools, and other costly, critical components

The greatest aid to troubleshooting a hydraulic system is the confidence that comes with knowing the intended operation of the system, along with a fundamental understanding of basic hydraulic principles. Every component in the system has an intended purpose. The construction and operating characteristics of each of these components should be clearly understood before attempting to troubleshoot the machine. For example, understanding that a solenoid controlled directional valve can be manually actuated will save considerable time in isolating a defective solenoid. Please familiarize yourself with the operational descriptions of the hydraulic circuits given in the Hydraulics section of this chapter.

It is also important to know the capabilities of the system. Each component in the system has a maximum rated speed, flow, torque, or pressure. If the system is loaded beyond the specifications, the possibility of failure is greatly increased. The correct operating pressures of a system must be known and must always be checked and set with a pressure gauge. Refer to the hydraulic schematic in the Bucyrus America, Inc. parts manual supplied with your machine for the correct operating parameters. When in doubt, always assume that the correct pressure is the lowest pressure that will allow adequate performance of the system function (s) while remaining below the maximum rating of the machine’s components.

______________________________________________________________ A6474X307 VASS/0 5.275

Troubleshooting ______________________________________________ The ability to recognize trouble indicators in a specific system is usually acquired with experience. the gaining of this experience can be greatly enhanced by developing a logical sequence for determining the cause of a hydraulic problem and implementing the proper remedy.

■

general safety procedure for shutting down the machine

■

troubleshooting excessive noise

■

troubleshooting excessive heat

■

troubleshooting incorrect flow

■

troubleshooting incorrect pressure

■

troubleshooting faulty movement/operation

■

general restart checklist and procedure

This general information is intended to enhance the understanding of basic hydraulic principles which will lead to the development of a logical troubleshooting procedure. Specific troubleshooting checklists for each hydraulic circuit are given directly after the very important section entitled “Contaminants in hydraulic systems”.

Contaminants in hydraulic systems SYSTEM CONTAMINATION is the primary cause of hydraulic component failure! Cleanliness must be a high priority when servicing the hydraulic system. Even very small particles can damage system components by scoring valves, clogging orifices, and wearing seals prematurely. It is not the intent of this operation manual to outline a contamination control program but some of the most effective steps that have been identified in successful programs are given below: 1. Ensure that bulk oils are at acceptable cleanliness levels.

Areas where Bucyrus America, Inc. customers have made improvements in the past include: –

implement ISO Cleanliness Code standards for bulk hydraulic oils

–

evaluate bulk oil shipments for cleanliness by conducting particle counts and maintain records

–

minimize drum usage by utilizing tote tanks and five gallon pails

–

utilize plastic versus steel storage tanks, if possible

________________________________________________________________ 5.276 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

Refer to the general troubleshooting charts in this section that illustrate the logical sequence for shutdown, troubleshooting, and restarting the machine. The charts cover:

___________________________________________________ Hydraulic –

install desiccant breathers on all bulk tanks

–

use sealed plastic containers for adding oil to small sumps

–

locate bulk tanks near equipment and pump directly to reservoirs

–

utilize filter carts to maintain oil cleanliness standards

–

properly train personnel on the importance of clean oil and best practices for storage and handling

–

monitor your program closely and look for continuous improvement

© BUCYRUS AMERICA, INC.

2. Eliminate contamination source through “clean” maintenance practices.

This is best achieved by understanding the primary sources of contamination during maintenance and troubleshooting which are given below: –

always clean the area around the component that is to be removed and inspected

–

store components in a plastic bag after inspection and prior to replacement on machine

–

cap off all open hoses/fittings

–

never touch a filter with bare hands when installing it back onto the machine

–

pay close attention to the filler/breather cap and replace it when damaged or in the recommended time frame

Contact your Bucyrus America, Inc. representative for more information on implementing an effective program to ensure that your oil and maintenance practices are not contributing to your equipment failure.

Specific hydraulic circuit troubleshooting Multi-function failure If more than one function fails to operate on the machine, check the output of the pumps. Since this is an “open center” circuit, the normal pressure (with all directional control valves in the center position) should be less than 100 psi. This pressure reading illustrates the necessary pressure to circulate the oil through the system. If the pressure reading under these conditions is significantly greater than 100 psi, it is likely that one of the control valves is trying to direct oil to one (or more) of the circuits on the machine.

______________________________________________________________ A6474X307 VASS/0 5.277

Troubleshooting ______________________________________________ The next step in troubleshooting a multi-function failure is to check the pilot pressure on the main control valve manifold. This pressure should be between 400 - 500 psi. If the pilot pressure is significantly below 350 psi, start with the General Troubleshooting Flow Chart IV - Incorrect Pressure.

Another step to resolve multi-function failure is to have an electrician check for power to the solenoid circuits.

Individual hydraulic circuit failures Perform the following checks on the individual circuits in conjunction with the general troubleshooting: Oil tank fill  Check the venturi ejector for blockage.  Check for low oil in the new oil supply.

Cutter head raise

 Check to see that hosing has not been crossed, especially if the problem occurs after maintenance or repair work.  Check that the "in-line" counterbalance holding valve is piloted and shifting to direct retract port cylinder oil flow back to tank.  Check to see that there is no mechanical bind.  Check cylinders for bypassing.  Check for pilot pressure on the cutter head cylinder’s holding valves. Also check that the valves are shifting to send (extend port) oil back to the tank.

Cutter head lower  Check the direction control valve for proper operation.  Check to see that hosing has not been crossed, especially if the problem occurs after maintenance or repair work.  Check to see that there is no mechanical bind or hydraulic block.  Check flow control valve cartridge.  Check cylinders for bypassing.  Check for pilot pressure on the cutter head cylinder's holding valves. Also check that the valves are shifting to send (extend port) oil back to the tank. Note: Cylinder removal will be required to safely achieve this.

________________________________________________________________ 5.278 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

 Check the directional control valve for proper operation.

_____________________________________________ Troubleshooting Gathering head raise  Check the directional control valve for proper operation.  Check to see that piping has not been crossed, especially if the problem occurs after maintenance or repair work.  Check pressure at the LH pressure gauge on scrubber.  Check to see that there is no mechanical bind.  Check cylinders for bypassing.  Check accumulator for 500 psi pre-charge, and that the bladder is functioning properly, depending on system installed.  Check needle valve on pilot circuit to verify that it is not open or leaking off.

© BUCYRUS AMERICA, INC.

 Check in-line counterbalance valve for proper operation or blockage.

Gathering head float  Check the control valve for proper operation.  Check to see that hosing has not been crossed, especially if the problem occurs after maintenance or repair work.  Check to see that there is no mechanical bind.  Check accumulator for 500 psi pre-charge, and that the bladder is functioning properly, depending on system installed.  Check cylinders for bypassing (they will leak out the top).  Check needle valve on pilot circuit to verify that it is not open or leaking off.  Check counterbalance valve for proper operation (See the schematic in the Bucyrus America, Inc. parts book supplied with your machine for the proper setting).

Conveyor raise  Check the directional control valve for proper operation.  Check to see that hosing has not been crossed, especially if the problem occurs after maintenance or repair work.  Be sure that the built-in atmospheric-vented reliefs on the cylinders are not dumping oil.  Check to see that there is no mechanical bind.  Verify that cylinders are not bypassing.

______________________________________________________________ A6474X307 VASS/0 5.279

Troubleshooting ______________________________________________ Conveyor lower  Check the directional control valve for proper operation.  Check to see that hosing has not been crossed, especially if the problem occurs after maintenance or repair work.  Verify that pilot pressure is being applied to open the piloted builtin checks.  Verify that cylinders are not bypassing.

Conveyor swing  Check the directional control valve for proper operation.

 Verify that the cylinder is not bypassing.

Stabilizer raise  Check the directional control valve for proper operation.  Check to see that hosing has not been crossed, especially if the problem occurs after maintenance or repair work.  Check for bound bushings.  Check for any mechanical bind or any obstruction blocking movement.  Check cylinder for bypassing.

Stabilizer lower  Check the control valve for proper operation.  Check to see that hosing has not been crossed, especially if the problem occurs after maintenance or repair work.  Check for bound bushings.  Check for any mechanical bind or any obstruction blocking movement.  Check cylinder for bypassing.

________________________________________________________________ 5.280 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

 Check for any mechanical bind or any obstruction blocking movement, either to the cylinder itself, the main pivot area, or to some point along or under the discharge conveyor itself. Also check to ensure that the pivot bushings have not frozen up from lack of lubrication.

___________________________________________________ Hydraulic General safety procedure for shutting down machine When shutting down the machine for maintenance:  lower or mechanically secure (block) all suspended loads  exhaust any pressure locked in the system  drain down all accumulators  isolate the electrical control system  isolate the electrical power supply

© BUCYRUS AMERICA, INC.

Follow all procedures listed in the Shutdown procedure in this chapter.

______________________________________________________________ A6474X307 VASS/0 5.281

Troubleshooting ______________________________________________ Table 3: Flow chart I for troubleshooting excessive noise Pump Noisy Cause

Motor Noisy Remedy

Cavitation

A

Air in fluid

B

Coupling misaligned

C

Pump worn or damaged

E

Cause

Relief/Counterbalance Valve Noisy Remedy

Cause

Remedy

C

Setting too low or too close to another valve setting

D

Worn poppet and seat

E

Motor or coupling worn or damaged

Remedies A. Any or all of the following:

 wash strainers in solvent compatible with system fluid  clean clogged inlet line  clean reservoir breather vent  change system fluid  change to proper pump drive motor speed  check fluid temperature B. Any or all of the following:  tighten leaky inlet connections  fill reservoir to proper levels: with few exceptions, all return lines should be below fluid level in the reservoir  bleed air from system  replace pump shaft seal; also replace shaft if worn at seal journal C. All of the following:  align unit  check condition of seals, bearings, and coupling D.  install and/or adjust pressure gauge E.  overhaul or replace defective parts

________________________________________________________________ 5.282 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

 replace dirty filters

_____________________________________________ Troubleshooting Table 4: Flow chart II for troubleshooting excessive heat

© BUCYRUS AMERICA, INC.

Pump Heated

Motor Heated Cause

Fluid Heated

Cause

Remedy

Cause

Remedy

See Fluid Heated

System pressure too high

D

Cause

Remedy

Fluid heated

See Fluid Heated

Cavitation

A

Relief valve set too high

D

Valve setting incorrect

D

Unloading valve set too high

D

Air in fluid

B

Excessive load

C

Worn or damaged valve

E

Fluid dirty or low supply

F

Relief valve set too high

D

Worn or damaged motor

E

Incorrect fluid viscosity

F

Excessive load

C

Worn or damaged pump

E

Worn pump, valve motor, cylinder, or other component

E

Fluid heated

Remedy

Relief Valve Heated

See Fluid Heated

Fluid heated

Remedies  locate and correct mechanical binding A. Any or all of the following:  check for workload in excess of circuit design  replace dirty filters  clean clogged inlet line

D.  install and/or adjust pressure gauge; keep at least 125 psi difference between valve settings

 clean reservoir breather vent

E.  overhaul or replace defective parts

 change system fluid

F.  change filters

 change to proper pump drive motor speed

 check system fluid viscosity; change if necessary

B. Any or all of the following:  fill reservoir to proper level  tighten leaky inlet connections  fill reservoir to proper levels: with few exceptions, all return lines should be below fluid level in the reservoir  bleed air from system  replace pump shaft seal; also replace shaft if worn at seal journal C. All of the following:  align unit  check condition of seals, bearings, and coupling

______________________________________________________________ A6474X307 VASS/0 5.283

Troubleshooting ______________________________________________ Table 5: Flow chart III for troubleshooting incorrect flow

Cause

Low Flow Remedy

Cause

Excessive Flow Remedy

Cause

Remedy

Pump not receiving fluid

A

Flow control set too low

D

Flow control set too high

D

Pump drive motor not operating

E

Relief or unloading valve set too low

D

RPM of pump drive motor incorrect

H

Pump to drive coupling sheared

C

Flow by-passing thru partially open valve

E of F

Improper size pump used for replacement

H

Pump drive motor turning in wrong direction

G

External leak in system

B

Directional control set in wrong position

F

RPM of pump drive motor incorrect

H

Entire flow passing over relief valve

D

Worn pump, valve, motor, cylinder, or other component

E

Damaged pump

C

Pilot filter clogged

A

Improperly assembled pump

E

Pilot filter clogged

A

Remedies A. Any or all of the following:

F. Any or all of the following

 replace dirty filters

 check position of manually operated controls

 clean clogged inlet line

 check electrical circuit on solenoid operated controls

 clean reservoir breather vent  repair or replace pilot pressure pump  fill reservoir to proper level G.  reverse rotation B. Any or all of the following: H.  replace with correct unit  tighten leaky inlet connections  bleed air from system C. All of the following:  check for damaged pump or pump drive  replace coupling D.  adjust setting on valve E.  overhaul or replace part

________________________________________________________________ 5.284 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

No Flow

_____________________________________________ Troubleshooting Table 6: Flow chart IV for troubleshooting incorrect pressure

© BUCYRUS AMERICA, INC.

No Pressure

Low Pressure

Cause

Remedy

Cause

No flow

See Table 5 Pressure relief path exists

Erratic Pressure

Remedy See Table 5

Cause

Excessive Pressure

Remedy

Cause

Remedy

Air in fluid

B

Pressure reducing, relief valve misadjusted

D

Pressure recuing, relief valve worn or damaged

E

Pressure reducing valve set too low

D

Worn relief valve

E

Pressure reducing valve damaged

E

Contamination in fluid

A

Damaged pump, motor, or cylinder

E

Accumulator defective or has lost charge

C

Worn pump, motor, or cylinder

E

Remedies A.  replace dirty filters and system fluid B.  tighten leaky connections  fill reservoir to proper level and bleed air from system C.  gas valve for leakage  pre-charge to correct pressure  overhaul if defective D.  adjust valve E.  overhaul or replace part

______________________________________________________________ A6474X307 VASS/0 5.285

Troubleshooting ______________________________________________ Table 7: Flow chart V for troubleshooting faulty operation

Cause No flow or pressure

Slow Movement

Remedy

Cause

See Table Low flow 5

Erratic Movement

Excessive Speed or Movement

Remedy

Cause

Remedy

See Table 5

Erratic pressure

See Table Excessive flow 6

See Table 5

Air in fluid

See Table Feedback 3 transducer malfunctioning

E

Limit or sequence device (mechanical, electrical, or hydraulic) inoperative or misadjusted

E

Fluid viscosity too high

A

Mechanical bind

B

Insufficient control pressure for valves

See Table 6

No lubrication of machine ways or linkage

G

No command signal to valve or amplifier

F

No lubrication of machine ways or linkage

G

Erratic command signal

F

Inoperative or misadjusted valve amplifier

C

Misadjusted or malfunctioning valve amplifier

C

Misadjusted or malfunctioning valve amplifier

C

Inoperative solenoid or proportional valve

E

Sticking valve

D

worn or damaged cylinder or motor

E

Worn or damaged cylinder or motor

E

Sticking valve

D

Pilot filter clogged

See Table 5

Worn or damaged cylinder or motor

E

Cause

Overriding work load

Remedy

H

Remedies A.  check fluid temperature  check system fluid viscosity; change if necessary B.  locate bind and repair C.  adjust, repair, or replace part D.  clean and adjust or replace part  check condition of system fluid and filters E.  overhaul or replace part F.  repair command console or interconnecting wires G.  lubricated H.  adjust, repair, or replace counterbalance valve

________________________________________________________________ 5.286 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

No Movement

___________________________________________________ Hydraulic Table 8: Restarting checklist Has the cause of the failure been remedied?

No

Carry out further investigation.

Yes

Clean or flush the system as required.

Yes Can dirt have entered the system by the unit failure or during replacement?

No Is the unit the correct one?

No

Modify or replace with correct unit.

No

Remedy installation.

No

Remedy installation.

Yes

Is the unit adjusted to a safe condition for start up?

Yes

© BUCYRUS AMERICA, INC.

Are all hydraulic connections correct?

Yes Are all electrical connections correct?

Yes Is the unit adjustable?

No

Adjust to a safe condition.

Yes No Have the cases of pumps and motors been filled?

No

Fill case.

Yes

Bleed or prime as necessary.

No

Remove safety interlocks.

No

Sound alarm or inform personnel.

Yes Will the system require bleeding or priming?

No Have all safety interlocks been removed

Yes Are all personnel aware the machine is restarting?

Yes Start machine (see Startup procedure in this chapter).

______________________________________________________________ A6474X307 VASS/0 5.287

Troubleshooting ______________________________________________ Water System including Circuits Table 9: Water system troubleshooting including circuits Trouble, symptom or cause

Probable cause

recommended water volume  Dynamic water pressure (psi) (gpm) cannot be maintained is not being supplied to the recommended psi.

Test, check and/or remedy  Change setting to the recommended psi.

 Water supply hose is not the minimum diameter

 Change hose to the recommended diameter size.

 Incoming supply of water has a problem.

 Check the water supply itself to see if there is an issue & fix.

damaged or clogged filter, con-  Dirt in the system. taminates in the water system

 Remove the filter and clean it thoroughly; flush the system as necessary.

plugged water nozzles are re-  Dirt in the system. stricting the flow of water or pressure fluctuates

 Remove the nozzles and clean thoroughly; flush the system as necessary.  Change water filter frequently.

pressure fluctuates and there is  Air in the system. extreme noise in the system  Pressure too high.

 Check for leaks.  Adjust the pressure.

excessive water blowing from  Excessive pressures on scrub-  Adjust psi setting. scrubber exhaust ber screen sprays.  Pressure setting on jet pump too low.

 Adjust psi setting.

 Damaged screen or mist eliminator.

 Replace.

 Mist eliminator not sealing.

 Replace seal.

 Sump needs cleaned.

 Remove mist eliminator and clean sump.

 Mist eliminator baffles dirty.

 Remove mist eliminator and clean.

water function will not shut  Hydraulic pilot operated water “OFF” with radio transmitter valve stuck open.

 Clean or replace.

 Faulty solenoid.

 Replace.

 Radio transmitter toggle switch faulty.

 Replace toggle switch.

________________________________________________________________ 5.288 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

 Change water filter frequently.

_____________________________________________ Troubleshooting Table 9 (continued): Water system troubleshooting including circuits Trouble, symptom or cause

Probable cause

no water pressure on the  Water filter plugged. pressure gauge  Main water ball valve “OFF”.  No incoming water. water filter stopping up  Contaminated water supply frequently scrubber water will not turn  Faulty solenoid plug connection.

“ON” when scrubber motor is running  Faulty solenoid.

© BUCYRUS AMERICA, INC.

 No hydraulic pilot pressure to water valve.

Test, check and/or remedy  Replace or clean.  Close valve.  Fix water supply issue.  Clean or filter the incoming water supply to the miner.  Check the connection.  Replace.  Check for pinched hose and check the hydraulic pilot valve.

scrubber water will not shut  Hydraulic pilot operated water “OFF” after scrubber motor valve stuck open. stops  Faulty solenoid

 Clean or replaced valve.

jet pump not removing water  Incorrect pressure reducing valve setting. from sump

 Adjust psi.

 Low water volume to scrubber circuit.

 Replace.

 Check water volume gpm.  Remove strainer and clean.

 Pressure reducing valve internal strainer dirty.  Jet pump nozzle plugged with dirt.

 Backflush pump, remove nozzle and clean.  Adjust psi.

 Excessive pressure setting on scrubber screen sprays.  Suction hose from sump to jet pump plugged with sludge or hose has a loose connection.

 Remove restriction or tighten hose connection.  Check for correct hose size.

 Incorrect hose size from jet pump to manifold. 

 Clean.

Manifold plugged.

scrubber screen dirty  Incorrect pressure reducing valve setting.

 Adjust psi.

 Low water volume to scrubber circuit.

 Check water volume gpm.

 Pressure reducing valve internal strainer dirty.

 Remove strainer and clean.

 Spray nozzles clogged or incorrect nozzle size.

 Clean nozzles and check nozzle part size.

______________________________________________________________ A6474X307 VASS/0 5.289

Troubleshooting ______________________________________________ Bearings Table 10: Bearing troubleshooting Probable cause

overheating bearing  Wrong type of grease or oil.  Low oil level; loss of lubricant through seal; excessive grease.

Test, check and/or remedy  Consult the lubrication chart for the proper lubricant.  Oil level should normally be at the center of lowest ball or roller in bearing; check seals for signs of leaking.

 Insufficient clearance in bearing.

 Replacement bearing should be identical to original equipment to ensure proper internal clearance.

 Housing bore out of round; housing warped; excessive distortion of housing; undersized housing bore.

 Check and scrape housing bore to relieve pinching of bearing; be sure pedestal surface is flat and shims cover entire area of pillow block base when applicable.

 Shaft out of line. noisy bearing  Insufficient clearance in bearing.

 Correct alignment and be sure shafts are coupled in a straight line.  Replacement bearing should be identical to original equipment to ensure proper internal clearance.

 Foreign matter acting as abrasive.

 Clean bearing housing and replace worn seals.

 Housing bore out of round; housing warped; excessive distortion of housing; undersized housing bore.

 Check and scrape housing bore to relieve pinching of bearing; be sure pedestal surface is flat and shims cover entire area of pillow block base when applicable.

 Shaft and other parts of bearing assembly distorted.

 Replace bearing, shaft and other parts as needed.

vibrating bearing  Enlarged housing bore causing spinning of outer ring in housing.

 Re-bore housing and press steel bushing in bore, then machine bore to correct size.

 Foreign matter acting as abrasive.

 Clean bearing housing and replace worn seals.

 Unbalanced loading

 Check balance of rotating parts and rebalance as needed.

unsatisfactory  Chip in bearing housing; insufficient performance clearance in bearing; Ball or roller dented from extreme loading.

 Replace with OEM bearing; do not hammer on any part of bearing; clean housing and use fresh lube.

________________________________________________________________ 5.290 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

Trouble, symptom or cause

_____________________________________________ Troubleshooting Electrical System Table 11: Electrical system troubleshooting Trouble, symptom or cause

Probable cause

motor contact chatter  Low voltage

 Poor contact in control circuit.

 Broken shading coil.

© BUCYRUS AMERICA, INC.

welding of motor contactor tips  Abnormal in rush current.

Test, check and/or remedy  Check supply voltage, especially during starting. Check coil voltage rating. Increase voltage or change coil rating as required.  Replace the contact or use holding-circuit interlock.

(3-wire control)  Replace magnet and armature assemblies.  Use the next larger size contactor or check for grounds, shorts or excessive motor current.

 Rapid jogging.

 Install larger device rated for jogging service.

 Insufficient contact pressure.

 Replace contacts and springs, check for contacts for abnormal wear or damage.

 Incorrect vacuum contactor gap.

 Use the over-travel gauge mounted on the front of the unit.

When the gap on the bottle goes below 0.010 inches, the unit should be replaced.

 Low voltage preventing magnet from sealing.  Foreign matter preventing contacts from closing.

 Vibration in starter mounting.  Short circuit.

 Check supply voltage to coil, especially for momentary voltage dip during starting.  Clean contacts with Freon. Contacts used at low current and voltage levels should be cleaned with Freon.  Insulate starter from shock and vibration.  Remove fault and check to be sure fuse or breaker size is correct.  For vacuum contactor: after a short circuit examine vacuum bottles, conductor bars, and cables for physical damage. Check overtravel on vacuum bottle.

______________________________________________________________ A6474X307 VASS/0 5.291

Troubleshooting ______________________________________________ Table 11 (continued): Electrical system troubleshooting Probable cause

chart contact life or  Filing or dressing. overheating of motor contactor

Test, check and/or remedy  Do not file silver contacts.

Rough spots or discoloration will not harm contacts or impair their efficiency.

 Interrupting excessively high currents.

 Install larger unit. Check for grounds, shorts or excessive motor currents.

 Excessive jogging.

 Install larger unit rated for jogging service.

 Short circuit or ground fault.

 Remove fault and check to be sure fuse or breaker size is correct.

 Loose connections in power circuit.

 Clean and tighten.

 Sustained overload.

 Check for excessive motor load current or install larger unit.

failure to pick-up and seal  Low voltage.

 Check system voltage and voltage dips during starting.

 Wrong coil or wrong connection.

 Check coil marking and wiring.

 Mechanical obstruction.

 With power off, check for free movement of armature and contacts.

 Coil open or overheated.

 Replace.

failure to drop out  Voltage not removed.

 Contacts welded.

open circuit  Mechanical damage.

 Check coil circuit or length of leads from supply voltage to coil. May be excessive.  See welding under contacts section.  Handle and store coils carefully.

________________________________________________________________ 5.292 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

Trouble, symptom or cause

_____________________________________________ Troubleshooting Table 11 (continued): Electrical system troubleshooting Trouble, symptom or cause

Probable cause

© BUCYRUS AMERICA, INC.

both cutter head motors do not  Three phase power not present start at contactors.

Test, check and/or remedy  Check three phase input to contactors.

 Pump not running.

 Start pump.

 Failed control relay contacts.

 Check contacts

 Cutter head motor start and stop switches, conveyor start switch, or pump start switch not working properly.

 Check for faulty switches.

 Overload relay.

 Check overload relays.

 Failed left cutter head motor contactor.

 Check contactor coil. Verify that contacts are free to move.

left cutter head motor starts but  Auxillary contacts not closing. right cutter head motor does not

 Check contactor auxillary contacts and wiring.

 Time delay malfunction.

 Check coil and timed closed contacts and wiring.

 Failed vaccuum starter.

 Check contactor coil and contact tips and wiring.

both cutter head motors start but  Problem with auxillary contacts.  Check right cutter head motor stop when pump start and cutter contactor auxillary contacts and head start switches are released associated wiring.  Overcurrent relays.

 Check overcurrent relays.

______________________________________________________________ A6474X307 VASS/0 5.293

Troubleshooting ______________________________________________ Table 11 (continued): Electrical system troubleshooting Trouble, symptom or cause

Probable cause

Test, check and/or remedy

conveyor starts forward operation  Problem in holding circuit. but stops when conveyor start switch is released

 Check normally open conveyor forward auxiliary contact and associated wiring.

conveyor will not start in forward  Pump not running. or reverse. Contactor IS NOT pulling in contacts  Failed control relay contacts.

 Start pump.  Check contacts.

 Conveyor start and stop switches or conveyor forward/ reverse not working properly

 Check for faulty switches.

 Overload relay tripped/faulty/

 Check overload relays.

 Conveyor forward/reverse contactor failure.

 Check contactor coils. Verify that contacts are free to move.

conveyor will not start in forward  Three phase power is not preor reverse. Contactor IS pulling in sent at contactors. contacts  Contactor tips are damaged.

 Check three phase power input to the contactors.

conveyor operates in forward only  Reverse switch.

 Check that the Reverse switch is completing the circuit.

 Conveyor Forward auxiliary contacts.

conveyor operates in reverse only  Forward switch.  Conveyor Reverse auxiliary contacts.

 Check contactor tips.

 Verify that the conveyor forward auxiliary normally closed contacts have not failed to open.  Check that the Forward switch is completing the circuit.  Verify that the conveyor reverse auxiliary normally closed contacts have not failed to open.

________________________________________________________________ 5.294 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

 Over current relay tripped/faulty.  Check over current relay.

_______________________________________________________________

6

Technical data

________________________________________________________________

_______________________________________________________________

________________________________________________________________

_______________________________________________ Technical data

Technical data This chapter contains the most important technical data on the 25M1AC Continuous Miner. Further data can be found in the spare parts lists. At the end of this chapter you will find information on the bolt tightening torques, HFA fluids, greases, etc. Read this chapter through carefully and pay particular attention in particular to the safety instructions.

IMPORTANT! The technical data listed in this chapter is for stock machines only.

Customer specials may not be listed.

Components of the 25M1AC Continuous Miner Technical data sheet

© BUCYRUS AMERICA, INC.

Note: All dimensions and rates are for a Miner with a 32” to 36” diameter cutter drum and 9” to 12” ground clearance. operating dimensions

Recommended mining range ...............................approx. 42 - 76 in (1,067 - 1,930 mm) Minimum height over cutter head assembly ........approx. 32.5 in (826 mm) Maximum reach (w/ 12” ground clearance)..........approx. 94 in (2,388 mm) Ground clearance.................................................approx. 9 in (229 mm) with 3” lift kit installation .........................approx. 12 in (305 mm) Length (rear bumper to bit tip) .........................approx. 26 ft 2 in (7.98 m)

transport dimensions

Frame width (including rub rails) .........................approx. 10ft 2 in (3.10 m) Overall length .......................................................approx. 35 ft 8 in (10.87 m) Weight (total) ........................................................approx. 115,000 lbs (52.2 metric tons)

cutter unit

dust suppression (optional)

Cutter drum diameter ...........................................approx. 32 - 36 in (813 - 914 mm) Cutter drum bit speed...........................................approx. 66 rpm/532 fpm (162 m/min) Cutter drum width .................................................approx. 11 ft 6 in (3.51 m) Cutter drum (continuous rating) ...........................2X175 HP/130kW

Scrubber type .......................................................Wet bed Scrubber capacity.................................................8,000 cfm @30HP (3.8 cms @22 kW)

______________________________________________________________ A6474X307 VASS/0 6.3

loading unit

Loading method.......................................................... 3 - 6 finger CLA Conveyor width........................................................... approx. 36 in (914 mm) Conveyor speed approx. 475 fpm (145 m/min) Conveyor depth .......................................................... 6 - 12 in (152 - 305 mm) Loading capacity ........................................................ 15 - 20 tpm (14 - 18 tones/min) Horse power On conveyor (continuous rating).......................... 2X40 HP (30kW) Through CLAs (one hour rating) .......................... 2X50 HP (37kW)

traction unit

Crawler chain width .................................................... 20 in (508 mm) Crawler assembly length ............................................ 9 ft 6 in (2.90 m) Ground pressure ........................................................ 25.2 psi (174kPa) Crawler speed ............................................................ 0 - 65 fpm (0 - 20 m/min)

electrical system

Machine voltage ......................................................... 950 VAC Control system ........................................................... Processor based/ radio remote control

hydraulic system

Hydraulic pump unit Tandem gear pump ............................................. 3,200 psi (220 bar) Horse power Continuous rating .......................................... 1X40 HP (30 kW) One hour rating ............................................. 1X50 HP (37 kW)

total installed horse power

Continuous rating (without scrubber) ......................... 570 HP (425 kW) One hour rating (without scrubber) ............................ 670 HP (500 kW)

________________________________________________________________ 6.4 Bucyrus – Model 25M1AC Continuous Miner

© Bucyrus America, Inc.

Technical data________________________________________________

___________________________________________ Tightening torques Tightening torques IMPORTANT! Due to the application of fasteners being subject to great stresses and heavy or extreme vibration, it is imperative that all bolts be applied with an adequate amount of torque. For this reason this list of recommended torque settings for different types and sizes of fasteners used has been compiled. The tightening torques stated in the spare parts lists have to be observed, as well, for installation and maintenance.

IMPORTANT! Use a calibrated torque wrench for accuracy!

© BUCYRUS AMERICA, INC.

Table 17: Hex head bolts, Grade 8 (calculated at 75% proof load) Bolt size

Recommended torque setting (ft-lbs) (dry)

Recommended torque setting (ft-lbs) (wet)

1/4 5/16

12 25

6 12

3/8

44

22

7/16

70

35

1/2

107

53

9/16

154

77

5/8

212

106

3/4

376

188

7/8

606

303

1

909

454

1-1/8

1287

644

1-1/4

1875

938

1-3/8

2382

1191

1-1/2

3161

1581

1-3/4

4988

2494

2

7500

3750

2-1/4

10969

5484

2-1/2

15000

7500

2-3/4

17794

8897

3

23507

11753

3-1/4

30286

15143

3-1/2

38266

19133

3-3/4

47545

23773

4

58100

29085

______________________________________________________________ A6474X307 VASS/0 6.5

Tightening torques ____________________________________________

Bolt size

#10

Recommended torque setting (ft-lbs) (dry) 72 in-lb

Recommended torque setting (ft-lbs) (wet) 48 in-lb

1/4

180 in-lb

120 in-lb

5/16

31

240 in-lb

3/8

54

35

7/16

87

56

1/2

132

86

9/16

184

120

5/8

254

165

3/4

452

293

7/8

727

473

1

1090

709

1-1/8

1546

1005

1-1/4

2181

1417

1-3/8

2858

1858

1-1/2

3794

2466

1-3/4

5983

3889

2

8994

5846

________________________________________________________________ 6.6 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

Table 18: Socket head bolts, Grade 8 (calculated at 75% proof load)

___________________________________________ Permissible media Permissible media Lubrication fluids and greases

© BUCYRUS AMERICA, INC.

NOTICE! Use only lubrication fluids and greases approved by Bucyrus America, Inc. ! These fluids and greases have been tested at Bucyrus America, Inc. and guarantee reliable operation of the mechanical and hydraulic functions of the machine.

IMPORTANT! The lubrication fluids and greases listed in the same table can be mixed. Other products may only be used if the supplier can guarantee that they are equivalent.

Differently composed fluids and greases must not be mixed as this may change the consistency, i.e. the mixture can become thinner so that the lubrication effect is not sufficient. It may also be dangerous to use lubricating greases and fluids having the same specification base but different origins.

In case of doubt, the manufacturer of the lubrication to be used should be contacted as to the compatibility of the lubrication in question.

IMPORTANT! Bucyrus America, Inc. expressly points out that the approval of the listed products relates only to the pure technical use in our mechanical and hydraulic systems. The responsibility for the constituents used in the hydraulic concentrates lies solely with the respective manufacturer.

IMPORTANT! Be sure to use the manufacturer’s instructions for use.

NOTICE! When performing maintenance on the machine, all used oil and lubricants should be stored and disposed of per your local EPA standards.

IMPORTANT! As lubrication technology evolves, manufacturers continue to reformulate their products to obtain improved characteristics regarding wear, water dispersion, water absorption, environmental impact and a variety of other performance criteria. When an approved lubricant on this list has been superseded by a new formulation, it is recommended that the new formulation be tested to ensure compliance with the appropriate Bucyrus specification. At a minimum, a statement of conformance from the lubricant supplier should be obtained.

______________________________________________________________ A6474X307 VASS/0 6.7

Permissible media ____________________________________________ Approved lubricants

Supplier

Brand name

1

Amoco Oil Company

Amoco AW Oil No.68

2

Gulf Oil

Harmony 68 AW

3

Mobil Oil Corporation

Mobil DTE-16

4

Chevron U.S.A.

5

Sun Oil Company

Chevron Hydraulic Oil Aw ISO 68 Sunvis 868

6

Unocal 76

Unax AW 68

7

Shell Oil Company

Shell Hydraulic Oil #33

8

Century (Fuchs)

Hydraulic AW 68

9

Atlantic Richfield Company

Duro AW S-315 Oil

10

Texaco Lubricants Company

Texaco Rando Oil HD 68

11

Exxon

Nuto 68

12

Pennzoil

Pennzbell AW 68 Hydraulic Oil

13

14

Standard Oil Company Standard Oil Co. of Ohio Boron Oil Company BP Oil Inc. Lubricating Engineers

Industron 54 Industron 53 Energol HLP-C68 6120 Monolec Hydraulic Oil

15

Conoco Inc.

Super Hydraulic oil 68

16

Hydrotex

Systems 5K 68

17

Phillips

Maginus A Oils 81350

18

Miners Oil

Hydraulic Oil 68AW

________________________________________________________________ 6.8 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

Table 19: Anti-wear hydraulic oil (Spec 100-1)

___________________________________________ Permissible media Approved lubricants

© BUCYRUS AMERICA, INC.

Table 20: Extreme pressure gear oils (Spec. 100-2) Supplier

Brand name

1

Amoco Oil Company

Amoco Permagear EP 460

2

Gulf Oil

EP Lubricant HD 460

3

Mobil Oil Corporation

4

Chevron U.S.A.

5

Sun Oil Company

Mobil Gear 634 Mobil Gear 636 Chevron Gear Compound EP ISO 460 Sunep 460

6

Unocal 76

7

Shell Oil Company

8

Century (Fuchs)

9 10

Texaco Lubricants Company Exxon

11

Pennzoil

12

Lubricating Engineers

13

Conoco Inc.

14

Hydrotex

15

Phillips

16

Miners Oil

Extra Duty NL Gear Lube 7 EP Extra Duty NL Gear Lube 8 EP Shell Omala 680 Hulbest EP-7 Powergear 460 Meropa 680 Spartan EP 460 Super Maxol EP 460 Gear Lube Super Maxol EP 460 Gear Lube 608 Almosal Vari-Purpose Gear Lubricant Gear Oil 460 933 Industrial Gear Lubricant All Purpose Gear Oil 85W-90 5EP Gear Oil EP460

______________________________________________________________ A6474X307 VASS/0 6.9

Permissible media ____________________________________________ Approved lubricants

1

Supplier Amoco Oil Company

2 3 4

Gulf Oil Mobil Oil Corporation Chevron U.S.A.

5 6 7 8

Sun Oil Company Unocal 76 Shell Oil Company Century (Fuchs)

9 10 11 12

Texaco Lubricants Company Exxon Pennzoil Lubricating Engineers

13

Conoco Inc.

14 15 16

Hydrotex Phillips Atlantic Richfield

Brand name Amolith Grease 2 EP Rykon Premium Grease 2 EP Gulfcrown Grease EP#2 Mobilux EP-2 Chevron Dura-Lith Grease EP-2 NLGI 2 Sun Prestige 742EP Multiplex EP2 Alvania EP-2 Hullith EP2 Multipurpose Grease or Replex2 or Uniwrl 2 or Uniwrl EMB or Hullith GP 2 or Hullith EP 2 Texaco Multifak EP 2 Lidok EP 2 Pennlith EP 712 Grease 3752 Almagard Vari-Purpose Lubricant EP Conolith grease No. 2 or Super Sta Grease No. 2 LC-65 Hyplex Philube EP Grease Litholine H EP-2 Grease

Approved lubricants Table 22: Semi-fluid grease (Spec. 100-4) 1 2 3 4 5 6

Supplier Texaco Lubricants Company Century (Fuchs) Hydrotex Pennzoil Unocal Exxon

Brand name Novatex EP 000 Joy Loader Semi-Fluid grease MPD-60 Ultra E.P. 000 Semi-Fluid 760 Grease MM Grease Lidok E.P. 000

________________________________________________________________ 6.10 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

Table 21: Lithium based general lubrication grease (Spec. 100-3)

___________________________________________ Permissible media Approved lubricants Table 23: Invert emulsion hydraulic fluid (Spec. 100-5) 1 2 3 4

Supplier Unocal 76 Conoco Inc. Atlantic Richfield Company Brooks Oil Company

5 6

Cincinnati – Vulcon Company Cities Service Oil Company

7 8

Century (Fuchs) Fiske Bros. Refining Company Getty Oil company (Veedol, Tidewater) Gulf Oil Company E.F. Houghton

9

© BUCYRUS AMERICA, INC.

10 11 12 13 14 15 16 17 18 19 20 21

Century (Fuchs) Imperial Oil and Grease Mobil Oil Corporation National Oil and Chemical Co. Pennzoil Quaker Chemical Company Henery E. Sanson and Sons MFGE Company Southwest Grease and Oil Company, Inc. Southwest Petroleum Corp.

22 23

Standard Oil Company of Ohio (Boron Sohio) Sun Oil Company Tower Oil Company

24 25

Wynn Oil Company Lubrication Engineers

26

Hydrotex

Brand name FR Fluid FR Hydraulic Fluid Duro FR-HD Brooks Fire Resistant Hydraulic Fluid B Vulcon FR Fluid #1 Citgo Pacemaker Invert FR Fluid Aquacent Light Lubriplate HO-Retard Veedol Auburn FRH FR Fluid Houghto-Safe 5046 Houghto-Safe 5046W Hulsafe 600 Astrol 587 Pyrogard D Erifon 1, 2, and 3 Maxmul FRP/G Quintolubric 958 Series Quintolubric 958 Series Hydra-Mul Premium Emulsion Fluid Invert Emulsion Fire Resistant Hydraulic Fluid Swepco Fire Resistant Hydraulic Oil #718 Staysol FR

Sunsafe F Safoil Anti-Wear Hydraulic Fluid Hydra-Safe Heavy Medium 6455 Monolec Fire Resistant Hydraulic Fluid HY-Guard

______________________________________________________________ A6474X307 VASS/0 6.11

Permissible media ____________________________________________ Approved lubricants

1

Supplier Amoco Oil Company

Brand name Amoco Premagear EP 320

2

Gulf Oil

EP Lubricant HD 320

3

Mobil Oil Corporation

Mobil Gear 632

4

Chevron U.S.A.

5

Sun Oil Company

Chevron Gear Compound EP ISO 320 Sunep 320

6

Unocal 76

Extra Duty NL Gear Lube 6EP

7

Shell Oil Company

Omala 75

8

Century (Fuchs)

Hulbest EP-6

9

Texaco Lubricants Company

Meropa 320

10

Exxon

Spartan EP 320

11

Pennzoil

Super Maxol EP 220 Gear Lube

12

Lubricating Engineers

13

Conoco Inc.

605 Almasol Vari-Purpose Gear Lubricant Gear Oil 320

14

Hydrotex

932 Industrial Gear Lube

15

Phillips

16

Atlantic Richfield

Philube All Purpose Gear Oil 85W-90 Pennant NL S-1000

17

Cities Service

Citgo EP Compound 110

18

Pennzoil

Pen Gear #320

19

Miner Oil

Gear Oil EP220

20

Texaco, Lubricants Company

Texaco Multigear EP 80W-90

________________________________________________________________ 6.12 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

Table 24: Extreme pressure gear oil, SAE 90 (Spec. 100-6)

___________________________________________ Permissible media Approved lubricants

© BUCYRUS AMERICA, INC.

Table 25: Medium-Heavy hydraulic and general purpose oil R&O inhibited (Spec. 100-7) 1

Supplier Amoco Oil Company

Brand name American Industrial Oil No. 68

2

Gulf Oil

Harmony 68

3

Mobil Oil Corporation

DTE Heavy – Medium

4

Chevron U.S.A.

5 6

Sun Oil Company Unocal 76

7

Shell Oil Company

Chevron Turbine Oil ISO 68 or Chevron Machine Oil R&O ISO 68 Sunvis 754 Unax RX68 or Turbine Oil 68 Turbo 68

8

Century (Fuchs)

Centraulic R&O 68

9

Texaco Lubricants Company

Regal Oil R&O N-68

10

Exxon

Tresstic 68

11

Pennzoil

Pennzbell RO 68

12

Lubricating Engineers

6120 Monolec Turbine Oil

13

Conoco Inc.

14

Hydrotex

Detol R&O 68 or Turbine Oil 68 Systems 1, System 5K 68

15

Atlantic Richfield

Duro 5.315

16

Cities Service

Citgo Pacemaker A/W68

17

Miner Oil

Hydraulic Oil AW68

18

Texaco, Lubricants Company

TDH 1893

______________________________________________________________ A6474X307 VASS/0 6.13

Permissible media ____________________________________________ Approved lubricants Table 26: Heavy hydraulic and general purpose oil/R&O inhibited (Spec. 100-8) Supplier

Brand name

1

Amoco Oil Company

American Industrial Oil No. 150

2

Gulf Oil

Harmony 150

3

Mobil Oil Corporation

DTE Oil EX. Heavy

4

Chevron U.S.A.

5

Sun Oil Company

Chevron Machine Oil AW ISO 150M or Chevron Machine Oil R&O ISO 150 Sunvis 961

6

Unocal 76

7 8

Shell Oil Company Century (Fuchs)

9

Atlantic Richfield Company

10

Texaco Lubricants Company

Duro 600 or S-700 Regal Oil R&O 150

11 12

Exxon Pennzoil

Teresstic 150 Pennzbell RO 150

13

Cities Service

Citgo Pacemaker 150

14

Lubrication Engineers

6405 Monolec Turbine Oil

15 16

Conoco Inc. Hydrotex

Dectol R&O 76 System 1 150, System 5k 150

17

Phillips

Magnus Oils 700

18

Miner Oil

ISO 150

Approved lubricants Table 27: Worm gear lubricant, compounded cylinder oil (Spec. 100-9) Supplier

Brand name

1 2 3

Amoco Oil Company Mobil Oil Corporation Chevron U.S.A.

4 5

Sun Oil Company Unocal 76

6 7 8 9 10 11

Century (Fuchs) Atlantic Richfield Company Texaco Lubricants Company Exxon Pennzoil Conoco Inc.

Cylinder Oil No. 1000 Extra Hecla Super Cylinder Oil Chevron Cylinder Oil W ISO 1000 Sun Steam Cylinder Oil Worm gear Lube 250 or Stevalc Garwal 680 Modoc 195 650 T Cylinder Oil 1000 Cylesstic TK-1000 Cylinder Oil #1000 Inca Oil 1000

________________________________________________________________ 6.14 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

Unax RX 700 or Turbine Oil 700 Turbo 150 Centraulic R&O 150

___________________________________________ Permissible media Approved lubricants

© BUCYRUS AMERICA, INC.

Table 28: Light gear oil, SAE 40 motor oil (Spec. 100-10) 1 2 3 4

Supplier Amoco Oil Company Gulf Oil Mobil Oil Corporation Chevron U.S.A.

5 6 7

Sun Oil Company Unocal 76 Shell Oil Company

8 9 10

Century (Fuchs) Texaco Lubricants Company Exxon

11 12 13

Pennzoil Lubricating Engineers Conoco Inc.

14 15

Hydrotex Phillips

Brand name Amoco 300 SAE 40 Super Duty 40 Delvac 1340 Chevron RPM Heavy Duty Motor Oil 15W-40 Sunoco Super C 40 Guardol Motor Oil SAE 40 Rotella Oil 40 (Automotive) Turbo Oil 150 (Industrial) Rimula CT40 (Foreign) Rotela SX40 (Foreign) Flexe SAE 40 Ursa Super Plus SAE 40 XD-3 Extra SAE 40 or XD-3 SAE 40 Long Life SAE 40 Motor Oil 8440 Monolex GFS Engine Oil Fleet Heavy Duty Motor Oil SAE 40 Hyfilm SAE 40 Super HD II Motor Oil SAE 15W-40

Approved lubricants Table 29: Synthetic EP gear lubricants (Spec. 100-11) 1

Supplier Century Lubricants Company

Brand name Synthetic EP Gear Lubricants

Approved lubricants Table 30: Multi-purpose tractor hydraulic fluid (Spec. 100-12) 1 2 3 4

Supplier Exxon / Mobil Century (Fuchs) Shell Chevron

Brand name Mobilfluid 424 Multitran Donax TD Tractor Hydraulic Fluid

5 6 7

BP Lubricants Quaker State Conoco

Tractran UTH Quaker State FCI HD Powertran Fluid

______________________________________________________________ A6474X307 VASS/0 6.15

Permissible media ____________________________________________ Approved lubricants Table 31: High emulsibility extreme pressure gear oil (Spec. 100-13) 1

Supplier Century (Fuchs)

Brand name Powergear H680

Approved lubricants Table 32: High temperature synthetic lithium complex grease (Spec. 100-14)

1

Supplier Mobil

Brand name Mobilith SHC 100

Approved lubricants

1

Supplier Conoco

Brand name GLW Gear Oil 220

________________________________________________________________ 6.16 Bucyrus – Model 25M1AC Continuous Miner

© BUCYRUS AMERICA, INC.

Table 33: High demulsibility extreme pressure gear oil (Spec. 100-15)

_______________________________________________________________

7

For your information

________________________________________________________________

_______________________________________________________________

________________________________________________________________

_________________________________________________ Our service

For your information Our service If you need to order spare parts or if technical problems occur, please contact our after-sales service personnel or contact us direct.

© BUCYRUS AMERICA, INC.

Service address Beckley, WV 351 Ragland Road Beckley, WV 25801 Phone: (304) 256-5927 Fax: (304) 256-5928

Craig, CO 400 Mack Lane Craig, CO 81625 Phone: (970) 824-3249 Fax: (970) 824-8851

Pulaski, VA 4041 Wurno Road Pulaski, VA 24301 Phone: 540-980-4530 Fax: 540-980-6211

Washington, PA 255 Berry Road Washington, PA 15301 Phone: (724) 743-1200 Fax: (724) 228-2177

Duffield, VA P.O. Box 847 6808 Fraley Avenue Duffield, VA 24244 Phone: (276) 431-7000 Fax: (276) 431-2464

Houston, PA 2045 West Pike Street Houston, PA 15342 Phone: (724) 743-1200 Fax: (724) 743-1201

Carrier Mills, IL 9580 State Route 13 West Carrier Mills, IL 62917 Phone: (618) 982-9000 Fax: (618) 982-9912

Oak Hill, WV P.O. Box 60 843 Lochgelly Road Oak Hill, WV 25901 Phone: (304) 469-3302 Fax: (304) 465-0450

Paonia, CO P.O. Box 566 719 Second Street Paonia, CO 81428 Phone: (970) 527-3151 Fax: (970) 527-6846

______________________________________________________________ A6474X307 VASS/0 7.3

Our service __________________________________________________ Rebuild facility address Huntington, UT P.O. Box 1190 Route 10, 1Mile North Huntington, UT 84528 Phone: (435) 687-9831 Fax: (435) 687-2522

Norris City, IL 635 Illinois Highway 1 Norris City, IL 62869 Phone: (618) 378-3441 Fax: (618) 378-3106

© Bucyrus America Inc.

Pearisburg, VA P.O. Box 463 222 Industrial Park Drive Pearisburg, VA 24134 Phone: (540) 921-2111 Fax: (540) 921-2711

________________________________________________________________ 7.4 Bucyrus – Model 25M1AC Continuous Miner

Forced Potato TITO Remote Console (Bucyrus 25M Miner Version)

Operator’s Manual Issue: KN5602.C

Forced Potato Mining Electronics

Contents Contents ............................................................................................... 2 Preface ................................................................................................. 3 Introduction ........................................................................................... 4 Notice ............................................................................................ 4 Safety Notice ........................................................................................ 5 What’s New........................................................................................... 6 Remote Control Battery Charger .......................................................... 8 Remote Control Diagnostics ............................................................... 11 Notice .......................................................................................... 12 User Setup .......................................................................................... 13 Password Entry ........................................................................... 13 Options ........................................................................................ 14 1. Radio Channel ....................................................................... 15 2. Radio Timeout ....................................................................... 15 3. Tilt Switch .............................................................................. 16 4. ID Number ............................................................................. 16 5. Saving Changes .................................................................... 17 Maintenance ....................................................................................... 18 Inspection Frequency .................................................................. 18 Factory Service Frequency ......................................................... 18 Tools ............................................................................................ 19 Disassembly ................................................................................ 20 Cleaning ...................................................................................... 21 Reassembly ................................................................................. 22

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Forced Potato Mining Electronics

Preface This document is intended to provide reference to the Type KN Remote Console. This version of the TITO remote console has been developed for operation of Bucyrus continuous miners.

Forced Potato Inc. 640 Bizzell Drive Lexington, KY 40510 Telephone: +859 252 4439 Fax: +859 252 4641 Web: www.forcedpotato.com © Forced Potato Inc. Other than is permitted by law, no part of this document may be reproduced, stored in a retrieval system or transmitted in any form or process without prior written consent of Forced Potato Inc. Every effort has been made to ensure the accuracy and correctness of the information presented within this document. However, Forced Potato does not provide guarantee of its correctness or accuracy.

Other than is required by law, no warranty of any kind is expressed or implied.

Copies of this manual, and other documentation pertaining to Forced Potato control system products, may be obtained by contacting Forced Potato directly.

For all matters involving servicing or purchase of Forced Potato control system components used with machinery manufactured by Bucyrus, please contact your Bucyrus representative or local Bucyrus service center.

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Forced Potato Mining Electronics

Introduction The Type L0KN Remote Console (RC) is a self-contained battery powered remote control that has been specifically designed to provide a safer, more efficient means of operating mining machinery.

Notice This manual includes information specific to the following part: Part# L0KN5602

Description Bucyrus UHF

If this manual does not correspond to your equipment’s part number, please contact Forced Potato Inc. immediately to obtain a copy of the correct publication.

To obtain service of your TITO L0KN56 model remote control handset please contact your local Bucyrus representative or service center.

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Forced Potato Mining Electronics

Safety Notice The advent of remote control has afforded the operator a notable improvement in personal safety. However, the potential for injury or fatality still exists when operating heavy machinery remotely.

Thus, it is expressly important that the operator observe safe work practice when operating a remote control mining machine. This will be defined by mine management and should encompass MSHA recommendations where applicable.

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Forced Potato Mining Electronics

What’s New The Type KN Remote Console has been designed to meet the requirements of AS4240 / MDG5001. These requirements compel a number of design variations over existing equipment manufactured by Forced Potato Inc.

•

Size Whilst a similar physical layout has been retained to support transparent integration, the overall size has grown to support control spacing standards as specified by AS4240.

•

Visual Diagnostics A highly efficient LED display has been integrated to facilitate operating diagnostics. Information such as operating frequency, power and general operating status is available at all times.

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Forced Potato Mining Electronics •

Battery To improve operational readiness, a larger battery pack has been incorporated which affords a minimum 20 hours of continuous remote control operation.

•

Tilt Monitoring Dual tilt switches have been installed to allow detection of the angle of inclination relative to the horizontal plane. This feature can be enabled or disabled via the User Setup Options on the Remote Control Battery Charger. By default, this option is disabled.

•

Safety The most important design addition is single electrical fault tolerance. By incorporating dual-pole switch architecture and a new approach to switch sampling, a high level of fault tolerance has been achieved.

The KN56 TITO remote console also features a push-button stop button. This push-button makes the device compliant with MSHA P03-3 recommendations.

•

Ergonomics In an effort to improve operator comfort, stylish comfort knobs have been added to the most commonly used functions – traction and shear. These are entirely optional and can be removed if required.

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Forced Potato Mining Electronics

Remote Control Battery Charger Connect the Remote Control Battery Charger to your mains power outlet. During initial power-up, the firmware release information is displayed for 10 seconds.

After this period, the charger will then display the main screen which details the charge status.

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Forced Potato Mining Electronics Diagnostics The Remote Control Battery Charger permits the operator to verify that all switches are operating as expected. Similarly, it provides a secondary means of determining the operating frequency.

Power Up Turn the RC on by asserting and holding the ON [SHIFT] key for twoseconds. This startup requirement has been introduced to reduce the likelihood of incidental activation.

After the two-second period has expired, the RC will show the operating frequency via the LED display. The available operating frequencies for the L0KN5602 (Bucyrus UHF) are as follows: Indicated Frequency UHF1 UHF2 UHF3 UHF4 UHF5 UHF6 UHF7 UHF8

Actual Frequency 458.500MHz 458.525MHz 458.550MHz 458.575MHz 458.600MHz 458.625MHz 458.650MHz 458.675MHz

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Forced Potato Mining Electronics The Remote Control Battery Charger continually scans all 8 channels in an attempt to recognize a supported RC. On average, the Remote Control Battery Charger requires approximately 4 seconds to acquire a signal.

Upon detecting a valid signal, an identification screen is displayed for three seconds to allow classification of the type and frequency of the operating RC.

After this period has expired, the diagnostic screen is displayed.

Operators should be satisfied that all key functions operate as expected prior to taking the equipment underground. Similarly, operators should verify that the operating frequency corresponds to that displayed on the RC – See the Frequency Table on the previous page.

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Forced Potato Mining Electronics

Remote Control Diagnostics The RC supports a number of inbuilt diagnostics to aid operation. The following table details each of these messages and their implication.

Message UHF1, UHF2, UHF3, UHF4, UHF5, UHF6, UHF7, UHF8 ON

Meaning Operating on Frequency 1, 2, 3, 4, 5, 6, 7 or 8

ON

Power is ON and a command is being sent to the machine.

(Flashing)

Power is ON

OFF

Powering down whilst issuing PUMP OFF command.

STOP

Radio Stop Activated

TILT

The RC’s angle of inclination is beyond 45° relative to horizontal. The STOP command is issued continuously until the unit is righted.

The internal battery is low with and expected remaining operating time of approximately 30 minutes.

Indicating possible service requirements, a fault condition has been detected.

LOW (Flashing) SERV

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Forced Potato Mining Electronics

Notice The SERV message is displayed when a fault condition has been detected. There are a number of problems that can generate this fault and most of these would typically require the unit to be submitted for factory service.

However, this condition can be triggered if the operator asserts switches prior to turning the unit ON. If switches other than those allocated to User Setup are asserted prior to power up, it is assumed that these switches are faulty, consequently resulting in automatic power down.

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Forced Potato Mining Electronics

User Setup The RC supports a number of user programmable options that can be adjusted via the Remote Control Battery Charger. To engage User Setup and with the RC turned off, assert the following keys, in sequence, for two seconds: Assert Assert Assert

CONVEYOR ► SHEAR UP ON [SHIFT]

The RC will display SET on its LED display to indicate that User Setup has been selected.

Password Entry When the Remote Control Battery Charger has acquired the signal, the following password entry screen is displayed:

The password FORCED must be entered before access to User Setup is granted.

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Forced Potato Mining Electronics To enter characters, use the following keys: To change a character: Assert CONVEYOR UP or CONVEYOR DOWN To change cursor position: Assert CONVEYOR ► or CONVEYOR ◄ To check the password: Assert ON [SHIFT] After entering the password, assert ON [SHIFT] to gain access to the System Menu.

Options There are five menu options available to the end user. To navigate the system menu, see the following:

To change the menu option: Assert CONVEYOR ► or CONVEYOR◄ To engage or leave the menu option: Assert ON [SHIFT] To change the option value: Assert CONVEYOR UP or CONVEYOR DOWN

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Forced Potato Mining Electronics

1. Radio Channel

There are 8 selectable channels available to the end-user. This allows the mine to support multiple machines.

2. Radio Timeout

The RC supports a timeout that automatically powers the unit down if there is no switch activity after a defined period of time. A selectable range of between 2 and 60 minutes can be chosen.

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Forced Potato Mining Electronics

3. Tilt Switch

To support AS4240 requirements, dual tilt switches which detect the angle of inclination have been installed. If this option is enabled, the RC will automatically issue the Radio Stop command until the unit is righted upon detecting tilt motion beyond 45° relative to horizontal. (The LED display will show TILT as a diagnostic response.) After being righted, power is automatically removed.

Importantly, a 250ms timer acts to filter our mild impacts to compensate for the effects of inertia. This is an essential requirement when Tilt Monitoring is enabled.

4. ID Number

Each Remote Console is programmed with its respective serial number upon leaving the factory. This feature is not accessible to the end user and is password protected.

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Forced Potato Mining Electronics

5. Saving Changes

To save changes to the setup, you must select the EXIT & SAVE option and assert ON [SHIFT]. To abort changes to the setup, you can simply turn the RC OFF.

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Forced Potato Mining Electronics

Maintenance The maintenance required for Remote Consoles is basically limited to assembly, cleaning & inspection. Coal dust and other particulate deposits foul switch operation and can eventually lead to premature seal failure if not regularly expunged.

Inspection Frequency The following routines should be undertaken daily.

•

Determine if cleaning and disassembly is necessary. Onsite conditions should be used to determine the regularity of this procedure. If cleaning is required, see the following pages.

Typically, cleaning on a weekly basis is sufficient.

•

Perform a functional test on the Remote Control Battery Charger.

Factory Service Frequency Factory Service of this equipment is required 12-months from the date of dispatch with an allowance of 1-month for logistics.

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Forced Potato Mining Electronics

Tools Forced Potato Inc. recommends that the Maintenance Accessory Kit be acquired (or similar) to aid systematic maintenance. A maintenance kit is available which includes the following parts: Allen Hex Set

Allen ⅝″ Socket

Multi-Bit Precision Torque Driver

Field Part Replacements

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Forced Potato Mining Electronics

Disassembly • • • • •

Remove the M3 bolts.

Remove the switch guard.

Remove the switch caps.

Remove the comfort knobs by loosening the grub screw.

Remove the engraved plate.

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Forced Potato Mining Electronics

Cleaning • • •

•

Expunge heavy debris from the switch assembly with a Soft Bristle Cleaning Brush.

Wash the transmitter with warm soapy water.

Inspect the switch seals for signs of deterioration. Seals exhibiting wear require the equipment to be scheduled for factory service.

Note: these seals are the primary seal, a secondary seal within the switch itself and an internal neoprene seal operate as a barrier to moisture ingress.

Dry the transmitter with light compressed air or cloth.

Important Do not use caustic solvents or displacement solutions as this may cause premature seal failure.

Do not use metal implements to dig out coal, mud or soapstone that may be found in the charge receptacle.

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Forced Potato Mining Electronics

Reassembly • •

• • • •

Ensure all switch seals are tight. If a seal appears loose, tighten the seal to the recommended torque of 2.5Nm. Ensure all switch plate M2 bolts are tight. If an M2 bolt appears loose, tighten the bolt to the recommended torque of 1.5Nm. Do NOT over tighten these bolts as this may break the enclosure seal.

Install the engraved plate.

Install the comfort knobs as depicted. Tighten the grub screw to the recommended torque of 2.5Nm. Install the switch caps Install the switch guard. Tighten the switch guard M3 bolts to the recommended torque of 2.5Nm.

After reassembly, test the unit on the Remote Control Battery Charger to verify operation.

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Forced Potato Mining Electronics

B

O

Battery · 7

Options · 14

C

P

Cleaning · 21

Password Entry · 13 Power Up · 9 Preface · 3

D Diagnostics · 9 Disassembly · 20

E Ergonomics · 7

I Introduction · 4

R Radio Channel · 15 Radio Timeout · 15 Reassembly · 22 Remote Control Battery Charger · 8 Remote Control Diagnostics · 11

S Safety · 7 Safety Notice · 5 Size · 6

M Maintenance · 18

N

T Tilt Monitoring · 7 Tilt Switch · 16, 17 Tools · 19

Notes on “SERV” · 12 Notice · 4

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Forced Potato Mining Electronics

U

W

User Setup · 13

What’s New · 6

V Visual Diagnostics · 6

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