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ThismanualisintendedtoprovideGENERALproductinformationfor theModel25M3ContinuousMiner.Theillustrations,descriptionsand procedurescontainedinthispublicationapplyonlytoTHISmachine. BucyrusAmerica,Inc.reservestherighttorevisemodelsanddesigns withoutpriornotice.
ThisContinuousMinerwasmanufacturedundertheguidelines,proceduresandrequirementsoftheU.S.FederalCoalMineHealthand SafetyAct,CodeofFederalRegulations,Title30,Chapter1,Subpart0, Part75forundergroundcoalmines,andotherapplicablenon-U.S. regulatoryagencystandards.
Atthecompletionofthemanufacturingprocess,thisunitwasissuedthe appropriateapprovalnumbersandnameplatesindicatingitmetthe technicalrequirementsoftheseregulatoryagencies.Anychangetothe designorstructureofthisunit,withouttheconsentofBucyrusAmerica, Inc.andtheseregulatoryagencies,oranyrepairorreplacementof partscontrarytoBucyrusAmerica,Inc.’sinstructions,mayinvalidate theseapprovalsandrenderthisunitunsafetooperate.
StrictcompliancewithallFederalandStateMininglaws,regulations andpracticesregardingthesafeoperationandmaintenanceofundergroundminingequipmentandstrictadherencetotheinstructionsinthis manualisnecessaryforthepersonalsafetyofthoseworkingonor aroundthisunit.
Whilethismanualattemptstoanticipatethemostimportantoperations andmaintenanceneedsforthisunit,unforeseencircumstancesmay arisethathavenotbeenaddressedinthismanual.Ifanyconcernsor questionsarise,pleasecontactyourBucyrusAmerica.Inc.Service Representative immediately
Thisworkcontainsinformationprotectedundertradesecretandother intellectualpropertylaws,andisprotectedundertheU.S.Copyright Actof1976,asamended.Thisworkisprovidedunderlicenseandthe licenseisnon-transferable.Distributionandaccessislimitedonlyto authorizedpersonnel.Disclosure,reproduction,distributionorunauthorizedusemaybeaviolationoffederalandstatelawsandmaysubjecttheunauthorizedusertocriminalliability.
2. Yoursafety 3. 4. Installation 7. Foryourinformation Aboutthismanual Aboutthismanual Thischapterprovidesimportantinformationmakingiteasierforyouto usethismanual.Youwillalsobegiveninformationonthestructureof themanualandthesymbolsandcharactersused.
Beforestartingtowork applicableoperatingmanual
machinetype
newoperationmanual
Takecaretoensurethattheoperatingmanualavailabletoyouisapplicableforthetypeofequipmentormachineused.
Thisoperatingmanualisintendedfor:
BucyrusModel25M3ContinuousMiner
SerialNo.:N/A
andisonlypermittedtobeusedforequipmentofthistype.
Theoperatingmanualmustbeaccessibleatalltimestoallpersons workingonorwiththemachine.Itshould,ifpossible,alwaysbeavailableattheplaceofoperation.
Sendforanewoperationmanualimmediatelyifthepresentmanualis nolongercompleteorhasbecomeillegible.
Whoisthisoperatingmanualintendedfor? Thisoperatingmanualisintendedforthosepersonswhoworkwithor onthemachine.Everypersonworkingonthefaceorintheintersectionbetweenfaceandentryorintheentrymustreadthisoperating manual.
Thisincludespersonswho:
■ areinchargeoftransport
■ performassembly/disassemblywork
■ operatethemachine
■ find/fixfaults
■ performdailyroutineworkonthefaceorintheentry
■ performmaintenancework
■ performrepairwork
supervisorypersonnelwho:
■ initiateand/orsupervisetheactivitiesjustindicated.
Beforestartingtowork Whatisthepurposeofthisoperatingmanual? Thisoperatingmanualisintendedtohelpyouworkefficientlyand safelywithourproduct.Itcontainsimportantinformationonalltheactivitiesrelatedtothemachine.
Readthisoperatingmanualcompletelyandatease.Payspecialattentiontothesafetyinstructions.Trytomemorizetheappearanceandthe meaningofthesafetyandinstructionsymbols.
Ifanydetailsarenotclearlyunderstood,pleasecontactourservicedepartment.Ourserviceaddressisgiveninthechaptertitled“Foryour information”.
Readthechapter“Foryoursafety”withspecialattention.Thechapter containsimportantinformationindicatingpossiblehazards.Observe theinformationgivenandfollowtheproceduralinstructions.
Charactersandsymbolsused Thefollowingcharactersandsymbolsareusedforsafetyinstructions andimportantinformationintheoperatingmanual.
Trytomemorizethesymbolsandtheirmeanings.
DANGER! Pointsinthetextmarkedwiththissymboldrawyourattentionto immediatelyimpendingdanger.Possibleconsequencesare: veryseriousinjuryorevendeath.
WARNING! Thesepointscontaininformationondangeroussituations.Possibleconsequencesare:veryseriousinjuryorevendeath.
CAUTION! Thissymboldrawsattentiontodangeroussituations.Possible consequencesare:lighttomoderatelyseriousinjuriesandmachinedamage.
NOTICE! Pointsinthetextmarkedwiththissymboldrawattentiontoharmfulsituations.Possibleconsequencesare:damagetothemachineordamageintheimmediatevicinity.
IMPORTANT! Pointsinthetextmarkedwiththissymbolcontainusefultipsand informationintendedtofacilitateworkforyou.Theydonotwarn aboutharmfulordangeroussituations.
■ Itemsinlistsaremarkedwithbullets.
– Pointsinsub-listsaremarkedwithalongdashatthestartof theline.
Pointsintextmarkedinthiswaydescribeindividualoperations. Followtheseinstructionsstepbystep.Theywillhelpyoucarryout yourworkfasterandmoreimportantly,safer.
Beforestartingtowork Yoursafety Thischapterprovidesvitalinformationforyoursafety.Payspecialattentiontothischapter.Thesafetyinstructionsandrulesofprocedure willhelpyoutoavoidhazardoussituationsandtoperformthenecessaryworkassafelyaspossible.
Themachinehasbeenmanufacturedinaccordancewiththestateof theartandgenerallyrecognizedsafetystandardsandregulations. Youandotherscan,nevertheless,beexposedtodangeroussituations e.g.asaresultofenvironmentalinfluences,machinedamageoroperatorerrors.
Donotmakeanyalterationsormodificationswhichcouldimpairthe safetyofthemachine.AllmodificationsandchangesmustbeapprovedbyBucyrusAmerica,Inc.andanyappropriateregulatory agency.
UseonlyoriginalsparepartsfromBucyrusAmerica,Inc.Notethatthe useofpartsfromothermanufacturerswillvoidthewarranty.
Inadditiontothisoperatingmanualbesuretoalsoobservetherespectivelegalprovisionsandregulationsinyourcountry.
Observethesafetyandaccidentpreventionregulations
■ ofthemine,
■ ofthemineinspector,and
■ oftheminingsupervisoryauthorities.
Readtheoperatingmanualsofthecomponentsrequiredforoperation, e.g.ofgearboxes,electricmotors,radioremotes,etc.,carefullyand thoroughly.Clarifyanyquestions before startingwork.
training
Personnel Operation Themachinemayonlybeoperatedbyqualified,trainedpersonnel. Themachineisonlyallowedtobeoperatedbyqualifiedpersonnelwho canprovideproofofhavingbeentrainedonthisunit.
Readingoftheoperationmanual,especiallythechapteronsafety,shall constituteapartofthistraining.
Youmusthaveadequateknowledgeofthe
■ mechanics,
■ hydraulics,and
■ controlengineering andmustbeabletoprovethisknowledge.
Installationandrepair Asafundamentalrule,installationandrepairworkmayonlybecarried outbypersonnelwhohavebeenadequatelytrainedfortheseparticular requirements.
Installationandrepairworkon:
■ safetycomponents(pressurereliefvalves,extinguishers,etc.)
■ theelectrics(motors,controllers,etc.)
■ thehydraulics(controls,cylinders,etc.)
mayonlybecarriedoutbyserviceengineersfromBucyrusAmerica, Inc.orbyspeciallyqualifiedpersonnelofthemine.
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Operatingconditions Intendeduse
TheContinuousMinerhasbeendesignedandmanufacturedforspecificuses.Intendedusesinclude:
■ extractionofcoal,phosphate,potash,salt,trona,andothermediumhardnessminerals
■ loadingthematerialslistedaboveontoahaulagesystemorshuttle car,ordumpingitontothegroundforloadingatalatertime
■ operationongradesoflessthan10degrees
Unauthorizeduse
Applicationsnotexpresslylistedasintendedusesareunauthorized usesandarenotallowedtobeperformedwiththemachine.
■ thetransportofpersons
■ stonedevelopmentorextraction
BucyrusAmerica,Inc.acceptsnoliabilityforanydamageresulting fromanysuchunauthorizeduse.
Safetyinstructions Generalrules:
general noiseemissions
safetyequipment symbolplates emergencystop lock-outandtag
Alwaysworkwithfullconcentration.
Familiarizeyourselfwithyourworkingenvironment.
Alwayswearyourpersonalprotectiveequipment.Thisalsoincludes earprotectorsasthenoiseemittedbyotherequipmentintheareamay attimesexceed85db(A).
Informyourcolleaguesof
■ yourexactlocation,
■ theworkyouareperforming,and
■ thetimethatyouwillprobablyrequire.
Startthemachineonlywhenitisinagoodandsafeoperatingcondition andallprotectivedevices,e.g.EMERGENCYSTOPdevices,cover plates,etc.arecorrectlyinstalled.
Observetheacousticandopticalstart-upwarningsofthemachine.
Observethesymbolplatesonthemachine.
PresstheEMERGENCYSTOPbuttonimmediatelyintheeventoffault orirregularitiesinoperation.Reportanyirregularitiestoyoursuperior sothatnecessarymeasurescanbetakenimmediately.
Disconnect,lock-out,andtagthepowersystemwhileperforming:
■ maintenancework
■ inspectionwork
■ repairwork
Followallmine,state,andFederalregulationsregardinglock-out/tag outprocedures.
cordonoffworkingarea movingparts
Cordonoffyourworkingareawidelyforthemachine.
Neverallowpartsofyourbodytocomebetweenpartswhichcould move,suchase.g.:
■ chains,flights,andchainsprockets
■ pivotpoints
■ cutterheadandloadinghead
■ crawlerassembliesandconveyors
■ cutterandgatheringheadassemblies
Safetyinstructions Storageandtransport Maintaintheprescribedstorageperiodsandobservetheinstructions forstorage.
Donotstorematerialsorpartsinthetravelwayorinyourworking area.
Informthepersonsinvolvedabouttheintendedtransportrouteandthe anticipateddurationofthetransport.
Ensurethatthetransportsafetydevicesarecorrectlyfitted. Fixallmovingpartswithtransportlocks.
Neverstandunderunsupportedpartsorsuspendedloads.
Connecttheliftingequipmentonlytothepointsofattachmentprovided forthatpurpose.Observethedifferentloadlimitsoftheattachment points.Alsoobservetheinstructionsonthetransportsheet.
Onlyusemeansofattachmentwhichareingoodconditionandhave beendesignedfortheloadstobehandled.
Forroundcomponentsusetransportstraps,only.Neverusechainsor steelcablesforthispurpose.
Donotdamagethetreatedorpolishedsurfacesofshafts,sealingsurfaces,etc.
Whenusingmobilehandlingsystemsfortransportmakesurethatthe centerofgravityisaslowaspossible.
Pre-startinspection Readthisentiremanualbeforeattemptingtooperatethismachine.
Inspectthemachineandhaveanymalfunctioning,brokenormissing partscorrectedorreplacedbeforeuse.
Verifythatallmaintenancehasbeenperformed.
Verifythatallinstructionandsafetytagsareinplaceandreadable. Theseareasimportantasanyotherequipmentonthemachine.
Cleananyforeignmaterialfromtheoperator’scompartment.
Thismachinemaybeshippedfromthefactoryequippedwithaprotectivecab/canopy.Thecab/canopymustbesecurelyinplacebeforeoperatingtheunit.
Installationandstart-up Oninclinedfacessecureallcomponentpartsbychains,e.g.tothe support.
Whenworkingwithoils,greasesandotherchemicalsubstances,observethesafetyregulationsapplicabletotheproduct.SafetyregulationscanbefoundonthecontainerorontheMaterialSafetyData Sheet(MSDS)fortheproduct.
Disposeofcleaningrags,etc.whichhavebeensoiledwithoil,grease orotherchemicalsubstancesinanenvironmentallysafemanner.
Whenstartingupmachine,donotoperateanycontrolslocatedinside theoperator’scompartment(optional)fromoutsidethecompartment.
Followthestartingprocedureinstructionsintheoperationsmanual.
Donotoperateanylevers,pedalsorcontrolsifanyoneisinthered zone.(SeeRedZoneinChapter5ofthismanual)
Operation Operatethemachineonlyifyouhaveaprofoundknowledgeofthe controlelementsandtheirfunctions.Itisnecessarythatyouhave beentasktrainedontherespectiveContinuousMiner.
Beforestart-up,ensurethattherearenopersonsorobstructionsin yourlineoftravelorinthearticulationareawhensteeringtheunit.
Checkthatallprotectivedevicesareinstalledonthemachineandfunctionproperly.
Cleantheoperator’scompartmentatregularintervals.Ensurethatthe operatingsymbolsarelegibleinordertoavoidanyoperatorerrorsand resultingaccidents.
Neverclimbonto,orclimboutofthemachinewhileitisinmotion.
Donotoperatethemachinewithanypartofyourbodyoutsideofthe operator’scompartmentinordertopreventbodypartsfrombeing crushedbetweenthemachineandoutsideobjects.
Useextremecautionwhentravelinginclosequartersorincongested orblind-travelareas.
Nevercarrypassengers.Passengersmaybethrownoffthemachine orcrushedbetweenthemachineandoutsideobjects.
Alwaysfollowallsafetyrulesofeachparticularminewhenoperating themachine.
Ifproblemsormalfunctionsareencounteredwhileoperatingtheunit,it mustbeproperlyshutdownandtheproblemcorrectedimmediately.
Safetyinstructions Stopping Donotleavetheoperator’scompartmentwiththeunitrunning.Always properlyshutdowntheunitbeforeleavingtheoperator’scompartment.
Alwaysparktheunitonsolid,levelground.Ifthisisnotpossible,park theunitatarightangletotheslopetopreventaccidentalmovementof themachine.
Useproperflags,warningsorbarrierswhenparkinginareasoftraffic.
Thereisauniquecodeswitchsetupwhichpermitseachoperatorto activateonlyhisdesignatedminer,allowingseveralremote-controlled minerstooperateinthesameareawithoutgettingtheirradiosignals crossed.Inaddition,animproperlydecodedradiosignalwillautomaticallyshut-offtheminer.Followthegeneralsafetynoticesandsafety recommendationslistedintheremotecontrolsystemtroubleshooting guide.
Maintenanceandrepair Besuretoobservetheprescribedmaintenanceandinspectionintervals.
Informthesupervisorypersonnelandthefacecrewofanymaintenance andrepairoperations.Givetheminformationontheintendedoperationsandtheanticipatedduration.
Beforeattemptinganyrepairs,a DANGER signmustbeattachedtothe appropriatecircuitatthepowerdistributionbox.Itismandatoryunder theUnitedStatesFederalLawthatthetrailingcablebeuncoupled, taggedandlocked-outfromthepowersourcetoprovidevisualevidencethattheminerisde-energized.
Secureyourworkingareaoverawiderange,inordertoavoidendangeringotherpersons.
Disconnectthepowerfromthemachinetopreventunauthorizedand unintentionalrestarting.
Protectyourworkareaagainstfallingrocks.
Passdefectivecomponentsremovedonforservicingwithoutdelayin ordertopreventthesepartsbeingreinstalledelsewhere.
Useonlysparepartswhichsatisfythespecifiedtechnicalrequirements. ThisisonlyensuredwithoriginalBucyrusAmerica,Inc.spareparts. Pleaserefertothesparepartslistsfortheordernumbers.
Beforeattemptinganyrepairsormaintenance,methaneairmonitoring mustbecompletedbeforeandduringtherepairandmaintenance.
handlingofhydraulicfluids lifting
maintenance,repair
Safetyinstructions ForraisingtheContinuousMineruseonly:
■ cribblockswithadequateload-holdingcapacity.
■ hoists,jacksorcraneswithadequateload-carryingcapacity.
Avoiddirectcontactbetweentheskinandhydraulicfluids.Hydraulic fluidcanpenetratetheskinandcauseseriousinfection.
Neverusehydraulicfluidforrinsingorcleaning.Hydraulicfluidrepresentsaveryseriousdangertohealth.
Onlypersonswhohaveandcandemonstrateaspecialknowledgeof hydraulicsareallowedtoworkonthehydraulicsystem.
Avoid,wheneverpossible,servicing,cleaningorexaminingthemachineincongestedareas.
Avoid,wheneverpossible,servicingorprovidingmaintenancetothe unitunlesstheappropriatesafetydevicesareplacedwhererecommendedtopreventaccidentalmovementoftheunit.
Donotaltertheelectricalorhydraulicsettingsfromthatindicatedinthis manualorassetatthefactory.
Alwaysreplacedamagedorlostdecalsandmetalinstructionplates.
Disconnectthepowerwhenworkingwiththeelectricalsystem,orwhen weldingontheunittopreventelectricalshock.
Alwaysfollowallsafetyproceduresofeachparticularminewhenperformingmaintenance.
Itisimportantthatanyprocedurenotspecificallyrecommendedinthis guidebethoroughlyevaluatedfromthestandpointofsafetybeforeitis implemented.
Safetyinstructions ____________________________________________ Someillustrationsinthismanualshowguardsorcoverpanelsremoved forpurposesofclarity.Neveroperateunitwithoutguardsorcoverpanelsinplace.
Carryoutavisualinspectionofallthehydrauliccomponentsatregular intervals.Inparticularcheckthat:
■ thehosesarenotpinchedortrapped.
■ thehoseshavenobubblesorblisters.
■ thehoseoroutersheathesofthehosearenotabnormallyrigidor hard.
■ theoutersheathofthehosesisnotdamaged.
■ theconnectorsaresecurelyinsertedintothesockets.
■ theconnectionsareleak-tight.
Ensurethatnodirtentersthehydraulicsystemduringrepairwork.Dirt inthehydraulicsystemcancauseseriousdamageinthewholesystem! Flushoutthehydrauliclinesthoroughlybeforeconnecting.
permissiblehoses
Ifhydraulichosecouplersaredifficulttodisconnectorcannotbedisconnected,thehydrauliclinemaystillbepressurized.Besuretodepressurizethelinebeforedisconnectingcouplers.
Securetheconnectorsofthehydraulicelementsonlywiththeproper couplingclamps.Alwaysfastentheclampscompletelyandwithboth sides.Neverusenails,wireorsimilarmaterialsforsecuring.
Afterfinishingrepairwork,checkallconnectorsandconnectionsfor leaksbeforepressurizingthesystemagain.
Useonlyhydraulichosesapprovedfortheprevailingpressures.
Donotuseanyhydraulichoseswithdamagedconnectorsorwornorings.
Replacehydraulichosesonlywithhosesofthesameorahigherquality.
Nevertrytoholdajumpinghydraulichose.Depressurizethelinein questionimmediately.
Nevertrytorepairdamagedhydraulichoses.
Replacehydraulichosesatthefirstsuspicionofdamage.
Safetyinstructions installinghydraulichoses
Installthehydraulichosesproperlybehindthebracketsandclamps providedforthem.
Alwaysinstallhydraulichosessothey:
■ alwayshavealittleslack.
Fig.1:Installinghydraulichoses,slack Right Wrong
■ arenottwisted.
Fig.2:Installinghydraulichoses,twisting Right Wrong
■ arenotbentdirectlybehindtheconnections. (distancemin.1.5xnominaldiameter).
Fig.3:Installinghydraulichoses,bending Right Wrong
Safetyinstructions ■ alwayshavealittleslack.
■ arenotkinked.
■ donothavetowithstandtensilestrains.
■ areprotectedagainstthermalradiation.
■ areaccessibleatalltimes.
Screwhydraulichosesintothesocketsonlybyhandandfingertighten. Nevertrytodrivethehydraulichosesinwithatoolasthiswilldamage theconnections.Usetheappropriateamountoftorquetoensurea properhosefit.
Wheninstallingthehydraulichoses,ensurethattheycannotbe:
■ tornout,
■ kinked,
■ crushed,
■ drivenoveror
■ twistedbymovementofthemachine.
Fig.4:Installinghydraulichoses,connectionsonmovingparts
Right
Overviewofthesafetyinstructions Thisisasummaryofallthesafetyinstructionswhichhavetobeobservedinthefollowingchapters.Thissummaryisintendedonlytogive youanoverviewofalltheinstructions.Insomecases,thereisnologicalrelationshipbetweentheindividualinstructions.
Chapter3:Storageandtransport IMPORTANT!
Takecaretoinsurethatnewmaintenancesuppliesarestored separatelyfromexistingstockandthatremovaltakesplaceonthe “firstin,firstout”principle.
WARNING!
Useonlyloadhandlingdevicescomplyingwiththetechnicaland legalregulationsforthetransportofloads. Youcouldbeseriouslyinjuredorevenkilledbyfallingloads.
WARNING!
DonotusetheeyebolttoliftthecomponentANDitsrelatedassemblies.
Chapter4:Installation CAUTION!
SeriousdamagecanbecausedtotheContinuousMinerasaresultofincorrectinstallation.TheunitshouldthereforeonlybeinstalledundertheinstructionofspecialistsfromBucyrusAmerica, Inc.
IMPORTANT!
Thesequenceofoperationsduringinstallationmustbeadaptedto theindividualconditionsprevailingatthesite.Beforestartingthe workadetailedlistofstepstobetakenwithrespecttotransport andassemblyshouldbepreparedandacorrespondingplan established.
NOTICE!
Themachinewasinspectedpriortoshipmentfromthefactoryto ensureproperfunctioningandinstallationofallcomponents. However,toensurethatnotransitdamagehasoccurred,thefollowingpre-startupchecksshouldbeperformed:
NOTICE!
Theoperatormustbecomefamiliarwithallthesafetyfeaturesand theirlocationonthemachinepriortoinstallationoroperation.
WARNING!
Ifeitherofthefiresuppressionactuators(optional)isactuated, thesystemmustbecompletelyrechargedwithdrychemicalsand expellants.
DANGER!
Donotoperatethemachinewithanyoftheguardsorcoversremoved.Youorotherpersonnelcouldbeseriouslyinjuredfrom
Overviewofsafetyinstructions Chapter5:Operation DANGER!
Incorrectoperationendangersyourselfandothers!Incorrectoperationofthemachineisoftenthecauseofveryseriousaccidents!Operatetheunitonlywhenyouhavebeensufficiently trainedonthemachineandhavereadandunderstoodthisoperatingmanual.Shouldanythingbeunclear,pleasecontactyourimmediatesupervisorortheirdesignee.
NOTICE! Beforebeginningcuttingoperations,carefullyunloadthetrailing cableprovidingenoughslackandplacingitwhereitallowsadequateclearanceforsafemaneuverabilityoftheminer.
WARNING!
TheContinuousMineristypicallyradioremotecontrolled.Manual operationisnotallowedforproductionoperationunlesstheminer hasanoperator’spitandcanopy.Manualoperationisgenerally fortroubleshootingandmaintenanceundersupportedroof.OperatingtheContinuousMinermanualfromtheOperator’sstation mayresultinseriousinjuryordeath.
IMPORTANT! MANUALONLY:TheContinuousMiner’stramandsteeringspeed isvariable.ThismeansthatthefartherthetramhandleisactuatedthefastertheContinuousMinerwilltravelorturn.
IMPORTANT! Oncethetram/steeringcontrolleverisreleasedbytheoperator thecontrolleverautomaticallyreturnstothecentered(neutral) position.
WARNING!
ManualoperationoftheContinuousMinerisnotallowedforproductionoperationunlesstheminerhasanoperator’spitandcanopy.Manualoperationisgenerallyfortroubleshootingandmaintenanceunderroofsupport.OperatingtheContinuousMiner manuallyfromtheoperator’sstationmayresultinseriousinjury ordeath.
WARNING! Themachinecircuitbreakerde-energizestheelectricalcontroller andmotors.However,electricalpowerisstillpresentinsidethe connectionboxtothecircuitbreaker.Ifthecircuitbreakerinside theconnectionboxrequiresservice,thetrailingcableshouldbe disconnectedfromthepowercenter.
WARNING!
Oncethebreakerhastripped,itwillnotstayinthe“ON”position withoutfirstbeingmovedtothe"RESET"position,andthento "ON".
WARNING!
Ifeitherofthefiresuppressionactuatorareactuated,thesystem mustbecompletelyrechargedwithdrychemicalsandexpellants.
WARNING!
BepreparedforasuddenstopwhentheE-stopisactuatedduringnormaltrammingofthemachine.
IMPORTANT!
Refertotheradioremotecontroloperationmanualsuppliedwith yourmachineforinformationregardingtheoperationofyour specificremotecontrol.
WARNING!
Failuretoreadandunderstandalloperatinginstructionsbefore startingtheContinuousMinercouldresultinseriousinjuryor deathtotheoperatororpersonsaroundthemachineorcause damagetothemachine.
WARNING!
Readallinstructionscarefullybeforeattemptingtostartoroperatemachine.
WARNING!
UnderstandthefunctionsofallcontrolsbeforestartingtheContinuousMiner.Readandfollowtheinstructionsonallwarning tagsonthemachine,observeallregulationsandsafetyprecautions.
WARNING!
NeveroperateaContinuousMinerwhichhasbeendamagedoris notoperatingproperly.AnypartoftheContinuousMinerwhich doesnotfunctionproperlycanbeahazard.Reportitimmediately toyoursupervisor.
WARNING!
BeforestartingtheContinuousMiner,makesurethatnooneisin theredzone(Fig.22throughFig.26).
NOTICE!
Inextremelycoldweather,allowmotorsandgearcasestoidle. Thiswillwarmthehydraulicoilsandlubricants.Stilloilsand greasescouldimmobilizethemachine.
IMPORTANT!
Apump“growl”meansnotenoughoilisreachingthepumps throughthesuctionlines.Ensurethepumpgetsprimedbefore continuingoperation.Alwayschecktheoillevel.
DANGER!
Improperpositioncouldresultininjuryordeathtotheoperator bycrushinghimagainsttheriborroofsupports.Itmayalso causehimtorunoverthetrailingcableordislodgetheroofsupports.
Overviewofsafetyinstructions _________________________________ WARNING!
Turningonthewatersprayspriortocuttingpreventstheaccumulationofdustandthegenerationofexcessiveheatwhichcould causeanignitionorexplosion.
IMPORTANT!
Beforestart-up,checkthatdailymaintenancehasbeenperformed onthemachine.
WARNING!
Visuallycheckforotherpersonnelandverballyshoutawarning beforestartingthismachine.Makesureallpersonnelarecompletelyclearofthemachineandit’scomponentsandcheckthat anyloosematerial,tools,oilcansorotherobjectsareclearfrom theareabeforestartingthemachine.
IMPORTANT!
The“PUMPON”keymustbereleasedbefore“SHIFT”.If“SHIFT” isreleasedfirst,thepumpmotorwillshutoff.
WARNING!
Afterturningoffthepowertothemachine,neverwalkawayand leavethetransmitterturnedon.Failuretoturnthetransmitteroff couldresultinanaccidentcausingseriousinjuryorlossoflife.
WARNING!
Trammingrequirescoolingwatertothetrammotors.Failureto coolthemotorswillresultinmotordamageandprematurefailure.
WARNING!
Adjustconveyorboomtoallowclearancefromroof,walls,and floor.Failuretodosowillresultindamagetotheconveyorboom.
WARNING!
Neverstartcutterheadmotorsunderaload.Startingmotorsunderloadmayresultinmotordamageorprematurefailure.
WARNING!
Warn“ALLCLEAR”beforestartingthecutterhead.Failuretodo somayresultinseriousinjuryordeath.
IMPORTANT!
Bothcuttermotorsdonotstartatthesametime.Thereisapreset timeddelaybetweentheleftcuttermotorstartingandtheright cuttermotorstarting.
IMPORTANT!
The“CUTTERON”keymustbereleasedbefore“SHIFT”.If “SHIFT”isreleasedfirst,thecuttermotorswillshutoff.
Overviewofsafetyinstructions WARNING!
Warn“ALLCLEAR”beforestartingtheconveyor.Failuretodoso mayresultinseriousinjuryordeath.
IMPORTANT!
The“CONVON”keymustbereleasedbefore“SHIFT”.If“SHIFT” isreleasedfirst,theconveyormotorswillshutoff.
IMPORTANT!
The“FANON”keymustbereleasedbefore“SHIFT”.If“SHIFT”is releasedfirst,thefanmotorwillshutoff.
CAUTION!
Alwaysensureoperatorsafetywhileoperatingthemachine.
CAUTION!
Alwaysbealerttohazardousconditionsandtakecorrectiveactionasnecessary.
IMPORTANT!
Careshouldbetakennottostallcuttersorconveyorduringcuttingoperations.Severedamagetomotorsandgearboxescould occurifcuttersorconveyorarerepeatedlystalled.
IMPORTANT!
Tramislimitedintheforwarddirectionwhilethecuttersarerunningwiththecutterheadfeedbackcircuit.Asthecuttersbeginto cutthematerialfromthefacethesumpspeedwillautomatically slowthetramtopreventoversumpingthemachine.
IMPORTANT!
Inspectionofthebitsandbitblocksbeforethestartofeachshift willreducelaterproblems.Miningwithdull,bentorbrokenbits andbitblocksincreasesdustandnoiselevels,aswellasputting excessivestrainonbothcuttermotorsandtramcomponents.
WARNING!
Failuretomaintainthehydraulicsystemwillresultindamageto itshydrauliccomponentswhichwillresultinincreasedwearand prematurefailure.
IMPORTANT!
Schematicsmayvaryfromoneunittothenext.ConsulttheBucyrusAmerica,Inc.partsbookfortheschematicforyourmachine.
IMPORTANT!
Duringdisassemblyofcontrolvalves,giveparticularattentionto identificationofpartsforreassembly.Spoolsareselectivelyfitted tovalvebodiesandmustbereturnedtothesamebodiesfrom whichtheywereremoved.SpoolsareNOTinterchangeablebetweenvalvebodies.
Overviewofsafetyinstructions _________________________________ WARNING!
Donotsalvagespoolsorvalvebodiesforlaterusein“new”combinations.Impropercomponentsusedduringassemblymayappearasinternalleakage,ora"sticking"or"hangingup"ofthe spoolinthevalvebody.Incorrectsetswillresultinimproperoperationofthevalvesection,possiblycausingunexpectedmachine operationthatcouldresultinmachinedamageorinjurytopersonnel.
WARNING!
Donotrelyontheloadholdingvalvewhenworkingunderthecutterheadortheconveyor.Alwaysblocktheconveyororthecutter headifitmustbeelevated.Seriousinjuryordeathmayresult fromnotblockingtheload.
WARNING!
Theloadholdingvalvesonthecutterheadandconveyorcylinders arepresetandDONOTrequireadjustment.Adjustmentofthese valvemayresultinveryseriousinjuryorevendeath.
DANGER!
Theareaunderandaroundtheraisedcutterheadisdangerous. Securelyblocktheheadbeforeperformingmaintenanceonor belowit.Failuretoblocktheraisedcutterheadcouldresultin seriousinjuryorevendeath.
DANGER!
Theloadholdingvalveispreset. DONOTADJUSTIT.Ifitmalfunctions,replaceitimmediately.
IMPORTANT!
Ensurethatthepowerfillsuctionhose istightlypluggedtopreventdirtandcontaminantsfromenteringthehydraulicsystem whennotinuse.
IMPORTANT!
Thepowerfillisactivatedbyengagingconveyordownfunction andopeningtheballvalve.
IMPORTANT!
Neverruntheconveyorwithouttheneedlevalveclosed.Injuryor deathmayoccur.
IMPORTANT!
Youmustmanuallyresetthe2-way,2-positionwatervalvetoreset thedelugefirespraycircuit.
IMPORTANT!
Thebackupaccumulatormustmaintainaminimumpressureof 500psifor12minutesafterthepumphasbeende-energized.For maintenanceonthecircuit,loosenthefittingSLOWLYuntilthe pressureisreleased.
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IMPORTANT!
Hangtrailingcablestopreventdamagefrommovingequipment!
WARNING!
Neverrunoveranunprotectedtrailingcable.Damagedcables shouldberepairedimmediately.
DANGER!
Neverhandleenergizedtrailingcablewithoutproperprotective equipment.Contactwithanenergizedtrailingcablewithcompromisedinsulationcouldresultindeathbyelectrocution.
WARNING!
Alwaysusecautionwhenstandingnearorcrossingtrailingcables.Thetrailingcablemaymoveasthemachinemoves.
IMPORTANT!
Ifthelowoilwarninglightcomesonwhenthecircuitbreakeris closed,besuretofillthereservoirbeforestartingthemotors.
CAUTION!
Onlyqualifiedtechniciansshouldtroubleshoottheelectricalsystems.Touchingorshortingenergizedcomponentscancauseseriousinjuryordeath.
WARNING!
Beforeperformingmaintenanceonthemachine,thecircuit breakermustbeinthe“OFF”positionandthepowershouldbe disconnectedatthemainpowersource.FollowallFederal,State, andMinesafetyregulationsforlockout/tagoutprocedures.Accidentalmachinemovementorelectricalshockcanresultinserious injuryordeathtoyouorotherpersonnel.
WARNING!
Donotmoveanyhydrauliccontrolleverunlessyouarecertain thateveryoneiscompletelyclearofanymachinemovement.Accidentalmachinemovementcancauseseriousinjuriesoreven deathtoyouorthemaintenanceperson.
WARNING!
Neverdisconnectahydraulichoseifthecircuitispressurizedorif thereisaloadonthecircuit.Ifahoseisdisconnectedwhilethe circuitispressurizedoraloadisonthecircuit,theloadwillfall causingdamagetothemachineorseriousinjuryordeathtoyou orotherworkers.
WARNING!
Youcouldbeseriouslyinjuredorevenkilledbyfallingloads.Observethesafeworkingloadlimitsofliftingorblockingdevices andkeepasafedistancefromsuspendedloads.
Overviewofsafetyinstructions _________________________________ NOTICE!
Ifthegearcaseisscheduledforoildrainandrefill,obtaintheoil samplepriortotheoilchange.
IMPORTANT!
Alwayscollectoilsamplesusingasiphonpump.Donotremove thedrainplugandcollectoilbyallowingittorunoutintothebottle.
IMPORTANT!
Alwaysusethecollectionhoseprovidedwitheachbottle.Always discardhoseimmediatelyfollowingcollectionoftheoilanddonot useitforthenextsample.Todosowillcontaminatethenext samplewithoilfromtheprevioussample.
NOTICE!
Incorrectgreaseorovergreasingoftheelectricmotormaycause seriousdamagetothemotor.FollowthegreasingprocedureoutlinedintheMaintenancesectionofChapter5.
WARNING!
Useextremecautionwhenperformingtestproceduresandmaking adjustments.Unlessnotedintheprocedures,allcontrolsaretobe intheneutralposition.
IMPORTANT!
Alwaysusethepropertoolswhenadjustingvalvecartridges.
IMPORTANT!
Donotstartanymotors - CLA,cutterhead,pump,ortractionmotors - untilallpressuresareset.Startthepumpmotorasdirected.
WARNING!
Neverrelyontheloadholdingvalveasameansofsupportingthe cutterorconveyorboomwhilemakingrepairs.Severeinjuryor deathcouldresult.
WARNING!
Alwaysallowfunctiontobottomoutandstopmovingbeforeadjustinganypressure.
IMPORTANT!
ReferencetheHydraulicsectioninthischapterforgeneralinformationontheindividualcircuits.Alwaysrefertothehydraulic schematicinyourBucyrusAmerica,Inc.partsmanualforinformationthatisspecifictoyourminer.
WARNING!
Twopeoplearerequiredtoadjustpressuresettings.Oneperson willmaketheadjustmentswhilethesecondpersonmustremain atthe“E-STOP”atalltimesduringtheadjustmentprocedure. Failuretodosomayresultinseriousinjuryordeath.
Overviewofsafetyinstructions IMPORTANT!
Beforemakinganyfurtheradjustments,verifythatthehydraulic oilisatoperatingtemperature.
IMPORTANT!
Themainreliefissethigherthantheportreliefsandwillonlyrelieveifaspikeoccursinthesystemoriftheportreliefdoesnot functionproperly.Thisprovidesprotectionofthemainpumpsection,A1.
CAUTION!
Donotadjustthemainreliefover3,000psi.Destructionofthe valvebankandthemainpumpcouldresult.
CAUTION!
Alwaysbealertforanyunintendedmachinemovement.
IMPORTANT!
ReferencetheHydraulicsectioninChapter5forindividualcircuitinformation.Alwaysrefertothehydraulicschematicinyour BucyrusAmerica,Inc.partsmanualforyourminer.
WARNING!
Keepbodypartsclearofmachinewhileinraisedpositionorseriousinjurycouldresult.
WARNING!
Youcouldbeseriouslyinjuredorkilledbyfallingloads.Observe thesafeworkingloadofallblockingdevices.
WARNING!
FollowallFederalandminelockout/tagoutregulationsandprocedures.Failuretodosocouldresultinmachinedamageorserious injuryordeathtopersonnel.
CAUTION!
Shimsmustbeinsertedcompletelyintotheidlerslidechannel.A shimthatisnotcorrectlyseatedontheidlerslidechannel’sinside surfaceprovidesunevensupportthatcancauseidlerslant.A slantedidlercancauseunevenwearandstressonthetramtrack andcancauseimproperoperationofordamagetothetramsystem.
IMPORTANT!
Checkthattheshimsarecorrectlyseatedontheidlerslidechannel’sinsidesurfacebylookingatthechannel’sinsidesurface fromtheoppositesideoftheminerthroughthespacebetween thegatheringheadandtheidlerassembly.
IMPORTANT!
Leftandrighttake-uprodsshouldberotatedequally.Thismaintainssteady,equalpressureonthetailrollerassemblyandkeeps theconveyorchainfromdriftingoffcenter.
Overviewofsafetyinstructions _________________________________ WARNING!
Donottestthealignmentoftheshearcylinderrodendbearings andthecutterboomclevisusingyourfingers.Shiftingofthe alignedpiecescouldcauseseriousinjury.
IMPORTANT!
Thepinshouldbeinsertedsothatitsretainingchannelremains outsidethebushing.
IMPORTANT!
Inadditiontotheshearcylinders,thestabilizerandgathering headcanalsobeusedtoadjustthecutterboom’spositiontoalloweasierinsertionofthecutterboompivotpins.
IMPORTANT!
Pressurefromthecutterboomontothepivotpincanmakeitsremovalverydifficult.Theshearcylinderscanbeusedtofindthe boompositionthatputstheleastpressureonthepin.
CAUTION!
Whenthepivotpinpullpointisfound,blockthecutterboomto preventitfromdroppingormovingwhenthepivotpinisremoved.
IMPORTANT!
Pressurefromthecutterboomontotheboompivotpincanmake itsremovalverydifficult.Theshearcylinderscanbeusedtofind theboompositionthatputstheleastpressureontothepin.This positioncanbedeterminedbystrikingthepin,slightlycontracting orextendingtheshearcylinder,thenstrikingthepivotagainand comparingthe“ring”;asboompressureonthepindecreases,the “ring”ofthepinwhenitisstruckbecomeslower.Whenthe“ring” ofthepinbecomesshortandlow,pinremovalismucheasier.
CAUTION!
Useextremecautionwhenadjustingtheboomwiththeshear cylindertofindthepivotpin’spullpoint.
IMPORTANT!
Onthebackofthetractorframeclevisthereisaweldedstrapthat keepstheboompivotpinfromrotating.Oneoftheflatsofthe boompivotpinmustparallelthisstraporthepincannotbecompletelyinserted.
IMPORTANT!
Ifitisextremelydifficulttoinserttheboompivotpinthroughthe alignedtractorframeclevisandboompivotbushings,extendor contracttheshearcylinderstoimprovethealignmentbetweenthe clevisandboom.
CAUTION!
Useextremecautionwhenadjustingtheclevisandboomalignmentwiththeshearcylinders.
Overviewofsafetyinstructions _________________________________ WARNING!
FollowallFederalandminelockout/tagoutregulationsandprocedures.Failuretodosocouldresultinmachinedamageorserious injuryordeathtopersonnel.
CAUTION!
Theshearcylinderisveryheavy.Verifyitsweightcanbesupported.
WARNING!
Replacementoftheshearcylinderinvolvesworkingarounda raisedcutterheadassembly.Neverworkunderanyraisedassemblywithoutproperblocking.Alwaysblockbetweentheraisedassemblyandthetractorframeinadditiontobetweentheraisedassemblyandthefloor.
WARNING!
Thisprocedureinvolvesdisconnectingthehydraulichoses.Alwaysusecautionwhenworkingwithoraroundhydraulicsystems theycanbeunderextremelyhighpressures.
WARNING!
Standclearoftheblockedcutterheadassemblyduringshearcylindercontraction.
WARNING!
FollowallFederalandminelockout/tagoutregulationsandprocedures.Failuretodosocouldresultinmachinedamageorserious injuryordeathtopersonnel.
WARNING!
Thenextstepsdisconnecttheshearcylinderfromthetractor frame.Theshearcylinderisextremelyheavy.Bepreparedtosupportitsweightbeforeperformingthefollowingsteps.
WARNING!
Neverdisconnectahydraulichoseifthecircuitispressurizedorif thereisaloadonthecircuit.Ifahoseisdisconnectedwhilethe circuitispressurizedoraloadisonit,theloadwillfall,causing damagetothemachineorseriousinjuryordeathtopersonnel.
WARNING!
Standclearoftheshearcylinderandtheblockedcutterheadassemblyduringextensionoftheshearcylinder.
WARNING!
Replacementofthecutterheadcenterdruminvolvesworking aroundaraisedcutterheadassembly.Neverworkunderany raisedassemblywithoutproperblocking.Alwaysblockbetween theraisedassemblyandthetractorframeinadditiontobetween theraisedassemblyandthefloor.
WARNING!
Thisprocedureinvolvesdisconnectingandreconnectingthe miner’strailingcable.Alwaysbeawareofwhetherornottheminer isenergized.Neverperformmaintenanceonanenergizedminer.
Overviewofsafetyinstructions _________________________________ WARNING!
Standclearofthecutterheadassemblyandtheunsecuredupper halfofthecenterdrumwhileloweringit.
WARNING!
Whilethispowercableisdetachedfromthemotor,thetrailing cableshouldnotbereconnectedtoenergizetheminer.Damageto theminer,personalinjuryordeathcouldresult.
WARNING!
Federallawrequiresthatminingequipmentelectricalconnections mustbeinspectedbyacertifiedelectricianbeforetheequipment canbeoperated.
WARNING!
Thisprocedureinvolvesattachinganelectricalpowercabletothe cutterheaddrumdrivemotor.Thetrailingcablemustbedisconnectedtosafelyperformthisoperationorseriousinjuryordeath willresult.
WARNING!
Thecutterheadgearcaseisextremelyheavy.Keepbodyparts andotherobjectsfromunderneathituntilitiscompletelysecured.
WARNING!
Useextremecautionwhentrammingtheminerforwardtoposition theboomfaceagainstthegearcase.
WARNING!
Standclearoftheblockedcutterheadandgatheringheadassembliesduringthecontractionofthegatheringheadliftcylinders.
CAUTION!
Whenseparatingthegatheringheadfromthetractorframe,ensurethatthedisconnectedendsoftheconveyorchainsmoothly slideoutofthegatheringhead.
CAUTION!
Whentrammingtheminertowardthegatheringhead,becareful thattheconveyorchainandgatheringheadliftcylindersdonot becomepinchedbetweenthetractorframeandthegathering head.
CAUTION!
Usecautionwhenusingtheliftcylindersandstabilizertoadjust thealignmentoftheclevisandpivotpins.
WARNING!
Thenextstepsdisconnectthegatheringheaddrivemotorfrom theadapterthatlinksittothegatheringheadgearcase.Thegatheringheaddrivemotorisextremelyheavy.Bepreparedtosupport thisweightbeforeperformingthefollowingsteps.
IMPORTANT!
Thebottomportsonthehighspeedinputcasesarethefilllines. Thetopportsonthehighspeedinputcasesarethechecklines.
IMPORTANT!
Improperconveyorchaintensioncanleadtoexcessivewear,mechanicalproblems,andminerdowntime.Alwayskeeptheconveyorchainatpropertension.
IMPORTANT!
Positionthefootshaftsoitssprocketwillengagetheconveyor chainlinkswhenthechainisreconnected.
NOTICE!
Hogringsshouldbeinstalledsothattheirsharppointsare directedclockwise.
WARNING!
Thenextstepremovesthesecondaryplanetarygearringfromthe secondaryplanetarygearassembly.Thesecondaryplanetary gearringisextremelyheavy.Bepreparedtosupportitsweight beforeremovingitfromthesecondaryplanetaryassembly.
IMPORTANT!
Theflatedgeofthecoverlocatedadjacenttothelubricationfitting isthetopofthecover.Orientthecoversothatthelubricantlevel checkplugisonthemotorsideofthecoverandthedrainplugis onthebottom.
WARNING!
Thenextstepremovesthetramcasefromthetractorframe.The tramcase(withsprocketandreachgears)isextremelyheavy.Be preparedtosupportthetramcasebeforeremovingitfromthe tractorframe.
WARNING!
Ensurethattheelectricalcablesandcoolingwaterhosesforthe trammotorarefreefromthetramcasesbeforeattemptingtoremovethetramcasefromthetractorframe.
IMPORTANT!
Theguidewireswillbeusedtopullthetramtracklinksontothe tramcasesprocketafterthetramcaseisinstalled.
WARNING!
Beforeattemptingtoslidethetramcaseintothetractorframe, ensurethatthetrammotorelectricalandwaterconnectionsare outoftheway.Failuretodosomayresultindamagetotheelectricalandwaterconnections.
Overviewofsafetyinstructions _________________________________ IMPORTANT! There-installationprocedureforthetramcaseincludesreinstallationoftheprimaryandsecondaryplanetarygearsandthe trammotor,andreconnectionofthetramtrack.
WARNING!
Thenextstepremovesthesprocketfromthetramcase.The sprocketisextremelyheavy.Bepreparedtosupportitsweight beforeremovingitfromthetramcase.
IMPORTANT!
Whenthebearingsleeveisinsertedintoposition,theo-ringforms asealbetweenthesleeveandthepiecethatholdsit.
WARNING!
Standclearoftheminerwhenusingthemotortopullthetram trackthroughthetramcase.
WARNING!
Doublecheckthatthelinksofthetramtrackarecorrectlyseated ontothetramdrivesprocket.Improperengagementofthetram tracklinksontothesprocketcancauseseriousmechanicaldamage.
WARNING!
Thehydraulicpumpmotorisnowdetachedfromthetractorframe andcanberemoved.Thehydraulicpumpmotorisextremely heavy.Preparetosupportitsweightbeforeremovingitfromthe tractorframe.
WARNING!
Thescrubberfan/motorisnowdetachedfromthetractorframe andcanberemoved.Thehydraulicpumpmotorisextremely heavy.Preparetosupportitsweightbeforeremovingitfromthe tractorframe.
WARNING!
Standclearoftheblockedtractorframeduringcontractionofthe stabilizercylinder.
WARNING!
Followallfederalandminelockout/tagoutregulations.Failureto dosocouldresultinmachinedamageorseriousinjuryordeathto personnel.
WARNING!
Thenextstepsrequirecrawlingundertheblocksupportedconveyortailsection.Verifythatthistailsectionisadequatelysecuredbeforeproceeding.
WARNING!
Eachstabilizercylinderisextremelyheavy.Thenextstepswill removethecylinderfromitstractorframemounting.Beprepared tosupporttheweightfromitstractorframemounting.Bepreparedtosupporttheweightofthecylinderwhenitbecomesfree fromthemounting.
IMPORTANT!
Toobtainmaximumperformance,theduoconesealsmustbeinstalledaccuratelytoinsureuniformloadingatthematingfaces andachieveastablerunningposition.Misalignmentorcockingof sealringsduringassemblycanproducenon-uniformloadingand wobblingofthesealsintheirhousingsresultinginleakagedueto scoringand/orpumpingofdebrispastthetoricrings.Improper installationcanalsoresultinbreakageofthemetalsealrings.
NOTICE!
Impropercareandinstallationofduoconesealscanresultinimmediateleakageorreducedservicelife.
IMPORTANT!
Thetoricmustlieuniformlyinthesealwiththesealingringand paralleltotheseatface.Besurethatthetoricisnottwistedand thatitrestsuniformlyagainsttheretaininglipornotdeeperinone sideoftheseatthantheother.
IMPORTANT!
Donotgetanyoilontotherubbertorics!
IMPORTANT!
Evenasmallpieceoflintcanholdthefacesapartandcauseleakage!
IMPORTANT!
Amixtureofmarkingcompoundandspindleoilisgoodlubefor thegearsunderlightloadsfor2-3revolutionsonly.Checktooth patternsallroundtomakesurethepattern/markingsareuniform.
CAUTION!
Becarefulnottosetfiretoanygreaseorlubricantwhenheating bearings!
IMPORTANT!
Observeallapplicablefireandsafetyregulationswhenheating bearings!
Overviewofsafetyinstructions _________________________________ CAUTION!
Becausegearmaintenancetechniquesarespecialized,they shouldbeperformedonlybyqualifiedpersonnel.
CAUTION!
Donotpowerwrenchtheleadthreadofthelockringinsertuntilit isengagedbyhandturning.Thentightennormally
IMPORTANT!
Anti-seizingcompoundsmaybeusedwiththistypeoflocknut. Washersarenotnormallyrequiredhere,butifassemblydoes,includethemastheyareneededduetohighstresstorque.
WARNING!
Componentsnotmeetingspecificationscanfail,causeserious injury,anddamageequipment.
WARNING!
Donotsubstitutematerialsorcompoundsnotcomplyingwiththe OEMspecifications.Useofnon-OEMsuppliesmayvoidwarranties.
IMPORTANT!
Whenperformingmaintenanceonthemachine,rememberthat fabrication,installation,modificationsoradjustmentsmustbeaccordingtoOEMspecifications.
IMPORTANT!
Airorelectricpowerwrenchesoftheappropriatesizemaybe usedforrunningupjackbolts.Attempttotightenasconsistently aspossibleandremovethepowerwrenchfrequently;donot tightenallatonce.Useastandardtorquewrenchtoverifyfinal torquevalues.
WARNING!
Sometroubleshootingproceduresmustbecarriedoutwiththe coveroftheelectricalcontrollerremovedandsomeprocedures requirethecontrollertobeenergizedduringthetests.Itisextremelyimportantthatyoutakeallnecessaryprecautionstopreventaccidentalelectricalshockwhileworkingwithinthecontroller.AnMSHA-certifiedelectricianmustsuperviseandinspectall workperformed.
Chapter6:Technicaldata IMPORTANT!
Thetechnicaldatalistedinthischapterisforstockmachines only.Customerspecialsmaynotbelisted.
IMPORTANT!
Duetotheapplicationoffastenersbeingsubjecttogreatstresses andheavyorextremevibration,itisimperativethatallboltsbe appliedwithanadequateamountoftorque.Forthisreasonthis listofrecommendedtorquesettingsfordifferenttypesandsizes offastenersusedhasbeencompiled.Thetighteningtorques statedinthesparepartslistshavetobeobserved,aswell,forinstallationandmaintenance.
IMPORTANT!
Useacalibratedtorquewrenchforaccuracy!
NOTICE!
UseonlylubricationfluidsandgreasesapprovedbyBucyrus America,Inc.!ThesefluidsandgreaseshavebeentestedatBucyrusAmerica,Inc.andguaranteereliableoperationofthemechanicalandhydraulicfunctionsofthemachine.
IMPORTANT!
Thelubricationfluidsandgreaseslistedinthesametablecanbe mixed.Otherproductsmayonlybeusedifthesuppliercanguaranteethattheyareequivalent.
Differentlycomposedfluidsandgreasesmustnotbemixedas thismaychangetheconsistency,i.e.themixturecanbecome thinnersothatthelubricationeffectisnotsufficient.Itmayalso bedangeroustouselubricatinggreasesandfluidshavingthe samespecificationbasebutdifferentorigins.
Incaseofdoubt,themanufacturerofthelubricationtobeused shouldbecontactedastothecompatibilityofthelubricationin question.
IMPORTANT!
BucyrusAmerica,Inc.expresslypointoutthattheapprovalofthe listedproductsrelatesonlytothepuretechnicaluseinourmechanicalandhydraulicsystems.Theresponsibilityfortheconstituentsusedinthehydraulicconcentratesliessolelywiththe respectivemanufacturer.
IMPORTANT!
Besuretousethemanufacturer’sinstructionsforuse.
NOTICE!
Whenperformingmaintenanceonthemachine,allusedoiland lubricantsshouldbestoredanddisposedofperyourlocalEPA standards.
Overviewofsafetyinstructions _________________________________ Storageandtransport Thischaptercontainsimportantinformationonthecorrectstorageand transportoftheContinuousMiner.Storageproceduresaregeneral. Forspecificproceduresforyourenvironment,contactBucyrusAmerica,Inc.Engineering.
Observanceoftheinstructionsandtipswillincreasetheservicelifeand availabilityofthemachine.Youwillalsobeabletocarryoutthetransportworkquickerandmoresafely.Carefulattentiontothepointsin thischapterwillhelpyoutosimplifyyourday-to-daywork.
Storage Componentscoatedwithtemporarycorrosioninhibitorareprotectedfor approximatelysixmonths.
Beforedelivery,thehydraulicfunctionsaretestedandthehydraulic pressuresarepresettoOEMspecifications.
Storageofthemachineandspareparts Storetheequipmentindoorsorcoverwithatarpaulintoprotectagainst directexposuretosunlight.
Protecttheequipmentandallsparepartsstoredoutdoorsagainst moistureanddirt,e.g.usingtarpaulins.
Protectthehydraulicplugconnectorsandtheconnectorsoftheelectricalcableswiththecapsandplugssupplied.
Duringshort-termstorage(approximately4weeks)ofequipmentoutdoors,butattemperaturesabovefreezing,electricalcomponentsneed notberemoved.Suchcomponentsmustbeparticularlyprotected againstexcessivetemperatures,dirt,andmoisture.
Iftheequipmentistobestoredmorethansixmonths,thefollowing lubricationandcorrosioninhibitingproceduresmustbefollowed:
■ Ifthecylinderrodsareexposed,therodsmustbecoatedwitha corrosioninhibitingfluid.
■ Completelyfillthehydraulicoiltankwithoil.
■ Fillallgearcase(s)tothemaximumfilllevel.Thegearcase(s) mustberotatedmonthlytoensurethattheinteriorofthegearcase remainslubricated.
■ Lubricateallgreasepoints(seetheMaintenancesectioninChapter5ofthismanual).
■ Completelydrainthewatersystemandrefillwitha50/50antifreeze/watersolution.Pumptheantifreezemixthroughthesystem untiltheantifreezemixcomesoutthewatersprays.ENSURE THATTHESYSTEMISCOMPLETELYPURGEDANDNOWATERORAIRPOCKETSEXIST.
■ Theequipmentmustbestoredinawellventilated,dryroom.Do notstoreoutdoors.
Storageandtransport ForcedPotatoelectroniccomponentshavethefollowingstoragerequirements:
■ Graphicdisplaysmustbestoredattemperaturesabove14°F (-10°C)
■ Powersupplies(partnumber295275)mustbestoredattemperaturesabove -3°F(-20°C)
■ Othercomponentsmustbestoredattemperaturesabove -13°F (-25°C)
Thetractiondrivesshouldbestoredat -10to50°C(14to122°F).
Majorproblemswithcondensationcanoccurifadriveisstoredina coldenvironmentandisthentakenintoadeepminewherethetemperatureismuchhigher.Eventhoughthehumiditymaybeatanacceptablelevel,condensationwilloccuronthecolddrive.Slightexposuretoacondensingenvironmentisnotharmfulprovidedthedriveis completelydrybeforeelectricalpowerisapplied.
Afterastorageperiodofapproximatelytwoyears,arandomsample inspectionmustbeperformedtodeterminewhetherthemeasures takenandthemethodofstoragehaspreventeddamage. Onrequest,theinspectioncanbecarriedoutbyBucyrusAmerica,Inc.
Evenwithproperstorage,sealsandhosesaresubjecttonaturalageing.Donotusethesepartsiftheyhavebeenstoredformorethantwo years.
Instructionsonthestorageofconcentratesforhydraulicfluidscanbe found,ifrequired,inchapter6inthisoperatingmanual.
IMPORTANT! Takecaretoinsurethatnewmaintenancesuppliesarestored separatelyfromexistingstockandthatremovaltakesplaceonthe “firstin,firstout”principle.
Long-termstorageofsparecomponents Ifacomponentistobestoredmorethansixmonths,thehydrauliccomponentmustbecompletelyfilledwithacorrosioninhibitingfluid.Fillthe hollowareasofhydrauliccomponents(e.g.thepistonchambers)in horizontalposition(portsfacingupwards)untiltheystarttooverflow thensealtheportswithplasticorsteelplugs.
Storetheelectricalequipment,electroniccomponents,sparepartsof rubberorplastic – suchassealsandhoses – andhydraulicfluidsonly inclosedroomsattemperaturesof60°F(15°C)to77°F(25°C).
Refertothemotormanufacturer’sstorageprocedureguideinyourBucyrusAmerica,Inc.partsmanual.
Rotatetheimpeller1-1/4turnoncepermonthtopreventdimplingofthe motorbearingsrollers.
Inordertopreventplasticdeformationofthesealelements,cylinders mustbestoredinanuprightposition.Somecylindersmustberemoved sothattheycanbestoredupright.
Transport Loadunits:dimensionsandweights Observethetransportsheetsforthemachineandspareparts.They containinformationon:
■ dimensions,
■ weights,
■ liftingpoints,etc.
Additionalinformationonthedimensionsandweightscanbefoundin chapter6andintheliftingweightguide(Table1)inthisoperatingsection.Fig.5illustratesthepositionofliftingeyesontheminer.
WARNING!
Useonlyloadhandlingdevicescomplyingwiththetechnicaland legalregulationsforthetransportofloads.Youcouldbeseriouslyinjuredorevenkilledbyfallingloads. Useonlysuitableloadhandlingdevices.
Table1:LiftingweightsofContinuousMinerAssemblies
removalandinstallationof heavycomponents Description
CompleteMachine 160,000lbs.
TractorFrameAssembly 75,000lbs.
GatheringHeadAssembly 23,000lbs.
ConveyorAssembly 17,000lbs.
CutterHeadAssembly 45,000lbs.
Wheneverpossible,allremovalsshouldbeaccomplishedusinganadjustableliftingbeam.Allsupportingmembers(chainsandcables) shouldbeparalleltoeachotherandasnearlyperpendicularaspossibletothetopoftheobjectbeinglifted.
Whenitisnecessarytoremoveacomponentonanangle,remember thatthecapacityofaneyeboltdiminishesastheanglebetweenthe supportingmembersandtheobjectincreases.Eyeboltsandbrackets shouldneverbebent.
Whenaneyeboltisprovidedtoliftacomponent,useittoliftonlythat component.
WARNING!
Youcouldbeseriouslyinjuredorkilledasaresultoffallingloads. Donotusetheeyebolttoliftthecomponent and itsrelatedassemblies.
Storageandtransport _________________________________________ Fig.5:Liftingpoints Liftingeye (8ton)
Liftingeye (3ton)
Liftingeye (1ton) (located oncover)
Liftingeye (3ton)
Liftingeye (8ton)
Liftingeye (3ton)
Liftingeye (1ton) (located oncover)
Liftingeye (3ton)
Fig.5(continued):Liftingpoints
Liftingeye(30ton)
Liftingeye(30ton)
Bumper
Storageandtransport Beforetransport Beforetransportingtheequipmentattemperaturesbelowfreezing,all hydrauliccomponentsoperatedwithemulsion(HFAEorHFAS)must becompletelydrainedandthenfilledwithacorrosioninhibitor/frostproofingfluid(e.g.CV50).
Transportofequipmentattemperaturesbetween -6°F(-21°C)and40° F(-40°C)isonlypermissiblewhencertainmeasuresweretakento meettheseconditionsatthedesignandmanufacturestages.Nevertheless,theindividualpartsanddevicesofthisequipmentmustnotbe subjectedtosuddenimpactloadsatsuchlowtemperaturesandmay onlybeloadedstaticallyorquasi-statically.
Duringtransportofthisequipmentwithfloor-mountedvehiclesatsuch lowtemperatures,measuresmustalsobetakentoensurethatthe partsanddevicesarenotsubjectedtosuddenimpactloads.Atvery lowtemperaturesandonpoorroads,thetransportvehiclespeedmust thereforebelimitedtoamaximumof15mph(25kph)fortrucktransport.
Electricalandelectroniccomponentsmustberemovedforoverseas transportorprolongedstorageoutdoorsunlessthesecomponentsor thecompleteequipmentisprotectedagainstharmfulenvironmental influencesbyasuitablepackaging.
Theelectricalcablesremainintheequipment.Theymustbecarefully protectedagainsttransportdamageandsoilingoftheconnections.
Installation Installation Pointstoobservepriortoinstallation
Whoisallowedtocarryoutinstallation?
Installationisonlyallowedtobecarriedoutbypersonnelhavingreceivedadequatetrainingtoperformthistask.
Workon:
■ thesafetycomponents(pressurereliefvalves,fireextinguishing equipmentetc.)
■ theelectricalequipment(controlunits,signalingdevices,etc.)
■ thehydraulicequipment(cylinders,directionalcontrolvalves, hosesetc.)
shouldonlybecarriedoutbyBucyrusAmerica,Inc.serviceengineers orbyspeciallytrainedpersonnel.
Whichtoolsarerequiredforinstallation? NospecialtoolsarerequiredtoputtheContinuousMinerintoservice. Variousitemsofauxiliaryequipmentandmachinesmayberequiredat thepointofinstallation.
Theseinclude:
■ hoistswithadequateliftingcapacity
■ meansofattachmentwithadequateliftingcapacity
■ unloadingdockandcribblocks
■ jackswithadequateliftingcapacity
■ 950VtoattachtemporarilytoSHO2/0shieldedcable
■ impactwrenches,includingaccessories
toolbox
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installationplan
Notesoninstallation CAUTION! SeriousdamagecanbecausedtotheContinuousMinerasaresultofincorrectinstallation.TheunitshouldthereforeonlybeinstalledundertheinstructionofspecialistsfromBucyrusAmerica, Inc.
BucyrusAmerica,Inc.ContinuousMinersareshippedtothecustomer sitepercustomerpreference.TheContinuousMiner canbeshippedto thecustomersiteasacompletemachineorincomponentsections. Thisdependsonmineconditions,transportationweightrestrictions/ requirements,orsize/weightrestrictionsatthemine.
reassemblyinstructions
IMPORTANT! Thesequenceofoperationsduringinstallationmustbeadaptedto theindividualconditionsprevailingatthesite.Beforestartingthe workadetailedlistofstepstobetakenwithrespecttotransport andassemblyshouldbepreparedandacorrespondingplanestablished.
Whenassemblyisrequiredaftershipmentofthemachine,theassistanceofspecialistsfromBucyrusAmerica,Inc.isrecommended.This willinsurethatthecorrectinstallation,safetyandmaintenanceproceduresarefollowed.
Pre-installationchecklist NOTICE! Themachinewasinspectedpriortoshipmentfromthefactoryto ensureproperfunctioningandinstallationofallcomponents. However,toensurethatnotransitdamagehasoccurred,thefollowingpre-startupchecksshouldbeperformed:
■ visuallyinspectallcylinders,gearboxes,tanks,andhydraulic componentsforleaksordamage.
■ visuallyinspectallelectricmotorsandelectricalcomponentsfor signsofdamage.
■ checkthefulllengthofthetrailingcablefordamage
■ ensurethatthetrailingcableisproperlysuspendedacrossinter sectionsandthatthetrailingcableclampattheContinuousMiner issecure
■ startupthemachineandcheckforcorrectoperationofallstop switches.
■ performdailymaintenance
■ visuallyinspectallhydraulichosesandelectricalcablesfordamage
■ cleananyforeignmaterialfromtheoptionaloperator’scompartment
■ checksafetyprovisionsforoperationalconditiononfiresuppressionsystem
■ startupthemachineandcheckforcorrectoperationofE-stopbuttons.
■ checkthatallcoversandguardsareinplaceandsecure
■ checkthatalltagsandinstructionlabelsareinplaceandsecure
■ checkthatoperator’scanopy(optional)issecureandinplace
■ startthemachineandallowthehydraulicsystemtowarmupfor five(5)toten(10)minutes
■ checkhydraulicsystempressures(refertothehydraulicschematic suppliedforyourparticularmachineforpressuresettings)
■ checkandoperateallcontrolhandlesandremoteswitchestoensureallmachinefunctionsareoperatingproperlyandareinneutral position
■ checkthetensionoftheconveyorchainandcrawlerchain
E-stopbutton
Safetyfeatures NOTICE! Theoperatormustbecomefamiliarwithallthesafetyfeaturesand theirlocationonthemachinepriortoinstallationoroperation.
Safetyfeaturesinclude:(ReferenceFig.6)
Themachineisequippedwithane-stoplocatedontheoffside.Theestop(s)areusedtobreakthecontrolcircuitonlyinemergencysituations,stoppingallmotors.Strikingwithasmallamountofforcewillactuatethee-stop.
canopy/cab(optional)
firesuppression
firesprays
Themachinemaybeshippedfromthefactorywithaprotectivecanopy/ cab(optional).Ensurethatthecanopy/cabisinplaceandsecureatall timestoprotecttheoperatorfromfallingdebris.
Themachinemaybeequippedwithfiresuppression(remote)actuators.Ifequipped,thelocationmayvary.Thisparticularsuppression systemispneumaticallyactuatedandextinguisheswithdrychemicals. Toactuatethesystemfromtheactuators,pullthesafetypinandstrike downwardontheplunger.Immediatelyaftertheplungerisstruck,dry chemicalwillbedispensedthroughoutthemachine.Thefiresuppressionsystemmustbecompletelyrechargedwithdrychemicalsandexpellantsafterithasbeenactuated.
WARNING! Ifeitherofthefiresuppressionactuatorsisactuated,thesystem mustbecompletelyrechargedwithdrychemicalsandexpellants.
Watercanbedirectedtothefirespraynozzles manuallyfromthe firesprayvalveabove theswitchboxintheoperator'scompartment or bythefiresprayvalveonthelefthandside ofthemachine.
Onradiounits,anelectronicallyactuated solenoidisusedtoactuate thefirespraysystem fromtheremoteposition.
IMPORTANT! Thefiresprayvalvemustbemanuallysettothenormalposition beforethedustsuppressionwaterspraysystemcanbeoperated.
CAUTION! Theminesupplywaterpressureatthemachineshouldnotexceed500psiandshouldsupply20gpmminimumforcooling.
Theremotefiresprayactuatorlocatedonthe mainfeedbehindthe minerisusedtoactivate thefirespraywhenthereisafireand powerhas beenturnedoff. Simplyturningthevalveallows'pilot'oil to feedintothesmallhosesecuredwithinthevalve assemblyand throughthemainfeedlineintothe miner,whereitcontactsasolenoidthatactivatesthefirespraysystem.
TheContinuousMinermaybeequippedwithanoptionaldustsuppressionpackage(scrubber).ThedustsuppressorallowstheMineroperatortousefaninducedventilationattheface.Thefansuctiondrawsin thedustandliberatedmethanefromtheintakeduct(s).Thedustladen airisthendrawnthroughthescrubberscreen,whichisconstantly floodedwithwaterspray.Thedirtywateristhenremovedfromtheair streambyade-misterwhichislocateddirectlybehindthescrubber screen.Thedirtywaterflowsdowntoasumptankwhereawaterpoweredjetpumpemptiesthesumpanddumpsthedirtywaterontothe conveyor.Theclean,dryairexitsthede-misterandisdischargedinto themineatmosphereattherearoftheminer,diffuseddownwardand towardstheribtopreventcoalfinesfrombeingblownontheoffside shuttlecaroperator.
Themachineisequippedwithguardsandcoverstoreducethepossibilityofpersonnelcomingincontactwithrotatingormovingparts.All guardsandcoversmustbeinstalledandsecurelyfastenedduringoperation.
DANGER! Donotoperatethemachinewithanyoftheguardsorcoversremoved.Youorotherpersonnelcouldbeseriouslyinjuredfrom movingorrotatingparts.
Therearetwocutterboomsafetysupports,oneoneachsideofthe cutterboom.Thesupportsareusedtoblockupthecutterboomduring maintenanceoperations.
Therearetwoconveyorsafetysupports,oneoneachsideoftheconveyor.Thesupportsareusedtoblockuptheconveyorduringmaintenanceoperations.
Everyswitchontheoperator’scontrollercasethatengagesafunction (pumpstart,cutterstart,etc.)isprotectedfromaccidentalactivationby acover.
Themachineisequippedwithamethanemonitorthatdetectsthepresenceofmethaneinthemineatmosphere.Whentheminerisbeing poweredup,themonitorlooksformethanebeforeanyotherfunctionis energized.Ifthemethanemonitordetectsalevelofmethanewithina presettolerance,themethanemonitorrelaywillcloseandpowerwillbe suppliedtotheotherfunctionsonthemachine.
Fig.6:SafetyfeaturesontheContinuousMiner
Methanemonitor display
Manualcircuit breakerreset (optional)(location
Emergencystop (locationtypical)
Fig.6(continued):SafetyfeaturesontheContinuousMiner
Cutterboom safetysupport(2)
Conveyorsafety support(2)
Operator’s station
Fig.7:OverviewoftheContinuousMiner
Cutterboom
Conveyorboom
Crawler assembly
Gathering headassem-
Scrubberintake
Operation Thischaptercontainsimportantinformationontheoperationandmaintenanceofthemachine.Italsoincludesinstructionsonthereplacementofwearparts.
Readthischaptercarefullyandthoroughly.Inparticular,observethe safetyinstructionsinchapter2“Yoursafety”.
Howtooperatethecontinuousminer DANGER! Incorrectoperationendangersyourselfandothers!Incorrectoperationofthemachineisoftenthecauseofveryseriousaccidents!Operatetheunitonlywhenyouhavebeensufficiently trainedonthemachineandhavereadandunderstoodthisoperatingmanual.Shouldanythingbeunclear,pleasecontactyourimmediatesupervisor.
Whoisallowedtooperatethecontinuousminer? TheContinuousMinerisonlyallowedtobeoperatedbypersonswith adequateknowledgeofthecompletemachine.
Thisalsoincludes:
■ whatsafetydevicesareinstalledonthemachine.
■ wherethesesafetydevicesarelocated.
■ howthesesafetydevicesaretobeoperated.
Whencanoperationbestarted? Operationmustnotbestarteduntilthesafeconditionandproperfunctionofthecompletemachinehasbeencheckedandthedailymaintenanceoperationshavebeencarriedout.
NOTICE! Beforebeginningcuttingoperations,carefullyunloadthetrailing cableprovidingenoughslackandplacingitwhereitallowsadequateclearanceforsafemaneuverabilityoftheminer.
TheBucyrus25M3ContinuousMinerisanelectricallypowered,drum type,radioremotecontrolledminer.
TheMinerismountedoncrawlertracksthatprovidefullmobilityanda sharpturningradiusinbothroomandpillarandlongwalldevelopment miningplans.Therangingcutterheadminesmaterialfromthesolid faceusingachainlessrotatingdrum,andaCLA-typegatheringhead withhighspeedconveyorefficientlymovesminedmaterialtoahaulage systembehindtheMiner.
Machinedescription Cutterboom The cutterboomconsistsofaboomframe,twoelectricmotors,twocutter headgear cases(drumdrives)andcutterhead.Thecutterheadconsists ofthreedrums(left,center,andright).
Gatheringhead Thegatheringheadconsistsofthepanframe,electricmotors,continuous loadingarms(CLAs),andCLAgear cases(pots).
Conveyorboom Theconveyorboomconsistsofamainsectionandatailsection.The conveyoristhecenteroftheMineranddeliversmaterialfromthefront tothe rearoftheminerviaaconveyorwithaconveyor chain.Two hydrauliccylindersraiseandlowertheconveyorboom duringoperationandathirdhydrauliccylinder,locatedonthesideoftheconveyor, isusedtopivottheconveyortailsectionineitherdirection.
Tramming TheMineristrammedbytwoelectrically-drivencrawlers,onelocated oneachsideofthemachine.Thecompletecrawlerdriveassemblies arehousedincrawlerframeswhichenclose,guide,andsupportthe tramcomponents.Eachtramdriveisindependentlycontrolledbythe operatorformovingtheminerforwardandbackwardandformaking turns.
Hydrauliccomponents Anelectricmotorisdirectlycoupledtothehydraulicpumpwhichdirects hydraulic pressuretovariousvalveslocatedthroughoutthemachine.The hydraulicpumpisa two-sectiongearpumpconsistingofasection dedicatedtohydrauliccylindermovementaswellasasectionforpilot controls.
Electricalequipment The25M3ContinuousMinerisa950volt,3phasemachine.Theelectricalequipmentincludesall switches,cables,andelectricalenclosures locatedatvariousplacesontheminer.
Watersystem Allmotorsandthetractionelectricalcasearecooledwithwaterwhich issuppliedto theminerthroughahose.Thewatersupplymustbecapableofproviding30gpmat250 psiatalltimes.Themachineis equippedwithhydraulicallypilotedwatervalvesthat turnonautomaticallywiththecuttermotors,toallowcoolwatertoflowtoall components.Uponexitingthecuttermotors,thewaterisdischarged ontheface throughtheheaddustspraymanifolds.Thewatersupplyis splitequallytotheleftand rightsideofthemachine.Ifthecuttermotorsarenotrunning,thefulldustsprayscan beturnedonmanually. Thedustsuppressionsystemmustbefully functionalatalltimestoproperlycoolmotorsandtractiondrives.
Controlsandindicators Operator’sstation AContinuousMineristypicallyradioremotecontrolled.Manualoperationisnotallowedforproductionoperationunlesstheminerhasan operator’spitandcanopy.Manualoperationisgenerallyfortroubleshootingandmaintenanceunderroofsupport.
WARNING! TheContinuousMineristypicallyradioremotecontrolled.Manual operationisnotallowedforproductionoperationunlesstheminer hasanoperator’spitandcanopy.Manualoperationisgenerally fortroubleshootingandmaintenanceunderroofsupport.OperatingtheContinuousMinermanuallyfromtheOperator’scasemay resultinseriousinjuryordeath.
Theprimarycontrolsforthemachinearenormallylocatedattheoperator’scase(Fig.8)ontherighthandsideofthemachineneartherear bumper,orintheoptionaloperator’scompartment.
Theexplosionproofoperator’scasehousesthecontrolsandindicators usedinthenormaloperationofthemachine.Mountedinsidethecase arethemaincircuitbreaker,auxiliarycircuitbreaker,controltransformer,methanemonitorrelay,electricalmeteringpackage,control breakers,headlightswitch,radio/manualswitches,manualstart/stop switches,andbridgerectifiers.Allcontrolbreakersarelocatedwithin thiscase,behindthesmallaccesscoverlocatedabovethetrailingcableentrance.Thetrailingcableentersintothisenclosureatthebottom leftcornerfacingthecase.Thepanicbarismountedontheenclosure andoperatesthepumpstopswitchtoshutthemachinedown.
Fig.8:Operator’scase
tramcontrollevers
Thetramcontrollevers(Fig.9)controlthespeedanddirectionofeach (leftandright)crawlerdrive.Thetramcontrolleverscanbeusedtogether(totramstraightforwardorstraightbackwards),inoppositedirections(forfastturns),orindividually(forslowturns).Wheninmanual mode,the“TRAMDEADMAN”switchmustbedepressedandthetram controlleversinthecenter(neutral)position,priortostartingthepump ortrammotors.
NOTICE! TheContinuousMinerhasskidtypesteering:itiscapableofturningwithinitsownlimits.
IMPORTANT! MANUALONLY:TheContinuousMiner’stramandsteeringspeed isvariable.ThismeansthatthefartherthetramhandleisactuatedthefastertheContinuousMinerwilltravelorturn.
IMPORTANT! Oncethetram/steeringcontrolleverisreleasedbytheoperator thecontrolleverautomaticallyreturnstothecentered(neutral) position.
Totramforward,pushthetramleverforward,awayfromtheoperator. Totraminreverse,pulltheleverback,towardtheoperator.Thefurthertheleverispushedorpulled,thefasterthetramming.Whenreleased,thetramleverreturnstothecentered(neutral)position.
Totramstraightforward,pushbothleversforwardatthesametime. Totramstraightback,pullbothleversbackatthesametime.
Toturnleft,pulltheleftcrawlerleverbackandpushtherightcrawler leverforward.Toturnright,pushtheleftcrawlerleverforwardandpull therightcrawlerleverback.Thespeedoftheturnisdeterminedby whethertheleversareoperatedatthesametimeorseparately.
Fig.9:Tramcontrollevers Pressingthepanicbar(Fig.10)willshutdownthepump,causingthe minertoshutdown.Torestartthemachineafterstrikingthepanicbar, follownormalpumpstartupprocedure(seeStartprocedureinthis chapter).
Electricalswitches Theelectricalswitches(Fig.11)thatcontrolthemachineoperationare agroupofpushbuttonswitcheslocatedonthecontrolcase.
WARNING! ManualoperationoftheContinuousMinerisnotallowedforproductionoperationunlesstheminerhasanoperator’spitandcanopy.Manualoperationisgenerallyfortroubleshootingandmaintenanceunderroofsupport.OperatingtheContinuousMiner manuallyfromtheoperator’sstationmayresultinseriousinjury ordeath.
The“PUMPSTART”switchstartsthepumpmotor.Tostartthemotor, depresstheswitch.
The“PUMPSTOP”switchstopsthepumpmotor.Tostopthemotor, depresstheswitch.
Startingthecuttermotorisatwo-handstart:pushthe“PUMPSTART” andthe“CUTTERSTART”switchatthesametime.Theleftcuttermotorwillstartfirstand,afterapresettime,therightcuttermotorwillstart.
The“CUTTERSTOP”switchshutsdownbothcuttermotors.Bothmotorsstopwhenthe“CUTTERSTOP”switchisdepressed.
Fig.10:Panicbar
Panicbar
Theconveyormotorscannotbestarteduntilthepumpmotorisstarted. Depressingthe“CONVEYORFWD”switchstartstheconveyormotors. Theforwarddirectionoftheconveyorchainisalwaysawayfromthe cutterhead.
Theconveyormotorscannotbestarteduntilthepumpmotorisstarted. Depressandholdthe“CONVEYORREV”switchtostarttheconveyor motors.Whentheconveyormotorsarerunninginreverse,theconveyorchainismovinginthedirectionofthecutterhead.Theconveyor willcontinuetoruninreverseuntilthe“CONVEYORREV”switchis released.Theconveyorcannotbestartedintheforwarddirectionuntil apresetamountoftimehaselapsedfromrunningtheconveyorinreverse.
Depressingthe“CONVEYORSTOP”switchwillstoptheconveyormotorswhentheconveyorisrunningforward(awayfromthecutterhead).
Thepumpmotormustberunningbeforethescrubbermotorwillstart. Depressandholdthe“SCRUBBER”switchtostartthescrubbermotors andtoenergizethescreensprays.Tostopthescrubbermotor,release the‘SCRUBBER”switch.
The“TRAMDEADMAN”switchmustbedepressedandheldtotram. Releasingthe“TRAMDEADMAN”switchwillstoptrammingfunctions.
The“LIGHTS”switchhasthreepositions:“MANUAL”,“OFF”,AND “RADIO”.The“OFF”positionturnsalllights,arealightsandheadlights, off.Whenthelightswitchisturnedtothe“MANUAL”position,the headlightsandthearealightswillbothturnon.whenthelightswitchis turnedtothe“RADIO”position,thearealightsareilluminatedandthe headlightscanbeturnedonandoffwiththeradioremote.
The“RADIO/MANUALSW.1”switchputsthemachineundermanualor radiocontrol.
The“RADIO/MANUALSW.2”switchconnectsmotorcontroltothe manualpushbuttonsandisolatescontrolfromtheradioreceiver.Inthe radioposition,“RADIO/MANUALSW.2”isolatesthepushbuttonsand connectsmotorcontroltotheradioreceiver.
Thecontrolbreakerswitchesturnthebreakersonandoffandarealso usedtoresetabreakerthathastripped.Allcontrolbreakersareturned onbypushingthebuttoninandareturnedoffbypullingthebuttonout. Ifabreakertrips,thebuttonmustbepulledouttoresetthebreaker, thenpushedintoturniton.Thecontrolbreakersmayvaryandcanbe identifiedbythelabelsonthefrontoftheoperator’scase. “CONVEYORREV”
Fig.11:Electricalcontrolswitch(s)
“PUMPSTART” (shownwithsafety coverinplace)
“CUTTERSTART” (shownwithsafety coverinplace)
“CONVEYORFWD” (shownwithsafety coverinplace)
“SCRUBBER” (shownwithsafety coverinplace)
“PUMP STOP”
circuit breaker resetpanel
“CUTTER STOP”
“CONVEYOR STOP”
“CONVEYORREV”
“LIGHTS”
“RADIO/MANUALSW.2”
“TRAMDEADMAN”
“RADIO/MANUALSW.1”
“LEFTCUTTERMOTOR” and
Electricalmeteringpackage(optional)
Theoptionalelectricalmeteringpackage(Fig.12)consistsofagroupof metersthatmonitorcurrentdrawonthemotors,machinevoltage,and cutterandconveyorhoursofoperation.
The“LEFTCUTTERMOTOR”and“RIGHTCUTTERMOTOR”ammetersmonitorthecurrentdrawbythecuttermotors.Duringnormaloperation,thetwometersshouldindicateapproximatelythesamecurrent draw.Ifonemeterconsistentlyreadshigherthantheothermeter,shutdownthemachine(seeShutdownprocedureinthischapter)andcontactMaintenance.
The“LEFTCONVEYORMOTOR”and“RIGHTCONVEYORMOTOR” ammetersmonitorthecurrentdrawbytheconveyormotors.During normaloperation,thetwometersshouldindicateapproximatelythe samecurrentdraw.Ifonemeterconsistentlyreadshigherthanthe othermeter,shutdownthemachine(seeShutdownprocedureinthis chapter)andcontactMaintenance.
The“MACHINEVOLTAGE”voltmeterindicatesthecontrolcircuitvoltage.Duringnormaloperation,theindicatorshouldstaybetween855 and1,045volts(950V±10%).Shouldthemeterindicatehighorlow voltage,shutdownthemachine(seeShutdownprocedureinthischapter)andcontactMaintenance.
The“CUTTERHOURS”meterindicatesthehoursofrunningtimefor thecutterheadmotors.
The“CONVEYORHOURS”meterindicatesthehoursofrunningtime fortheconveyormotors.
Fig.12:Electricalmeteringpackage(optional)
“LEFTCUTTER MOTOR”ammeter “LEFTCONVEYOR MOTOR”ammeter
MOTOR”ammeter
HOURS”meter
Fig.13:“LOWOIL”light(optional) “LOWOIL”light(optional)
Theoptional“LOWOIL”light(Fig.13)illuminateswhenthehydraulic oillevelinthemachineislow.Ifthe“LOWOIL”lightcomeson,shutdownthemachine(seeShutdownprocedureinthischapter)andcheck thehydraulicoillevel.Ifoilisneeded,addoil(seeprocedureinMaintenancesectionofthischapter).
Gaugepanel(optional)
Theoptionalgaugepanel(Fig.14)consistsofgaugesusedtomonitor waterandhydraulicpressurethroughouttheminer.
The“PILOTCIRCUITPRESSURE”gaugeisusedtomonitorthesupplypressureforallpilotfunctions.Duringnormaloperations,thegauge shouldreadapproximately600psi(±50psi).Ifthegaugereadingis higherthanthisrange,thereliefvalveonthepilotpumpoutletshould beadjustedtosetthepressurebacktoitsnormaloperatingrange.
The“MCVPILOTPRESSURE”gaugeisusedtomonitorthelowpilot pressureatthe Main Control Valvebank.ThepurposeoftheMCVpilotpressureistoprovidethenecessaryforcetoshiftthecontrolvalves whenthesolenoidsareenergized.Duringnormaloperations,the gaugeshouldread350psi(±50psi).WhentheMCVpilotpressure becomestoolow,themachineoperationswillbecome“sluggish”.this istypicallyanindicationofacloggedpilotfilterandthefiltershouldbe changed.
The“ACCUMULATORPRESSURE”gaugeisusedtomonitoraccumulatorpressure.Thepurposeoftheaccumulatoristostorethenecessarypilotpressuretoallowremoteoperationofthefiresuppression andbreakeron/offcontrolvalveswhenthepumpisnotoperational. Theaccumulatorpressureshouldcloselytrackthepilotcircuitpressure.Ifthe“ACCUMULATORPRESSURE”gaugedropsbelow450 psi,shutdownthemachine(seeShutdownprocedureinthischapter) andcallmaintenance.Iftheaccumulatordoesnotholdpressurewhen thepumpisshutdown,callmaintenance.
“LOWOIL”
“GHFLOATPRESSURE” (gatheringhead)
The“GHFLOATPRESSURE”gaugemonitorsthepressureoftheextendportofthegatheringheadfloatcylinders.Thispressuregauge displaysdifferentreadingsdependingontheoperationconditionofthe cylinders:
■ Withthegatheringheadworkingsectionofthemaincontrolvalvein theGatheringHeadUp(GHU)positionandthecylinderfullyextended,thegaugewilldisplaythesettingofthereliefvalve“CR”.
■ Withthegatheringheadworkingsectionofthemaincontrolvalvein theGatheringHeadFloat(GHD/F)position,thegaugecanbeused toadjustthepressureinthegatheringheadfloatcounterbalance valve“VR”.
■ Withthegatheringheadworkingsectionofthemaincontrolvalvein thecenterposition,thegaugedisplaysthepilotpressureatthe valvemanifold.
■ Thegaugewillalsodisplayhighpressuresseenbythegathering headcylindersduringnormaloperation.
The“MINEWATERPRESSURE”gaugemonitorsthepressureofthe supplywatercomingintothewatersystemfromthemine.The“MINE WATERPRESSURE”hastobeataminimumof250psiunderdynamicconditions.Thispressureshouldnotexceed500psi.Ifthe pressureexceeds500psi,immediatelyadjustthesupplywaterpressureorshutdownthemachine(seeShutdownprocedureinthischapter).
The“MINERWATERPRESSURE”gaugemonitorsthepressureatthe maindistributionmanifoldforthewatersystemontheminer.The “MINERWATERPRESSURE”shouldbeataminimumof250psi. whenthedifferencebetweenthe“MINEWATERPRESSURE”andthe “MINERWATERPRESSURE”gaugesisgreaterthan75psi,itisan indicationthatthestrainerand/orfilterneedchanged.Ifthe“MINER WATERPRESSURE”gaugereadsbelow250psi,shutdownthemachine(seeShutdownprocedureinthischapter)andcallmaintenance.
The“LHHEADSPRAYPRESSURE”and“RHHEADSPRAYPRESSURE”gaugesmonitorthewaterpressureatthelefthandandright handcutterheadspraymanifoldsinthedustsuppressionsystem.The gaugereadingsaredependentontheindividualminerequirements. ConsulttheschematicintheBucyrusAmerica,Inc.partsmanualsuppliedwithyourmachine.
centermanifold,leftandright
“PILOTCIRCUIT PRESSURE”
“MINEWATER PRESSURE”
“LHHEAD SPRAY PRESSURE”
“ACCUMULATOR PRESSURE”
“MCVPILOT PRESSURE”
“MINERWATER PRESSURE”
“RHHEAD SPRAY PRESSURE”
“GHFLOAT PRESSURE”
Thecentermanifoldcutterheadspraygauges(Fig.15)arelocatedto therightofthepressuregaugepanel.Thesecutterheadspraygauges monitorthewaterpressureofthedustsuppressionsprayattheright andleftnozzlesonthesplitcentermanifold.Thegaugereadingsare dependentontheindividualminerequirements.Consulttheschematic intheBucyrusAmerica,Inc.partsmanualsuppliedwithyourmachine.
Fig.15:Cutterheadspraycentermanifoldgauges
Fig.14:Gaugepanel
cutterheadspray
Cutterheadspraycentermanifold,left
Cutterheadspraycentermanifold,right
circuitbreaker
manualcircuitbreakerreset (optional)
Thecircuitbreakeristhemaincircuitbreakerforthemachine.The circuitbreakerhastwo(2)positions:"OFF,"tode-energizethemachine'selectricalsystemsand"ON,"fornormaloperation.Thecircuit breakershouldbeinthe"OFF"positionbeforethemachineisserviced orshutdown.
WARNING!
Themachinecircuitbreakerde-energizestheelectricalcontroller andmotors.However,electricalpowerisstillpresentinsidethe connectionboxtothecircuitbreaker.Ifthecircuitbreakerinside theconnectionboxrequiresservice,thetrailingcableshouldbe disconnectedfromthepowercenter.
Themanualcircuitbreakerresetlevers(Fig.16)arelocatedbelowthe electricalswitchesattheoperator’scontrolstation.Thecircuitbreaker tripswhentheelectricalsystemisoverloadedorshorted.
WARNING!
Oncethebreakerhastripped,itwillnotstayinthe“ON”position withoutfirstbeingmovedtothe"RESET"position,andthento "ON".
Toresetthecircuitbreakermanuallyproceedasfollows:
Movetheselectorto“RESET”positionandmovethecircuit breakertofull“OFF”position.
Movetheselectortothe“ON”positionfornormaloperation.
Fig.16:Manualcircuitbreakerreset
firesuppressionactuator (optional)
Thefiresuppressionactuator(optional)(Fig.17)isusedtoactivatethe firesuppressionsystemonthemachine.Thefiresuppressionsystem ispneumaticallyactuatedandextinguisheswithdrychemicals.Toactuatethesystem,pullthesafetypinandstrikedownwardonthe plunger.Immediatelyaftertheplungerisstruck,drychemicalwillbe dispensedthroughoutthemachine.Thefiresuppressionsystemmust becompletelyrechargedwithdrychemicalsandexpellantsafterithas beenactuated.
WARNING! Ifeitherofthefiresuppressionactuatorareactuated,thesystem mustbecompletelyrechargedwithdrychemicalsandexpellants.
Fig.17:Firesuppressionactuator(typical)
CO2cartridge (bomb)
Plunger Pin
emergencystop
methanemonitor(typical)
TheContinuousMinerisequippedwithanemergencystopbutton(Fig. 18)locatedoffthesideofthemachine.Theemergencystopbuttonis usedtobreakthecontrolcircuitinemergencysituations,stoppingall motors.Strikingwithasmallamountofforcewillactuatetheemergencystop.
WARNING!
BepreparedforasuddenstopwhentheE-stopisactuatedduringnormaltrammingofthemachine.
Fig.18:Emergencystop
Emergencystop (locationtypical)
Themethanemonitorconsistsofthreeparts - thereadoutmodule(Fig. 19)locatedinthebackbumper;thepowersupply,locatedinsidethe controllerintheoperator'scase;andthesensor("sniffer")locatedon thefrontofthemachine.Anytimetheminerisshutdownandrestarted, themethanemonitorwillautomaticallyreset(ifequippedwithautomatic resetmonitors).Duringoperation,thesensorconstantlymonitorsthe airforthepresenceofmethane.
Fortypicalapplications,whengasconcentrationexceeds1%,theamberlightfor“LowAlarm”willcomeon.Ifgasbuild-upcontinuestothe 2%level,thered“HighAlarm”lightwillcomeonandtheminerwill automaticallybeshutdown.Torestartthemachine,thegasconcentrationmustbebelow2%andthemonitorresetbypushingthe"RESET" buttonlocatedonthereadoutmodule(manualresetmodels).For monitorsequippedwithautomaticresetmonitors,themonitorwillbe resetwhentheminerisrestarted.Shouldhighgaslevelspersist,shutdowntheminerandcorrectventilationbeforeattemptingtocontinue.
NOTE:Thisinformationisprovidedasgeneralinformationonmethane monitoring.Alwaysrefertothemethanemonitordocumentationfor yourmachineandthemineventilationplan.
Fig.19:Methanemonitordisplay(typical)
Methanemonitor display
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operator’scompartment (optional)
Theoptionaloperator’scompartmentcontainsthecontrolslistedinthis sectionfortheoperator’sstationalongwithaseat,adjustablecanopy anddroppit.Allnecessarycontrolsandindicatorstooperatetheminer arewithintheoperator’sreach.Thisincludesemergencyswitchesand allsafetyfeaturessuchasthefiresprays,dustspraysandmethane monitor.
Whenoperatedbyaradio(Fig.20),aportablewirelesstransmitter withauniquecodefeaturesendsradiocommandstoareceiverinthe switchconsoleviaawhipantennasetup.Thesmallwhipantennae intercepttheradiosignalswhichthereceivertranslatesintoelectrical commandstovariouselectricalcircuitstoperformthefunctionselected.Thesecircuitsenergizesolenoidswhichactuatepilot-valves, switches,orrelayscontrollingaspecificmechanical,hydraulic,orelectricalfunction.
Thereareeightselectablefrequencieswhichpermitseachoperatorto activateonlyhisdesignatedminer,allowingseveralremote-controlled minerstooperateinthesameareawithoutgettingtheirradiosignals crossed.Inaddition,animproperlydecodedradiosignalwillautomaticallyshutdowntheminer.
Alwaysrefertothespecificradioremotecontroloperationmanualsuppliedwithyourspecificmachinefordetailsandoptionsontheradio remotecontrol.
IMPORTANT! Refertotheradioremotecontroloperationmanualsuppliedwith yourmachineforinformationregardingtheoperationofyourspecificremotecontrol.
Fig.20:Radioremotecontrol(typical)
tramcaseammeters Theammetersmountedinthetramcase(Fig.21)areforuseduring maintenanceandtroubleshooting.
Fig.21:Tramcaseammeters
Meterdisplays (optional)
Redzone Remotecontrolledcontinuousminers
Theremotecontrolofminersintroducescertainpotentialsafetyhazards whichthemineroperatormustwatchforandbeawareof.Whilethe operatorisnowfreetopositionhimselfforconvenientvisibilityofmining operationsattheface,hecaneasilyexposehimselftothedangerof beingnearmobileheavyequipment.
Mostsignificantly,theoperator’sgreatestdangerisfromhisContinuous Miner,especiallywhenheismaneuveringitduringminingoperations. Themineriscapableofslewingwhenturning,especiallywhenthe crawlersaresplit.Thedischargeconveyorcanalsoswing.Ineachof thesecases,themineroperatorisindangerofbeinghit,orworseyet, runoverbyhisownmachine.Equallydangerousisthepossibilityof theoperatorbeingpinnedagainsttheribbyhisownminer.
Mineroperatordangerareas,orRedzones Sometypicalsituationsdangeroustothemineroperatorareillustrated onthefollowingpages.Thedangerarea,orredzone(Fig.22)isindicatedbyalternatingredandwhitediagonalstripes.
Fig.22:Redzone
Trammingtheminer (Fig.23)fromoneplacetoanother,especially maneuveringaroundintersections.Thisillustratesthattheoperator shouldnotplacehimselfbetweenhisminerandtherib.
Beginningthefirstsump (Fig.23)inanewcut.Theminerisagainst theleftribandthedischargeconveyorisswungtowardthecenterof theentryreadyforthehaulagecar.Theoperatormuststayclearofthe dischargeconveyorandtherearoftheminer.
Fig.23:Redzones Trammingtheminerredzone Beginning1stsumpredzone
Sumpinginthelefthandside ofthecut(Fig.24).Astheminerpenetratestheface,newunsupportedroofisbeingexposed,andtheoperatornowhasanadditionalconstrainttohismovements.Hemustalso stayclearofthehaulagevehicleattherearoftheminerasitapproachestheminerandwhileitisloading.
Repositioningtheminerfortherighthandcut (Fig.24).Because theminerisbackingoutandturninginclosequarters,theoperator muststaybehindtheminertobesafe.
Sumpingintherighthandcut (Fig.24).Again,theoperatormust stayawayfromthefacewherethenewly-exposedroofisunsupported, aswellasstayingclearofthehaulagevehiclewhileitapproachesand loads.
Sumpingonthelefthand sideredzone
Sumpingintherighthand cutredzone
Repositioningminerforright handcutredzone
Fig.24:Redzones
Crosscutredzones (Fig.25). Beginningandcompletingcrosscuts requiresalotofmaneuveringoftheminerandloadingthehaulagevehiclewhileatawkwardpositions.Crosscutsalsoresultinnewlyexposedunsupportedroof.Respectingareddangerzoneisimportant tooperatorsafetyintheseconditions.
Whentheminerbeginningarighthandcrosscutitisnearlyagainstthe opposite(lefthand)rib,whilethedischargeconveyorisswungtoits maximum45o rightpositionforloadingthehaulagevehicle.Hence,the entirerearofthemineristreatedasaredzone.Therearetwoother dangerareas.Ontherighthandside,theminerformsapinchpointat theribwhichmustbeavoided.Also,onthelefthandsideoftheminer, astheminerprogressesintotherib,asharp-angledfenderwillbe formedwhichwillbesusceptibletosloughingandfallingoff.Hence, thatribmustbeconsideredaredzone.
Theredzonesurroundstheminerasthedischargeconveyorisfreeto swingeitherwayandmoreunsupportedroofisexposedduringthefurtherdevelopmentoftherighthandcrosscut.
Beginningarighthand crosscutredzone
Righthandcrosscut development
Fig.25:Crosscutredzones
Pillaringredzones (Fig.26) Remotecontroloffersasignificantsafety advantageinpartialorcompleteremovalofthepillarsinretreatmining becauseitplacestheoperatorfurtherawayfrompotentialcollapsing roof.
Muchoftheareaaroundtheminermustbeconsideredaredzone, mostlybecauseofextensiveunsupportedroofandtheneedfortemporarysupportsunderweakenedroof.Withremotecontrol,theoperator canpositionhimselfsafelyawayfromtheminerwhilestillretaininga goodviewoftheminingcycle.
Aredzonearoundtheminerisnolongerapplicablewhenworkingin theoppositerighthandpillar,astheoperatorisnowexcludedfromthe entireworkingareabecauseoffailingroofconsiderations, evenwiththe existenceoftemporaryroofsupports
Whenmakinganadditionalendcutintothepillar,creatingafenderof coalbetweenthetwocuts,additionaltemporaryroofsupportsareinstalled.
Becauseofroofpressures,thefenderwilltendtosloughitsribsinthe processofeventuallycrushing.Hence,theoperatormuststayaway fromthisfenderaswellasavoidingtheentryandcrosscutareasas shown.
Fig.26:Pillaringredzones
Safetyprecautionsforundergroundoperation InadditiontotheprecedinginstructionsforoperatingtheContinuous Miner,observethefollowingspecialprecautionsaftertheContinuous Mineristakenunderground.
■ Communicationisakeyelementinmaintainingsafety.Exactinstructionsandwarningsshouldbegivento,andthoroughlyunderstoodbyeachworkman.Goodcommunicationsbetweentheentire crewmustbemaintainedthroughouttheshift.
■ Checktheconditionofthetrailingcablebeforeturningpoweronat thepowersource.
■ Thismachinemustbemaintainedinapermissiblecondition,followingallstateandfederallaws.
■ MakeavisualcheckoftheContinuousMinerbeforeenergizing. Lookforloosebolts,covers,lockingdevices,damagedparts,and crackedorbrokenlenses.Anypartofthemachinewhichdoesnot functionproperlyisahazard.Reportitimmediatelytoyourimmediatesupervisorortheirdesignee.
■ Priortooperation,makesuretheworkingareaissafe.Makeavisualinspectionofroofandribsandtakeallstepsnecessarytoinsuresafety.
Trammingsafetyrules ■ CommunicateyourintentionstotheworkmenaffectedbythemovementoftheContinuousMiner.
■ Checkthepositionofthewaterhoseandtrailingcabletobe sure thereissufficientslacktofinishtheoperation.
■ Notetheconditionoftheroadwaysandphysicalsurroundingsof theroute.
■ Positionthecutterandgatheringheadfortramming.
■ Positionthestabilizershoeandboomsfortramming.
■ Positionyourbodycompletelyinsidetheoperator'scompartment (optional),facingtheintendeddirectionoftravel.
■ PositiontheContinuousMinerinthecenteroftheroadwaytoallow maximumsafeclearance.Consistentlymaintainclearance,which iscriticaltothesafemovementoftheContinuousMiner.
Startingprocedure WARNING!
Failuretoreadandunderstandalloperatinginstructionsbefore startingtheContinuousMinercouldresultinseriousinjuryor deathtotheoperatororpersonsaroundthemachineorcause damagetothemachine.
WARNING!
Readallinstructionscarefullybeforeattemptingtostartoroperatemachine.
WARNING!
UnderstandthefunctionsofallcontrolsbeforestartingtheContinuousMiner.Readandfollowtheinstructionsonallwarning tagsonthemachine,observeallregulationsandsafetyprecautions.
WARNING!
NeveroperateaContinuousMinerwhichhasbeendamagedoris notoperatingproperly.AnypartoftheContinuousMinerwhich doesnotfunctionproperlycanbeahazard.Reportitimmediately toyoursupervisorortheirdesignee.
WARNING!
BeforestartingtheContinuousMiner,makesurethatnooneisin theredzone(Fig.22throughFig.26).
NOTICE!
Inextremelycoldweather,allowmotorsandgearcasestoidle. Thiswillwarmthehydraulicoilsandlubricants.Stilloilsand greasescouldimmobilizethemachine.
IMPORTANT! Apump“growl”meansnotenoughoilisreachingthepumps throughthesuctionlines.Ensurethepumpgetsprimedbefore continuingoperation.Alwayschecktheoillevel.
DANGER! Improperpositioncouldresultininjuryordeathtotheoperator bycrushinghimagainsttheriborroofsupports.Itmayalso causehimtorunoverthetrailingcableordislodgetheroofsupports.
WARNING!
Turningonthewatersprayspriortocuttingpreventstheaccumulationofdustandthegenerationofexcessiveheatwhichcould causeanignitionorexplosion.
Afterreadingthepreviousdescriptionsandlocatingeachcontrol,the operatorisreadytooperatetheContinuousMiner.Anexperienced operatorshouldmonitoranewoperator’sindoctrinationtothestarting procedure.
TheContinuousMineristypicallyoperatedbyradioremotecontrol. Manualoperationisnotallowedforproductionoperationunlessthe minerhasanoperator’spitandcanopy.Manualoperationgenerallyis fortroubleshootingandmaintenanceunderroofsupport.
WARNING!
TheContinuousMineristypicallyoperatedbyradioremotecontrol.Manualoperationisnotallowedforproductionoperation unlesstheminerhasanoperator’spitandcanopy.Manualoperationgenerallyisfortroubleshootingandmaintenanceunderroof support.
Theoperatingprocedureslistedinthefollowingsectionsareforradio operation.
IMPORTANT!
Beforestart-up,checkthatdailymaintenancehasbeenperformed onthemachine.
WARNING!
Visuallycheckforotherpersonnelandverballyshoutawarning beforestartingthismachine.Makesureallpersonnelarecompletelyclearofthemachineandit’scomponentsandcheckthat anyloosematerial,tools,oilcansorotherobjectsareclearfrom theareabeforestartingthemachine.
Turnthemaincircuitbreakertothe“ON”position.
Select“RADIO”onthe“RADIO/MANUALSW.1”and“RADIO/ MANUALSW.2”ontheoperator’scaseontheminer.
Turnthepowerswitchonradiotransmittertotheonposition.
Press“SHIFT”andwait1/4second.
Whilepressing“SHIFT”,press“PUMPON”.Holdbothkeysinuntil thepumpstarts.
Releasethe“PUMPON”key.
IMPORTANT!
The“PUMPON”keymustbereleasedbefore“SHIFT”.If“SHIFT” isreleasedfirst,thepumpmotorwillshutoff.
Releasethe“SHIFT”key.
Shutdownprocedure TheContinuousMinermustbeproperlyshutdownbeforeleavingthe areaorbeforeperforminganymaintenanceorservice.Somemaintenanceorserviceproceduresmayrequireadditionalstepstoinsurethe safetyofthemaintenancepersonnelworkingonoraroundthemachine andwillbelistedinthemaintenancesectionofthisguide.
Backthemineraboutonefootfromthefaceprovidingsufficient clearanceandshutoffthecutterheadmotors(seeCutteroperation inthissection).
Tramtheminertoanareaofwellsupportedroof.Parkthemachine initsdesignatedparkingareaoutoftraffic,onflat,solidground.Ifit isnotpossibletoparkthemachineonflatground,parkthemachine atarightangletotheslope.
WARNING! Afterturningoffthepowertothemachine,neverwalkawayand leavethetransmitterturnedon.Failuretoturnthetransmitteroff couldresultinanaccidentcausingseriousinjuryorlossoflife.
Emptytheconveyorandshutitoff(seeConveyoroperationinthis chapter).
Lowerthecutterheadtothefloor.
Lowertheconveyorandgatheringhead.
Pressandholdthe“PUMPOFF”key.Thepumpmotorshould shutdownimmediately.
Releasethe“PUMPOFF”key.
Turnoffthewatersprays.
PositionallleversandcontrolstoNeutralorOff.
Shutoffthemainpowersupply.
Shutofftheminewatersupply.
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