Cat Bucyrus Continuous Miner 30M-4NP Maintenance Manual - PDF DOWNLOAD

Maintenance Manual Bucyrus - Continuous Miner Model - 30M-4NP Doc. No.:

A6474X263

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

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

Internet: www.bucyrus.com

__________________________________________________________

This manual is intended to provide GENERAL product maintenance information for the Model 30M-4NP 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 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 maintenance manual intended for?................... 1.3 What is the purpose of this maintenance 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................................................................ 2.7 General rules: ................................................................. 2.7 Storage and transport ..................................................... 2.8 Pre-start inspection ......................................................... 2.8 Installation and start-up................................................... 2.9 Operation ........................................................................ 2.9 Stopping .........................................................................2.10 Maintenance and repair .................................................2.10 Overview of the safety instructions .....................................2.15 Chapter 3: Storage and transport ..................................2.15 Chapter 4: Installation ....................................................2.15 Chapter 5: Operation .....................................................2.16 Chapter 6: Technical data..............................................2.17

3. Storage and transport Storage and transport ............................................................ 3.3 Storage ................................................................................ 3.3 Storage of the machine and spare parts......................... 3.3 Transport.............................................................................. 3.4 Before transport .............................................................. 3.5

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

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Table of contents _________________________________________________ 5. Maintenance Maintenance ............................................................................ 5.3 Instructions on the maintenance.......................................... 5.4 Important notes ............................................................... 5.4 Before maintenance........................................................ 5.4 Lubrication and maintenance schedule .......................... 5.6 Lubrication chart ............................................................. 5.8 Specific lubrication and maintenance instructions ..............5.10 Every shift ......................................................................5.10 Every third shift ..............................................................5.10 Every twenty shifts .........................................................5.20 Every thirty shifts............................................................5.22 Every sixty shifts ............................................................5.24 Every three hundred sixty shifts.....................................5.28 As required.....................................................................5.29

Technical data ......................................................................... 6.3 Tightening torques ............................................................... 6.5 Permissible media...............................................................6.11

7. For your information For your information .............................................................. 7.3 Our service........................................................................... 7.3 Service address .............................................................. 7.3 Rebuild facility address ................................................... 7.4

_________________________________________________________________ Bucyrus – Model 30M-4NP Continuous Miner

© BUCYRUS AMERICA, INC.

6. Technical data

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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 maintenance manual machine type

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

This maintenance manual is intended for: Bucyrus – Model, 30M-4NP Serial No.: N/A and is only permitted to be used for equipment of this type.

© BUCYRUS AMERICA, INC.

new maintenance manual

The maintenance 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 maintenance manual immediately if the present manual is no longer complete or has become illegible.

Who is this maintenance manual intended for?

This maintenance 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 maintenance manual.

This includes persons who: ■ ■ ■ ■ ■ ■ ■ ■

are in charge of transport prepare the rise heading perform assembly / disassembly work operate the machine eliminate faults perform daily routine work on the face or in the entry perform maintenance work perform repair work

supervisory personnel who: ■ ■

initiate and/or supervise the activities just indicated.

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

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

Read this maintenance 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 maintenance 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.

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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.

© BUCYRUS AMERICA, INC.

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

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

Observe the safety and accident prevention regulations:

further maintenance manuals

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of the mine.

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of the Mines Inspector and

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of the mining supervisory authorities

Please read also the operating manuals of the components required for operation, e.g. of gearboxes, electric motors, 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.

You must have adequate knowledge of the ■

mechanics,

■

hydraulics and

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control engineering

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

Installation and repair work on: ■

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

■

the electrics (motors, controllers, etc.)

■

the hydraulics (controls, cylinders, etc.)

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

_________________________________________________________________ 2.4 Bucyrus – Model 30M-4NP Continuous Miner

© BUCYRUS AMERICA, INC.

and must be able to prove this knowledge.

_________________________________________ Operating conditions Operating conditions Intended use The continuous miner has been designed and manufactured purely for extracting coal.

Intended uses include: ■

the extracting of coal and conveying of mined material. To a haulage source

Unauthorized use

© BUCYRUS AMERICA, INC.

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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the extraction of any other mined material or stone

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

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© BUCYRUS AMERICA, INC.

Operating conditions __________________________________________

_________________________________________________________________ 2.6 Bucyrus – Model 30M-4NP Continuous Miner

___________________________________________ Safety instructions Safety instructions General rules: general

Always work with full concentration.

Familiarize yourself with your working environment.

noise emissions

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

© BUCYRUS AMERICA, INC.

Inform your colleagues of:

safety equipment

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your exact location.

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the work you are performing.

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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 (panic switch)

lock-out

cordon off working area moving parts

Observe the symbol plates on the machine.

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

Lock-out 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 e.g.: ■

conveyor chains

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pivot points

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cutter shafts

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boom assemblies

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crawler assemblies

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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.

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 the operation manual and this entire guide 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 area cab/canopy

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 area.

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

_________________________________________________________________ 2.8 Bucyrus – Model 30M-4NP Continuous Miner

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means of attachment

________________________________ Overview of 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

starting procedures hazard zone

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

Follow the starting procedure instructions in the operation manual.

Do not operate any levers, pedals or controls if anyone is in the hazard zone.

© BUCYRUS AMERICA, INC.

Operation training

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

before start-up

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

protective devices

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

operator’s area

Clean the operator’s area 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 to prevent the passengers from being thrown off 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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Safety instructions ____________________________________________ Stopping operator’s area

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

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.

Chock both crawlers in both directions whenever possible.

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

securing

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

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

Protect your work area against falling rocks.

replacing components

Disconnect 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

lifting

handling of hydraulic fluids

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.

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.

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© BUCYRUS AMERICA, INC.

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.

___________________________________________ Safety instructions maintenance, repair

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

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

Avoid, whenever possible, servicing or providing maintenance to the unit unless crawlers are chocked and boom supports are inplace to prevent booms from accidentally falling.

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.

© BUCYRUS AMERICA, INC.

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.

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

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

the hoses are not pinched or trapped.

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the hoses have no bubbles or blisters.

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

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the outer sheath of the hoses is not damaged.

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the connectors are securely inserted into the sockets.

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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.

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Safety instructions ____________________________________________ 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. permissible hoses

Use only hydraulic hoses approved for the prevailing pressures.

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

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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© BUCYRUS AMERICA, INC.

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

___________________________________________ Safety instructions laying hydraulic hoses

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

Always lay hydraulic hoses so they: ■

always have a little slack.

Fig. 1: Laying hydraulic hoses, slack Right

■

Wrong

are not twisted.

© BUCYRUS AMERICA, INC.

Fig. 2: Laying hydraulic hoses, twisting Right

■

Wrong

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

Fig. 3: Laying hydraulic hoses, bending Right

Wrong

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Safety instructions ____________________________________________ ■

always have a little slack.

Fig. 4: Laying hydraulic hoses, crossing Right

■ ■ ■ ■

Wrong

are not kinked. do not have to withstand tensile strains. are protected against thermal radiation. are accessible at all times.

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

torn out, kinked, crushed, driven over or twisted by movement of the machine.

Fig. 5: Laying hydraulic hoses, connections on moving parts Right

Wrong

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© BUCYRUS AMERICA, INC.

Push hydraulic hoses into the sockets only by hand. Never try to drive the hydraulic hoses in with a tool as this will damage the connections.

________________________________ Overview of safety instructions Overview of the safety instructions This is a summary of all the safety instructions which have to be observed in the following chapters. This summary is intended only to give you an overview of all the instructions. In some cases, there is no logical relationship between the individual instructions.

Chapter 3: Storage and transport Instructions on the storage of concentrates for hydraulic fluids can be found, if required, in chapter 6 in this operating manual.

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

© BUCYRUS AMERICA, INC.

Additional information on the dimensions and weights can be found in chapter 6 in this operating manual.

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.

Chapter 4: 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. 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 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 prestartup checks should be performed.

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

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Overview of safety instructions _________________________________ Chapter 5: Operation DANGER! Incorrect maintenance endangers yourself and others!

Incorrect maintenance of the machine is often the cause of very serious accidents!

Perform maintenance on the unit only when you have been sufficiently trained and have read and understood this maintenance manual.

Should anything be unclear, please contact your immediate supervisor.

WARNING! Do not move any 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.

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.

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© BUCYRUS AMERICA, INC.

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. Electrical shock and accidental machine movement can cause serious injuries or even death to you or the maintenance person.

________________________________ Overview of safety instructions Chapter 6: Technical data 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.

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.

© BUCYRUS AMERICA, INC.

NOTICE! When performing maintenance on the machine, all used oil and lubricants should be disposed of per your local EPA standards.

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© BUCYRUS AMERICA, INC.

Overview of safety instructions _________________________________

_________________________________________________________________ 2.18 Bucyrus – Model 30M-4NP 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.

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 hydraulically operated equipment is operated and all gear boxes, hydraulic oil tank, etc. are filled to their maximum fill point.

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. 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).

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

The mounting surfaces of hydraulic components must be protected against corrosion and sealed with blind plates. Protect the hydraulic plug connectors and the connectors of the electrical cables with the caps and plugs supplied.

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 hydraulic components must be completely filled with a corrosion inhibiting/frostproofing fluid such e.g. CV 50.

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.

The equipment must be stored in a well ventilated, dry room. Do not store outdoors.

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Storage and transport _________________________________________ 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.

random sample inspection

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

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

natural aging

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

HFA fluids

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

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

Dimensions

■

Weight

■

lifting points, etc.

Additional information on the dimensions and weights can be found in chapter 6 of this maintenance manual.

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.

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© BUCYRUS AMERICA, INC.

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

________________________________________ Storage and transport Fig. 6: Lifting points on the continuous miner sub-assemblies

Lifting lug (2 places)

Main frame

© BUCYRUS AMERICA, INC.

Lifting lug (2 places)

Lifting lug (2 places)

Rear bumper Wrap chains here if drums are not installed (both sides)

Lifting lug (2 places)

Lifting lug (2 places)

Cutter head

Gathering head

Lifting lug (2 places)

Lifting lug (2 places)

Conveyor

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Storage and transport _________________________________________ Before transport temperatures below freezing

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

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

electronic components

Electrical and electronic components must be removed for overseas transport or prolonged storage outdoors unless these components or the complete equipment is protected against harmful environmental influences by a suitable packaging.

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© 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.

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4

Installation

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__________________________________________________Installation

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

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

Work on: the safety components (pressure relief valves, fire extinguishing equipment etc.) the electrical equipment (control units, signaling devices, etc.)

And

© BUCYRUS AMERICA, INC.

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

No special tools are required to put the machine into service.

In addition, various items of auxiliary equipment and machines may be required at the point of installation.

These include i.e.: ■

hoists with adequate lifting capacity

■

means of attachment with adequate lifting capacity

■

unloading dock

■

jacks with adequate lifting capacity

______________________________________________________________ A6474X263 SVOT / 01 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

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.

© 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

_________________________________________________________________ 4.4 Bucyrus – Model 30M-4NP Continuous Miner

__________________________________________________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: ■

wash and clean the machine as much as possible utilizing the wash-down hose

■

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

■

visually inspect water system for plugged sprays, leaks or damage

■

visually inspect the dust collector screen for signs of damage or clean if required with the machine wash-down hose

■

ensure that all machine covers are in place and properly installed

■

check the full length of the trailing cable for damage

■

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

■

visually inspect all hydraulic hoses and electrical cables for damage

■

perform all daily maintenance procedures

■

operate all control valve handles and remote switches to ensure that they are free and are in the neutral position

■

check conveyor and gathering head area for any foreign objects and clear any material that may cause a jam

■

check tension of conveyor chain

■

check safety provisions for operational condition on fire suppression system

■

jog the conveyor to check for correct rotation of conveyor chain

■

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

■

check the operation of the remote start switches

______________________________________________________________ A6474X263 SVOT / 01 4.5

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

■

check hydraulic system pressures (see spare parts manual for proper hydraulic schematic)

© BUCYRUS AMERICA, INC.

■

_________________________________________________________________ 4.6 Bucyrus – Model 30M-4NP Continuous Miner

_______________________________________________________________

5

Maintenance

________________________________________________________________

________________________________________________________________

_________________________________________________________________

________________________________________________ Maintenance

Maintenance This chapter contains important information on the maintenance of the machine. Read this chapter carefully and thoroughly. In particular, observe the safety instructions in chapter 2 “Your safety”.

DANGER! Incorrect maintenance endangers yourself and others!

Incorrect maintenance of the machine is often the cause of very serious accidents!

Perform maintenance on the unit only when you have been sufficiently trained and have read and understood this maintenance manual.

Should anything be unclear, please contact your immediate supervisor.

© BUCYRUS AMERICA, INC.

Who is allowed to perform maintenance?

The continuous miner is only allowed to be maintained 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.

______________________________________________________________ A6474X263 SVOT / 01 5.3

Maintenance _________________________________________________ Instructions on the maintenance Maintenance at regular intervals increases the operational safety and prolongs the service life of the machine.

In particular, 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 maintenance 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 and the power should be disconnected at the main power source.

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. Electrical shock and accidental machine movement can cause serious injuries or even death to you or the maintenance person.

■

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

WARNING! Do not move any 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.

_________________________________________________________________ 5.4 Bucyrus – Model 30M-4NP Continuous Miner

© BUCYRUS AMERICA, INC.

Please observe the following:

________________________________________________ Maintenance ■

During maintenance or servicing, if either of the tram drives are to be run, the side that is to be run must be jacked clear of the ground and securely blocked.

■

Do not perform maintenance on any boom while there is a load resting on the hydraulic cylinder. Booms must have safety supports installed and/or securely blocked if maintenance is to be performed with either 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

© BUCYRUS AMERICA, INC.

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 can not 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.

______________________________________________________________ A6474X263 SVOT / 01 5.5

Maintenance _________________________________________________ Table 1: Lubrication and maintenance schedule Item

Description

Places

Lubricant Type

Every shift 1

Cutter head bitts

Inspect

Input cutting head gear case

2

ISO 220 EP gear oil

3

Main cutting head gear case

2

ISO 220 EP gear oil

4

Input gathering head gear case

2

ISO 220 EP gear oil

5

Main gathering head gear case

2

ISO 220 EP gear oil

6

Tram gear case

2

ISO 220 EP gear oil

7

Crawler idler roller

2

ISO 220 EP gear oil

8

Main hydraulic tank

1

ISO 68AW hydraulic oil

9

Cutting head pivot

2

EP2 multi-purpose grease

10

Gathering head pivot

2

EP2 multi-purpose grease

11

Conveyor raise pivot

2

EP2 multi-purpose grease

12

Conveyor swing pivot

8

EP2 multi-purpose grease

13

Stab shoe pivot pin

2

EP2 multi-purpose grease

14

Upper cutting head cylinder pin

2

EP2 multi-purpose grease

15

Lower cutting head cylinder pin

2

EP2 multi-purpose grease

16

Upper gathering head cylinder pin

2

EP2 multi-purpose grease

17

Lower gathering head cylinder pin

2

EP2 multi-purpose grease

18

Upper conveyor raise cylinder pin

2

EP2 multi-purpose grease

19

Lower conveyor raise cylinder pin

2

EP2 multi-purpose grease

20

Front conveyor swing cylinder pin

1

EP2 multi-purpose grease

21

Rear conveyor swing cylinder pin

1

EP2 multi-purpose grease

22

Upper stab shoe cylinder pin

2

EP2 multi-purpose grease

23

Lower stab shoe cylinder pin

2

EP2 multi-purpose grease

24

Crawler chain (Inspect)

2

Waste oil

25

Conveyor chain (Inspect)

1

Waste oil

26

Conveyor take-up shaft

2

EP2 multi-purpose grease

27

Fasteners (Nuts, bolts and screws)

Inspect

28 29

Electrical cables, conduits and glands Hydraulic/water hoses and connections

Inspect Inspect

30 31

Lighting (Inspect) Reflectors and warning tags

Inspect Inspect

32

E-stop switch (Check)

Inspect

_________________________________________________________________ 5.6 Bucyrus – Model 30M-4NP Continuous Miner

© BUCYRUS AMERICA, INC.

Every third shift 2

________________________________________________ Maintenance Table 1 (continued): Lubrication and maintenance schedule Item

Description Every twenty shifts

Places

Lubricant Type

33

Cutting head motor (s)

2

High temperature lithium complex grease

34

Gathering head motor (s)

2

High temperature lithium complex grease

35

Dust collector motor

1

High temperature lithium complex grease

36

pump motor

1

High temperature lithium complex grease

Every thirty shifts 37

Input cutting head gear case (Change)

2

ISO 220 EP gear oil

38

Main cutting head gear case (Change)

2

ISO 220 EP gear oil

© BUCYRUS AMERICA, INC.

Every sixty shifts 39

Input gathering head gear case (Change)

2

ISO 220 EP gear oil

40

Main gathering head gear case (Change)

2

ISO 220 EP gear oil

41

Input cutting head gear case (Sample)

2

42

Main cutting head gear case (Sample)

2

43

Input gathering head gear case (Sample)

2

44

Main gathering head gear case (Sample)

2

45

Tram gear case (Sample)

2

46

Crawler idler roller (Sample)

2

47

Main hydraulic tank (Sample)

1

Every three hundred sixty shifts 48

Tram gear case (Replace)

2

49

Crawler idler roller (Replace)

2

As required 50

Main hydraulic tank (Change)

1

51

Pilot filter (Change)

1

52

Pressure filter (Change)

1

53

Return filter (Change)

1

54

Breather (Hydraulic tank) (Change)

2

55

Strainer (Inspect)

1

56

Oil filter (Change)

1

57

Water filter Change)

1

58

Back flushing strainer (Inspect)

1

59

Jet pump (Inspect)

1

ISO 68AW hydraulic oil

______________________________________________________________ A6474X263 SVOT / 01 5.7

Maintenance _________________________________________________

© BUCYRUS AMERICA, INC.

Fig. 7: Lubrication chart

_________________________________________________________________ 5.8 Bucyrus – Model 30M-4NP Continuous Miner

________________________________________________ Maintenance

© BUCYRUS AMERICA, INC.

Fig. 7: Lubrication chart (continued)

______________________________________________________________ A6474X263 SVOT / 01 5.9

Maintenance _________________________________________________ Specific lubrication and maintenance procedures See lubrication and maintenance schedule, Table 1, for lubrication type.

Every shift cutter head bits

Inspect the cutter head bits to ensure that they will rotate in their holders and for damaged or missing bits (Fig. 8). Replace bits immediately if any are missing or damaged.

Inspect cutter head bits

Every third shift input cutting head gear case

With the cutter head to the horizontal position, check both of the input cutting head gear case (s) oil level by removing the check plug located on the side of each gear case to view sight glasses (Fig. 9). Lower sight glass should be filled with oil and top sight glass should be empty.

If oil level is low, add oil through the fill plug hole located on top of each gear case until lower sight glass is full.

Fig. 9: Input cutting head gear case (s) oil level Sight glasses (Two for each side)

Oil level/check plug (One for each side)

Oil fill plug (One for each side)

_________________________________________________________________ 5.10 Bucyrus – Model 30M-4NP Continuous Miner

© BUCYRUS AMERICA, INC.

Fig. 8: Cutter head bit inspection

________________________________________________ Maintenance main cutting head gear case

With the cutter head lowered to ground level, check both of the main cutting head gear case (s) oil level by removing the check plug located on the front of each gear case (Fig. 10). 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. 10: Main cutter head gear case (s) oil level Oil fill plug (One for each side)

© BUCYRUS AMERICA, INC.

Oil level/check plug (One for each side)

input gathering head gear case

With the gathering head lowered to ground level, check both of the input gathering head gear cases oil level by removing the check plug located on each side of the gathering head assembly (Fig. 11). 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. 11: Input gathering head gear case (s) oil level

Oil fill plug (One for each side)

Oil level/check plug (One for each side)

______________________________________________________________ A6474X263 SVOT / 01 5.11

Maintenance _________________________________________________ main gathering head gear case

With the gathering head lowered to ground level, check both of the main cutting head gear cases oil level by looking at the sight glass located on each side of the gathering head assembly (Fig. 12). Oil should be visible within each sight glass. If oil level is low, add oil through the fill fittings located on each side of the gathering head.

Oil level sight glass (One for each side)

tram gear case

Oil fill plug (One for each side)

Check both of the tram gear cases oil level by looking at the sight glass located on the side of each gear case (Fig. 13). Oil should be visible within each sight glass. If oil level is low, add oil through the fill plug hole located on top of each gear case.

Fig. 13: Tram gear case (s) oil level Oil fill plug (One for each side)

Breather

Oil level sight glass (One for each side)

_________________________________________________________________ 5.12 Bucyrus – Model 30M-4NP Continuous Miner

© BUCYRUS AMERICA, INC.

Fig. 12: Main gathering head gear case (s) oil check

________________________________________________ Maintenance crawler idler roller

Check both of the crawler idler rollers oil level by position the two (2) pipe plugs at the 3 o-clock and 9 o-clock position. Remove either of the plugs and oil should flow from the idler (Fig. 14). If oil level is low, add oil through either of the fill plug holes until oil begins to flow from the other.

Fig. 14: Crawler idler roller (s) oil level

© BUCYRUS AMERICA, INC.

Oil fill/check plug (One for each side)

main hydraulic tank

Oil level/check plug (One for each side)

Check the hydraulic tank oil level (Fig. 15). 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. 15: Hydraulic oil tank oil level Breather

Oil level dipstick

______________________________________________________________ A6474X263 SVOT / 01 5.13

Maintenance _________________________________________________ cutting head pivot

Lubricate the left and right cutter head pivot points through the grease fittings located on the left and right front lubrication panels (Fig. 16).

Pump approximately 3 cu. in. (50 cu. cm.) into each fitting.

gathering head pivot

Lubricate the left and right gathering head pivot points through the grease fittings located on the left and right front lubrication panels (Fig. 16). Pump approximately 3 cu. in. (50 cu. cm.) into each fitting.

conveyor raise pivot

Lubricate the left and right conveyor raise pivot points through the grease fittings located on the left and right front lubrication panels (Fig. 16). Pump approximately 3 cu. in. (50 cu. cm.) into each fitting.

lower cutting head cylinder pin

Lubricate the left and right lower cutting head cylinder pins through the grease fittings located on the left and right front lubrication panels (Fig. 16). Pump approximately 3 cu. in. (50 cu. cm.) into each fitting.

© BUCYRUS AMERICA, INC.

Fig. 16: Central lubrication (front left and right)

Lower cutting head cylinder pin (One for each side)

upper cutting head cylinder pin

Gathering head pivot lube (One for each side)

Cutting head pivot lube (One for each side)

Conveyor pivot lube (One for each side)

Lubricate the left and right upper cutting head cylinder pins through the grease fittings located on each cylinder pin (Fig. 17). Pump approximately 3 cu. in. (50 cu. cm.) into each fitting.

_________________________________________________________________ 5.14 Bucyrus – Model 30M-4NP Continuous Miner

________________________________________________ Maintenance

© BUCYRUS AMERICA, INC.

Fig. 17: Upper cutting head cylinder pin lubrication point

Upper cutting head cylinder pin lubrication point (One for each side)

upper and lower gathering head cylinder pins

Lubricate the left and right upper and lower gathering head cylinder pins through the grease fittings located on each cylinder pin (Fig. 18). Pump approximately 3 cu. in. (50 cu. cm.) into each fitting.

Fig. 18: Upper and lower gathering head cylinder pin lubrication points

Upper gathering head cylinder pin lubrication point (One for each side)

Lower gathering head cylinder pin lubrication point (One for each side)

______________________________________________________________ A6474X263 SVOT / 01 5.15

Maintenance _________________________________________________ conveyor take-up shaft

Lubricate the conveyor take-up shaft through the two (2) grease fittings located on the shaft (Fig. 19). Pump approximately 3 cu. in. (50 cu. cm.) into each fitting.

Grease fitting

conveyor swing pivot

Grease fitting

Lubricate the conveyor swing pivot through the eight (8) grease fittings located on each side of the conveyor (Fig. 20). Pump approximately 3 cu. in. (50 cu. cm.) into each fitting.

Fig. 20: Conveyor swing pivot lubrication

Grease fittings (four (4) per side)

_________________________________________________________________ 5.16 Bucyrus – Model 30M-4NP Continuous Miner

© BUCYRUS AMERICA, INC.

Fig. 19: Conveyor take-up shaft lubrication

________________________________________________ Maintenance lower conveyor raise cylinder pins

Lubricate the left and right lower conveyor raise cylinder pins through the grease fittings located on the lubrication panel (Fig. 21). Pump approximately 3 cu. in. (50 cu. cm.) into each fitting.

stab shoe pivot pin

Lubricate the stab shoe pivot pin through the grease fittings located on the lubrication panel (Fig. 21). Pump approximately 3 cu. in. (50 cu. cm.) into each fitting.

upper stab shoe cylinder pins

Lubricate the upper stab shoe cylinder through the grease fittings located on the lubrication panel (Fig. 21). Pump approximately 3 cu. in.

(50 cu. cm.) into each fitting.

© BUCYRUS AMERICA, INC.

Fig. 21: Conveyor cylinder, stab shoe cylinder and pivot lubrication

Left and right lower conveyor raise cylinder pin

lower stab shoe cylinder pins

Stab shoe pivot pin

Left and right upper stab shoe cylinder pin

Lubricate the lower stab shoe cylinder pins through the grease fittings located on the rod end of each cylinder (Fig. 22). Pump approximately 3 cu. in. (50 cu. cm.) into each fitting.

Fig. 22: Lower stab shoe cylinder pin lubrication

Lower stab shoe cylinder pin grease fitting

Lower stab shoe cylinder pin grease fitting

______________________________________________________________ A6474X263 SVOT / 01 5.17

Maintenance _________________________________________________ upper conveyor raise cylinder pins

Lubricate the left and right upper conveyor raise cylinder pins through the grease fittings located on the lubrication panel that is located on the side of the intermediate conveyor frame (Fig. 23). Pump approximately 3 cu. in. (50 cu. cm.) into each fitting.

Fig. 23: Upper conveyor raise cylinder pin lubrication

front and rear conveyor swing cylinder pins

Lubricate the front and rear conveyor swing cylinder pins through the grease fittings located on each end of the cylinder (Fig. 24). Pump approximately 3 cu. in. (50 cu. cm.) into each fitting.

Fig. 24: Conveyor swing cylinder pin lubrication Conveyor swing cylinder pin grease fitting

Conveyor swing cylinder pin grease fitting

_________________________________________________________________ 5.18 Bucyrus – Model 30M-4NP Continuous Miner

© BUCYRUS AMERICA, INC.

Left and right upper conveyor raise cylinder pin lubrication

© BUCYRUS AMERICA, INC.

________________________________________________ Maintenance crawler chains

Lubricate the crawler chains with waste oil and visually inspect for wear, correct adjustment and missing parts.

conveyor chain

Lubricate the conveyor chain with waste oil and visually inspect for wear, correct adjustment and missing parts. With the machine running, visually inspect tail shaft to ensure shaft is turning and conveyor chain is not sliding across tail shaft.

fasteners (nuts, bolts and screws)

Loose fasteners will cause premature wear and failure to machine and components. Visually inspect for loose fasteners and tighten as required.

electrical cables, conduits and glands

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

hydraulic/water hoses and connections

Visually inspect all hydraulic/water hoses and connections for signs of wear, damage or leakage.

lighting

Turn on all lighting and visually inspect for bulbs that need replaced or signs of damage.

reflectors and warning plates

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

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

“E-STOP” switch

Check the “E-STOP” switches located on each side of the machine.

Start the machine and strike the “E-STOP” switches to be certain that they are operating properly, tripping the machine circuit breaker and shutting down the machine.

______________________________________________________________ A6474X263 SVOT / 01 5.19

Maintenance _________________________________________________ Every twenty shifts IMPORTANT! Apply grease to motors slowly to allow time for grease to pass through relief. cutting head motor (s)

Lubricate the left and right cutting head motors through the grease fittings located on each side of the cutting head assembly (Fig. 25).

Pump approximately 1/2 cu. in. (8 cu. cm.) into each fitting.

Fig. 25: Cutting head motor lubrication

cutting head motor (s)

Lubricate the left and right gathering head motors through the grease fittings located on each side of the gathering head assembly (Fig. 26).

Pump approximately 1/2 cu. in. (8 cu. cm.) into each fitting.

Fig. 26: Gathering head motor lubrication

Gathering head motor grease fitting (one per side)

Gathering head motor grease fitting located behind access door (one per side)

_________________________________________________________________ 5.20 Bucyrus – Model 30M-4NP Continuous Miner

© BUCYRUS AMERICA, INC.

Cutting head motor grease fittings (two per side)

________________________________________________ Maintenance dust collector motor

Lubricate the dust collector motor through the two (2)grease fittings located the left side of the machine (Fig. 27). Pump approximately 1/2 cu. in. (8 cu. cm.) into each fitting.

© BUCYRUS AMERICA, INC.

Fig. 27: Dust collector motor lubrication

Dust collector motor grease fitting

pump motor

Dust collector motor grease fitting

Lubricate the pump motor through the two (2)grease fittings located the left side of the machine (Fig. 28). Pump approximately 1/2 cu. in. (8 cu. cm.) into each fitting.

Fig. 28: Pump motor lubrication

Pump motor grease fitting

Pump motor grease fitting

______________________________________________________________ A6474X263 SVOT / 01 5.21

Maintenance _________________________________________________ Every thirty shifts input cutting head gear case

Change oil in both input cutting head gear cases (Fig. 29).  Position cutting head to a horizontal position (flat back in vertical position), clean dirt and debris from around the drain plug located under gear case.  Remove drain plug and allow oil to completely drain from the gear case.  Clean and reinstall drain plug.  Clean dirt and debris from around the level/check plug and remove plug.

 Add oil through the fill plug hole slowly, the lower sight glass is full of oil. Allow sufficient time for the oil to travel throughout the gear case when filling.  Clean and reinstall plugs.

Fig. 29: Input cutting head gear case (s) oil Oil fill plug (One for each side) Flat back

Sight glasses (Two for each side)

Oil level/check plug (One for each side)

_________________________________________________________________ 5.22 Bucyrus – Model 30M-4NP Continuous Miner

© BUCYRUS AMERICA, INC.

 Clean dirt and debris from around the fill plug and remove plug.

________________________________________________ Maintenance main cutting head gear case

Change oil in both main cutting head gear cases (Fig. 30).  Lower cutting head completely to ground, clean dirt and debris from around the drain plug located under gear case.  Remove drain plug and allow oil to completely drain from the gear case.  Clean and reinstall drain plug.  Clean dirt and debris from around the level/check plug and remove plug.  Clean dirt and debris from around the fill plug and remove plug.  Add oil through the fill plug hole slowly, just until it starts to flow back out of the level/check plug hole. Allow sufficient time for the oil to travel throughout the gear case when filling.

© BUCYRUS AMERICA, INC.

 Clean and reinstall plugs.

Fig. 30: Main cutter head gear case (s) oil change

Oil fill plug (One for each side)

Oil level/check plug (One for each side)

Oil drain plug (One for each side)

______________________________________________________________ A6474X263 SVOT / 01 5.23

Maintenance _________________________________________________ Every sixty shifts input gathering head gear case

Change oil in both input gathering head gear cases (Fig. 31).  Lower gathering head completely to ground, clean dirt and debris from around the drain plug located under gear case.  Remove drain plug and allow oil to completely drain from the gear case.  Clean and reinstall drain plug.  Clean dirt and debris from around the level/check plug and remove plug.  Clean dirt and debris from around the fill plug and remove plug.

 Clean and reinstall plugs.

Fig. 31: Input gathering head gear case (s) oil change

Oil fill plug (One for each side)

Oil level/check plug (One for each side)

_________________________________________________________________ 5.24 Bucyrus – Model 30M-4NP Continuous Miner

© BUCYRUS AMERICA, INC.

 Add oil through the fill plug hole slowly, just until it starts to flow back out of the level/check plug hole. Allow sufficient time for the oil to travel throughout the gear case when filling.

________________________________________________ Maintenance main gathering head gear case

Change oil in both main gathering head gear cases (Fig. 32).  Lower gathering head completely to ground, clean dirt and debris from around the drain plug located under gear case.  Remove drain plug and allow oil to completely drain from the gear case.  Clean and reinstall drain plug.  Clean dirt and debris from around the fill fitting.  Add oil through the fill fitting slowly until it is visible in the oil level sight glass. Allow sufficient time for the oil to travel throughout the gear case when filling.

© BUCYRUS AMERICA, INC.

Fig. 32: Main gathering head gear case (s) oil change

Oil level sight glass (One for each side)

Oil fill plug (One for each side)

______________________________________________________________ A6474X263 SVOT / 01 5.25

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. 33) sufficient to sample each identified gear case (every sixty shifts).

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.

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.

_________________________________________________________________ 5.26 Bucyrus – Model 30M-4NP Continuous Miner

© 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 cutting head gear case, right front, etc.).

________________________________________________ Maintenance Recommended gear cases to be sampled: ■

Input cutting head gear case (left and right)

■

Main cutting head gear case (left and right)

■

Input gathering head gear case (left and right)

■

Main gathering head gear case (left and right)

■

Tram gear case (left and right)

■

Crawler idler roller (left and right)

■

Main hydraulic oil tank

Fig. 33: Oil sampling procedure

© BUCYRUS AMERICA, INC.

Oil fill plug

Typical siphon pump and bottle

Oil level

Place end of siphon tube approximately half way into sump

Note: Hold sample pump and bottle below oil level

______________________________________________________________ A6474X263 SVOT / 01 5.27

Maintenance _________________________________________________ Every three hundred sixty shifts tram gear case

crawler idler roller

Replace both right and left tram gear cases (Fig. 34). Refer to the parts manual supplied with your machine for removal and installation.

Replace both right and left crawler idler rollers (Fig. 34). Refer to the parts manual supplied with your machine for removal and installation.

Crawler idler roller

Tram gear case

_________________________________________________________________ 5.28 Bucyrus – Model 30M-4NP Continuous Miner

© BUCYRUS AMERICA, INC.

Fig. 34: Tram gear case and crawler idler roller location

________________________________________________ Maintenance As required main hydraulic tank

Change oil in the hydraulic oil tank (Fig. 35).  Remove drain plug and allow oil to completely drain from the tank.  Clean and reinstall drain plug.  Refill the tank manually with oil to full level indicated on dip stick.  Start the machine and allow the hydraulic pump to run in order to purge air from the system.  Shutdown the machine and recheck the oil level. Add oil if necessary.

IMPORTANT! Hydraulic oil tank capacity is 80 gal. (300 l)

© BUCYRUS AMERICA, INC.

Fig. 35: Hydraulic oil tank oil change Breather

Oil level dipstick

______________________________________________________________ A6474X263 SVOT / 01 5.29

Maintenance _________________________________________________

strainers

The following filter elements must be changed as required by the conditions at the mine site: Refer to lubrication chart (Fig. 7) for location.

■

Pilot filter (dirt alarm indicator) (Item 50)

■

Pressure filter (dirt alarm indicator) (Item 51)

■

Return filter (dirt alarm indicator) (Item 52)

■

Oil filter (Item 56)

■

Breathers (hydraulic oil tank) (Item 54)

■

Water filter (Item 57)

The following screens must be changed as required by the conditions at the mine site: Refer to lubrication chart (Fig. 7) for location.

IMPORTANT: If strainers are not torn or damaged, they can be cleaned using kerosene and a soft brush and dried thoroughly. If strainers are damaged, they must be replaced.

■

Strainer (Item 55)

■

Back flushing strainer (Item 58)

■

Jet pump strainer (Item 59)

_________________________________________________________________ 5.30 Bucyrus – Model 30M-4NP Continuous Miner

© BUCYRUS AMERICA, INC.

filters

_______________________________________________________________

6

Technical data

________________________________________________________________

________________________________________________________________

_________________________________________________________________

_______________________________________________ Technical data

Technical data This chapter contains the most important technical data on the 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.

The technical data listed in this chapter is for stock machines only.

Customer specials may not be listed.

Technical data of the continuous miner Technical data sheet

© BUCYRUS AMERICA, INC.

general

Length: Width (cutting head): Width (main frame): Ground clearance: Machine height: Conveyor height (Minimum): Conveyor height (Maximum): Conveyor swing (both directions): Conveyor width: Cutting height (Maximum): Cutting head diameter: Crawler track width: Weight:

approx. 11,256 mm approx. 3,505 mm approx. 3,219 mm approx. 362 mm approx. 1,796 mm approx. 1,464 mm approx. 2,698 mm approx. 45° approx. 762 mm approx. 4,622 mm approx. 1,118 mm approx. 560 mm approx. 83,915 kg (185,000 lb)

______________________________________________________________ A6474X263 SVOT / 01 6.3

© Bucyrus America, Inc.

Technical data ________________________________________________

_________________________________________________________________ 6.4 Bucyrus – Model 30M-4NP Continuous Miner

___________________________________________ Tightening torques Tightening torques IMPORTANT! Due to the application of fasteners being subject to great stresses and heavy or extreme vibration, it is imperative that all bolts be applied with an adequate amount of torque. For this reason this list of recommended torque settings for different types and sizes of fasteners used has been compiled.

The tightening torques stated in the spare parts lists have to be observed, as well, for installation and maintenance.

Set screws

© BUCYRUS AMERICA, INC.

Table 2: Set screws (Socket long-lok) Nominal diameter

Recommended torque setting

#6

6 in-lbs

#8

9 in-lbs

#10

13 in-lbs

¼”

30 in-lbs

5/16”

5 ft-lbs

3/8”

8 ft-lbs

7/16”

11 ft-lbs

½”

16.7 ft-lbs

Table 3: Set screws (Socket standard steel) Nominal diameter

Recommended torque setting

#6

9 in-lbs

#8

16 in-lbs

#10

30 in-lbs

¼”

6 ft-lbs

5/16”

12 ft-lbs

3/8”

18 ft-lbs

7/16”

29 ft-lbs

½”

43 ft-lbs

5/8”

100 ft-lbs

¾”

146 ft-lbs

7/8”

199 ft-lbs

1”

262 ft-lbs

______________________________________________________________ A6474X263 SVOT / 01 6.5

Tightening torques ____________________________________________ Table 4: FSR hex bolts (SAE 5 and 325 steel) Recommended torque setting

¼”

9 ft-lbs

5/16”

18 ft-lbs

3/8”

31 ft-lbs

7/16”

50 ft-lbs

½”

75 ft-lbs

9/16”

110 ft-lbs

5/8”

150 ft-lbs

¾”

250 ft-lbs

7/8”

378 ft-lbs

1”

583 ft-lbs

1 1/8”

782 ft-lbs

1 ¼”

1,097 ft-lbs

1 3/8”

1,461 ft-lbs

1 ½”

1,748 ft-lbs

1 ¾”

3,114 ft-lbs

2”

4,504 ft-lbs

2 ¼”

6,497 ft-lbs

2 ½”

7,144 ft-lbs

2 ¾”

12,092 ft-lbs

3”

15,744 ft-lbs

Table 5: FSR hex bolts (SAE 5 and 325 steel) Nominal diameter #6 #8 #10 ¼” 5/16” 3/8” 7/16” ½” 5/8” ¾” 7/8” 1” 1 1/8” 1 ¼” 1 3/8” 1 ½”

Recommended torque setting 26 in-lbs 52 in-lbs 6 ft-lbs 14 ft-lbs 30 ft-lbs 50 ft-lbs 81 ft-lbs 121 ft-lbs 240 ft-lbs 395 ft-lbs 629 ft-lbs 964 ft-lbs 1,523 ft-lbs 2,121 ft-lbs 2,843 ft-lbs 3,402 ft-lbs

_________________________________________________________________ 6.6 Bucyrus – Model 30M-4NP Continuous Miner

© BUCYRUS AMERICA, INC.

Nominal diameter

___________________________________________ Tightening torques Table 6: Untreated screw, black finish (Coarse thread) Property class 5.6 8.8 10.9 12.9

Torque Ma

Recommended torque setting M3 M4 M5

Nominal diameter M6

M7

M8

M10

Nm

0.60

1.37

2.70

4.5

7.8

11

22

Ft-lbs

0.44

1.01

1.99

3.3

5.6

8.1

16

Nm

1.37

3.10

6.15

10.5

17.5

26

61

Ft-lbs

1.01

2.29

4.54

7.7

12.9

19

37

Nm

1.92

4.40

8.55

15

25

36

72

Ft-lbs

1.42

3.25

6.38

11

18.4

26

53

Nm

2.30

5.25

10.4

18

29

43

87

Ft-lbs

1.70

3.87

7.6

13

21.3

31

64

© BUCYRUS AMERICA, INC.

Table 7: Untreated screw, black finish (Coarse thread, continued) Property class 5.6 8.8 10.9 12.9

Torque Ma

Recommended torque setting M12 M14 M16

Nominal diameter M18

M20

M22

M24

Nm

39

62

85

130

184

250

315

Ft-lbs

28

45

70

95

135

184

232

Nm

89

141

215

295

420

570

725

Ft-lbs

65

103

158

217

308

420

634

Nm

125

198

305

420

690

800

1020

Ft-lbs

92

146

224

309

435

590

752

Nm

150

240

365

500

710

960

1220

Ft-lbs

110

177

269

368

523

708

899

Table 8: Untreated screw, black finish (Coarse thread, continued) Property class

Torque Ma

5.6 8.8 10.9 12.9

Recommended torque setting M27 M30

Nominal diameter M33

M36

M39

Nm

470

635

865

1111

1440

Ft-lbs

346

468

637

819

1062

Nm

1070

1450

1970

2630

3290

Ft-lbs

789

1069

1452

1885

2428

Nm

1510

2050

2770

3560

4620

Ft-lbs

1113

1511

2042

2625

3407

Nm

1810

2450

3330

4280

5550

Ft-lbs

1334

1606

2455

3156

4093

______________________________________________________________ A6474X263 SVOT / 01 6.7

Tightening torques ____________________________________________ Table 9: Untreated screw, black finish (Fine thread) Property class

Torque Ma

8.8 10.9 12.9

Recommended Nominal diameter torque setting M8 X 1 M10 X 1.25 M12 X 1.25

Nm

27

52

95

Ft-lbs

19

38

70

Nm

38

73

135

Ft-lbs

28

53

99

Nm

45

88

160

Ft-lbs

33

64

118

Property class

Torque Ma

8.8 10.9 12.9

Recommended Nominal diameter torque setting M14 X 1.5 M16 X 1.5 M18 X 1.5

Nm

150

225

325

Ft-lbs

110

165

239

Nm

210

315

460

Ft-lbs

154

232

339

Nm

260

380

550

Ft-lbs

184

280

405

Table 11: Untreated screw, black finish (Fine thread, continued)

Property class

Torque Ma

8.8

Nm

Recommended Nominal diameter torque setting M20 X 1.5 M22 X 1.5 M24 X 2 399

Ft-lbs 10.9 12.9

610

780

449

575

Nm

640

860

1100

Ft-lbs

472

634

811

Nm

770

1050

1300

Ft-lbs

567

774

958

_________________________________________________________________ 6.8 Bucyrus – Model 30M-4NP Continuous Miner

© BUCYRUS AMERICA, INC.

Table 10: Untreated screw, black finish (Fine thread, continued)

___________________________________________ Tightening torques Table 12: Electrically zinc plated (Coarse thread) Property class 5.6 8.8 10.9 12.9

Torque Ma

Recommended torque setting M33 M4 M5

Nominal diameter M6

M7

M8

M10

Nm

0.56

1.28

2.50

4.3

7.1

10.5

21

Ft-lbs

0.41

0.94

1.84

3.1

5.2

7.7

15

Nm

1.28

2.90

5.75

9.9

16.5

24

48

Ft-lbs

0.94

2.14

4.24

7.3

12.1

17.7

35

Nm

1.80

4.10

8.10

14

23

34

67

Ft-lbs

1.33

3.02

5.97

10.3

16.9

25

49

Nm

2.15

4.95

9.70

16.5

27

40

81

Ft-lbs

1.59

3.65

7.15

12.1

19.9

29

59

© BUCYRUS AMERICA, INC.

Table 13: Electrically zinc plated (Coarse thread, continued) Property class 5.6 8.8 10.9 12.9

Torque Ma

Recommended torque setting M12 M14 M16

Nm

36

Ft-lbs

26

42

Nm

83

132

Ft-lbs

61

97

58

Nominal diameter M18

M20

M22

121

171

230

54

89

126

169

200

275

390

530

147

202

287

390

88

Nm

117

185

285

390

550

745

Ft-lbs

86.2

136

210

287

405

549

Nm

140

220

340

470

660

890

Ft-lbs

103

162

250

346

486

656

Table 14: Electrically zinc plated (Coarse thread, continued) Property class 5.6

8.8

10.9

12.9

Torque Ma

Recommended torque setting M24 M27 M30

Nominal diameter

Nm

295

435

590

800

1030

1340

Ft-lbs

217

320

435

590

759

988

Nm

675

995

1350

1830

2360

3050

Ft-lbs

497

733

995

1349

1740

2249

Nm

960

1400

1900

2680

3310

4290

Ft-lbs

708

1032

1401

1902

2441

3163

Nm

1140

1680

2280

3090

3980

5150

Ft-lbs

840

1239

1661

2278

2935

3798

______________________________________________________________ A6474X263 SVOT / 01 6.9

Tightening torques ____________________________________________ Table 15: Electrically zinc plated (Fine thread) Property class 8.8 10.9 12.9

Torque Ma Nm Ft-lbs Nm Ft-lbs Nm Ft-lbs

Recommended torque setting M8 X 1 25 18 35 25 42 30

Nominal diameter M10 X 1.25 49 36 68 50 82 60

M12 X 1.25 88 84 125 92 150 110

Table 16: Electrically zinc plated (Fine thread, continued)

8.8 10.9 12.9

Torque Ma

Recommended torque setting M14 X 1.5

Nominal diameter M16 X 1.5

M18 X 1.5

Nm

140

210

305

Ft-lbs

103

154

224

Nm

195

295

425

Ft-lbs

143

217

313

Nm

235

350

510

Ft-lbs

173

258

376

Table 17: Electrically zinc plated (Fine thread, continued) Property class 8.8 10.9 12.9

Torque Ma

Recommended torque setting M20 X 1.5

Nominal diameter M22 X 1.5

M24 X 2

Nm

425

570

720

Ft-lbs

313

420

531

Nm

600

800

1000

Ft-lbs

442

590

737

Nm

720

960

1200

Ft-lbs

531

708

885

_________________________________________________________________ 6.10 Bucyrus – Model 30M-4NP Continuous Miner

© BUCYRUS AMERICA, INC.

Property class

___________________________________________ Permissible media Permissible media Lubrication fluids and greases NOTICE! Use only lubrication fluids and greases approved by Bucyrus America, Inc. ! These fluids and greases have been tested at Bucyrus America, Inc. and guarantee reliable operation of the mechanical and hydraulic functions of the machine.

IMPORTANT! Be sure to use the manufacturer’s instructions for use.

© BUCYRUS AMERICA, INC.

NOTICE! When performing maintenance on the machine, all used oil and lubricants should be disposed of per your local EPA standards.

______________________________________________________________ A6474X263 SVOT / 01 6.11

© BUCYRUS AMERICA, INC.

Permissible media ____________________________________________

_________________________________________________________________ 6.12 Bucyrus – Model 30M-4NP Continuous Miner

_______________________________________________________________

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 200 George Street, Suite 4 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

Duffield, VA P.O. Box 847 6808 Fraley Avenue Duffield, VA 24244 Phone: (276) 431-7000 Fax: (276) 431-2464

Houston, PA (Corporate Headquarters) 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 Oak Hill, WV 25901

Paonia, CO P.O. Box 566 Paonia, CO 81428

Price, UT 1814 North 1500 West P.O. Box 1016 Price, UT 84501 Phone: (435) 637-3930 Fax: (435) 637-9754

719 Second Street Paonia, CO 81428 Phone: (970) 527-3151 Fax: (970) 527-6846 Pulaski, VA 4041 Wurno Road Pulaski, VA 24301 Phone: 540-980-4530 Fax: 540-980-6211

843 Lochgelly Road Oak Hill, WV 25901 Phone: (304) 469-3302 Fax: (304) 465-0450

Washington, PA 255 Berry Road Washington, PA 15301 Phone: (724) 743-1200 Fax: (724) 228-2177

______________________________________________________________ A6474X263 SVOT / 01 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 30M-4NP Continuous Miner

IRIS (Intelligent Response Information System) for Continuous Miners in India

Troubleshooting Guide DN: G005.1-TShoot_RCSysContMiners_In-M

2008 Cervis, Inc.

RC System for Continuous Miners in India

This document is the property of Cervis, Inc. and cannot be copied, modified, e-mailed, or reproduced without the express prior written consent of Cervis, Inc. Cervis, Inc. reserves the right to change this manual or edit, delete, or modify any information without prior notification.

Cervis, Inc. Visit our Web site at:

www.cervisinc.com

BUCYRUS® and the Bucyrus logo are registered trademarks of Bucyrus International, Inc. ®  2008 Cervis, Inc. All rights reserved. Content is subject to change without notice.

Troubleshooting Guide

General Safety Notices This section addresses some general safety guidelines involved with BUCYRUS products. These guidelines are intended to promote safe usage of equipment. It is not intended to replace present safety practices at your site.

It is the responsibility of the contractor, installer, purchaser, owner, and user to install, maintain, and operate the parts or components manufactured and supplied by Bucyrus in such a manner as to comply with the MSHA Safety Standards and all state and local laws, ordinances, regulations.

If malfunctions occur in any aspect to the transmitter or receiver operation do not continue to operate; power down the system, fill out the service tag, and return it to the factory for inspection and CAUTION repair. When the system is in use and if any part of the unit is damaged physically, discontinue operation and return it to the factory for inspection and repair. At anytime during usage of the system any damage is found physically or electronically, it is crucial for the safety of the operator and others in the operating area that the system is not allowed to continue in operation.

Mine Safety and Health Problem Recognition Ghosting (gosting), v., 1: Unplanned movement by machines that use Computer Control Technology.

The Mine Safety and Health Administration has recognized a problem involving malfunctions of electro-hydraulic shield advance systems at various longwall installations. This has lead MSHA to issue the following recommendations for the safe operation of all computer controlled mining equipment to prevent the condition known as ‘ghosting’.

Safety Recommendations 1. Mine personnel who operate this equipment should be trained to insure the proper operational procedures and sequences are used to recognize improper system operation, alarms, and displays.

2. Maintenance of the system is critical for safe operation. Hardware malfunctions, such as sticking solenoid valves, should be immediately repaired.

3. Mine personnel should be made aware that the entry of moisture or water into the transmitter or umbilical enclosure could cause undesired machine movements. Transmitter cases should be inspected for damage that could compromise the sealing features designed into these units and allow moisture entry. Signs of mechanical distortion or bent control housings, damaged gaskets or seals, damaged keypads, corrosion, or evidence of internal moisture indicate that the enclosure sealing may have been compromised. The control unit enclosures should not be disassembled for inspection because proper resealing is too difficult to accomplish in the field.

2008 Cervis, Inc.

i

BUCYRUS®

IRIS for Continuous Miners in India

4. Any abnormal operational sequences of the system, alarm displays, or unintended machine movement which might be due to a software programming error should be noted, reported to the manufacturer, and corrected immediately.

5. Any equipment removed to correct “ghosting” problems should be sent to the manufacturer to determine the exact cause of the problem. Corrective action will then be taken by either the manufacturer or the operator to prevent similar occurrences.

6. Whenever an unplanned machine movement is observed, the hardwired emergency stop system should be activated, not the stop button on the electronic control unit.

These recommendations, though originally made in response to the unplanned movement of longwall shield advance systems utilizing computer control technology, are equally applicable to all equipment with machine control circuits utilizing computer control technology. The recommendations above should be followed on a continuing basis on all machines utilizing computer control technology.

ii

G005.1-TShoot_RCSysContMiners_In-M

Troubleshooting Guide

Table of Contents General Safety Notices ................................................................................................................. i Mine Safety and Health Problem Recognition ........................................................................... i Safety Recommendations ............................................................................................................ i Table of Contents ........................................................................................................................ iii List of Figures ............................................................................................................................. iv List of Tables ............................................................................................................................... iv Document Conventions .............................................................................................................. iv 1.0 How to Troubleshoot This System ..................................................................................... 1 1.1 When You Experience Any Fault .................................................................................... 1 1.1.1 When Troubleshooting the System .............................................................................. 1 2.0 System Status Indicators .................................................................................................... 2 2.1 Introduction ....................................................................................................................... 2 2.2 Status LED Functional Categorization ........................................................................... 2 2.2.1 Abnormal Status Indication .......................................................................................... 4 2.3 MCU945 Status LED Descriptions .................................................................................. 5 2.4 TX945 Transmitter .......................................................................................................... 11 2.5 RX944 Receiver ............................................................................................................... 13 2.6 CPS945 ............................................................................................................................. 13 2.7 DCD100 DC Tram Drive .................................................................................................. 14 2.8 CST945 Pendent Drive Controller ................................................................................. 15 3.0 Alarms, Warnings, and Display Information ................................................................... 17 3.1 Coded Alarms and Warnings......................................................................................... 17 3.1.1 Alarm Codes ............................................................................................................... 17 3.1.2 Warning Codes ........................................................................................................... 21 4.0 Component Identification .................................................................................................. 27 4.1 Remote Control System Components .......................................................................... 27 4.2 Remote Control System Components Tie-in ............................................................... 28

2008 Cervis, Inc.

iii

BUCYRUS®

IRIS for Continuous Miners in India

List of Figures Figure 1. MCU945 Custom PLC Status LEDs...............................................................................3 Figure 2. TX945 Transmitter Status LEDs ................................................................................. 11 Figure 3. RX944 Receiver Status LEDs ..................................................................................... 13 Figure 4. CPS945 Power Supply Status LEDs .......................................................................... 14 Figure 5. DCD100 DC Tram Drive Status LEDs......................................................................... 14 Figure 6. CST945 LEDs ............................................................................................................... 15 Figure 7. Display Screen Messages ........................................................................................... 17 Figure 8. Remote Control System Components Layout .......................................................... 28

List of Tables Table 1. MCU945 LED Functional Categories ..............................................................................4 Table 2. MCU945 Status LED Description (R1 & R2) ...................................................................5 Table 3. MCU945 Status LED Description (R3 & R4) ...................................................................6 Table 4. MCU945 Status LED Description (R5 & R6) ...................................................................7 Table 5. MCU945 Status LED Description (R11 & R12) ...............................................................8 Table 6. MCU945 Status LED Description (R13 & R14) ...............................................................9 Table 7. MCU945 Status LED Description (R15 to R20) ........................................................... 10 Table 8. MCU945 Status LED Description (R21 to R22) ........................................................... 10 Table 9. TX945 Status LED Response Analysis ....................................................................... 11 Table 10. RX944 Status LED Description .................................................................................. 13 Table 11. CPS945 Status LED Response Analysis .................................................................. 14 Table 12. DCD100 Status LED Response Analysis .................................................................. 15 Table 13. CST945 LED Indicators ............................................................................................... 16 Table 14. Display Screen Top Banner General Description .................................................... 17 Table 15. Alarm Codes ................................................................................................................ 17 Table 16. Warning Codes ............................................................................................................ 21 Table 17. System Components................................................................................................... 27

Document Conventions

WARNING This is an example of a Warning. These provide vital information warning that an activity or action of the user can adversely affect the operation, be harmful, or cause death.

Note: This is an example of the Note. A Note provides information or hints that will usually aid the user.

iv

G005.1-TShoot_RCSysContMiners_In-M

Troubleshooting Guide

1.0 How to Troubleshoot This System This system has visual troubleshooting aids to allow operators and maintenance personnel to quickly determine the cause of most operating faults. These troubleshooting aids consist of: WARNING

• • • •

•

Before troubleshooting beyond the level of observing the fault log, read this entire manual and contact your supervisor

Display – Graphics or text device that shows run time data and fault log.

Fault Message – A machine local graphics display messages that appear for ten (10) seconds when the system detects a fault.

Fault Log – A permanent, machine-local, displayed time-stamped record of the fault. It can be paged from the remote control transmitter.

Operational Error Message – A machine local graphics display message that appears whenever an action is prevented from execution due to a fault condition.

LED Indicators – Light emitting diode (LED) indicators are placed strategically on most system sub-assemblies for aid in troubleshooting.

1.1 When You Experience Any Fault • •

Page to the fault log and try to redo faulted machine function while watching for fault message at display.

If fault reoccurs, note message from display or log and proceed to Section 2 to troubleshoot using system LED indicators.

1.1.1 When Troubleshooting the System When troubleshooting the system, the following points should be noted: • •

•

The remote control system does not recognize problems in the machine hydraulic system unrelated to the pump motor.

Most faults only affect one machine function. However, if dependent faults should occur, the most significant fault message appears first, then the next after the first fault is corrected, and so on.

The system will not recognize power lost to the machine unless initiated by the machine control unit. In that case, the system will indicate such action once power to the machine has been restored.

BUCYRUS®

IRIS for Continuous Miners in India

2.0 System Status Indicators 2.1 Introduction WARNING

Although this guide includes measurement information, it is not intended to imply breaching of any methane or hazardous isolation barriers to make actual measurements. Contact your supervisor if it is suspected that a more comprehensive troubleshooting method is required

A sufficient complement of status LEDs is provided on the MCU945 to assist in quickly determining the source of most problems that may arise during operation. Additional status LEDs are provided on the RX944, TX945, CPS945, and DCD100 units. Use Table 1 through Table 12 to troubleshoot the system using the status LEDs.

2.2 Status LED Functional Categorization The majority of status LEDs of interest in troubleshooting this remote radio control system are located on the MCU945. Each LED has a one-to-one correspondence with its connector pin. The layout of the connectors on the face plate is such that pins, and thus the LEDs, are grouped in functional categories as shown in Figure 1 and described in Table 1.

Note: LED locations on the MCU945 are with reference to their associated connector. The LEDs are located to the right of their connector.

WARNING

2

Only qualified personnel with approved training on this equipment and knowledgeable of MSHA safety requirements should perform troubleshooting of this system.

G005.1-TShoot_RCSysContMiners_In-M

Troubleshooting Guide

Figure 1. MCU945 Custom PLC Status LEDs

2008 Cervis, Inc.

3

BUCYRUS®

IRIS for Continuous Miners in India

2.2.1 Abnormal Status Indication Generally, an abnormal status indication can be quickly attributed to either a fault in a component of the remote control system or controlled machine.

Table 1. MCU945 LED Functional Categories LED Location

4

Functional Category

R1-R6

A contact output. Either a solenoid output or a relay output. When ON, contact should be closed. Note that these outputs have +24VDC applied to one side.

R11

120VAC inputs. When ON, 120VAC is present. For normal operation of the miner, MACHINE STOP (R11-1) and LEFT STOP (R11-2) LEDs should be ON.

R12

120VAC inputs. When ON, 120VAC is present.

R13

12VDC inputs and outputs.

Top Three LEDs are associated with outputs Bottom Three LEDs are associated with inputs.

R14

120VAC inputs. When ON, 120VAC is present.

R15

Top LED: Flashes whenever the MCU945 is transmitting. At the moment, this will only occur during Teach/Learn. In Teach/Learn, the top LED will flash a minimum of three times during a successful Teach/Learn cycle.

Bottom LED: Flashes whenever the MCU945 has received valid messages from the Receiver (RX944). This can only occur if the mode is not LOCAL, checksum is valid, and proper transmitter is communicating to MCU945

R16

Top LED: Indicates whenever the display is transmitting.

Bottom LED: Indicates when the display responds to the MCU945.

R17

Top LED: Flashes whenever there is activity between the MCU945 and IR receiver.

R18

Top LED: Flashes quickly (looks steady) whenever the MCU945 is transmitting.

Bottom LED: Flashes quickly (looks steady) whenever a valid message has been received from either the left or right drive.

R19

Not used.

R20

Indicates activity with respect to the download/debug cable connection.

R21

Not used.

R22

Indicates voltage levels inside the MCU945.

Top LED: Indicates +5V is present.

Middle LED: Indicates +12V is present.

Bottom LED: Flashes whenever the MCU945 is in UMBILICAL mode with the TX945.

Rotary Switch

Top LED: (Located left of the rotary switch) flashes whenever there have been multiple internal backplane communication errors inside the MCU945.

Other Three LEDs: Engineering Use

G005.1-TShoot_RCSysContMiners_In-M

Troubleshooting Guide

2.3 MCU945 Status LED Descriptions Generally, LED locations and functions are associated with their respective connector designations R1 through R22 with the exception of connectors R7 and R8 for which there are no LEDs. MCU945 status LEDs are described in Table 2 through Table 8 to allow quick access to specific status LED analysis locations on the MCU945 from the Table of Contents.

Table 2. MCU945 Status LED Description (R1 & R2) LED Function

LED Location

Description

NOT USED

R1-1

SCRUBBER SPRAY SOLENOID

R1-2

On when fan water spray solenoids is energized. Action is slaved to fan operation.

LEFT TRAM BRAKE OPEN

R1-3

Active when contact is closed. Action is controlled by transmitter via tram handles.

DUST SUPPRESSION

R1-4

Active when dust suppression is closed. Action is controlled from transmitter.

CUTTER RAISE SOLENOID

R1-5

Active when cutter raise contact is closed. Action is controlled from transmitter.

GATHERING HEAD FLOAT SOLENOID

R1-6

Active when gathering head float contact is closed. This action will latch and is deactivated only when gathering head raise solenoid is active or pump is inactive.

Requires pump active prior to use.

CUTTER LOWER SOLENOID

R2-1

Active when contact is closed. Action is controlled by transmitter.

CONVEYOR RAISE SOLENOID

R2-2

Active when contact is closed. Action is controlled by transmitter.

CONVEOR LOWER SOLENOID

R2-3

Active when contact is closed. Action is controlled by transmitter.

CNVYR SWING LEFT SOLENOID

R2-4

Active when contact is closed. Action is controlled by transmitter.

CNVYR SWING RIGHT SOLENOID

R2-5

Active when contact is closed. Action is controlled by transmitter.

STAB UP SOLENOID

R2-6

Active when contact is closed. Action is controlled by transmitter.

STAB DOWN SOLENOID

R2-7

Active when contact is closed. Action is controlled by transmitter.

GATHERING HEAD RAISE SOLENOID

R2-8

Active when contact is closed. Action is controlled by transmitter.

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Table 3. MCU945 Status LED Description (R3 & R4) LED Function

6

LED Location

Description

MACHINE STOP OVERRIDE

R3-1

Active when contact is closed. Action is controlled from transmitter.

RIGHT TRAM BRAKE OPEN SOLENOID

R3-2

Active when contact is closed. Action is controlled from transmitter via tram handles.

CONVEYOR REV CONTACTOR

R3-3

Active when reverse conveyor contact is closed. Action is controlled from transmitter.

FAN CONTACTOR

R3-4

Active when fan contact is closed. Action is controlled from transmitter and also configuration.

TRAM CONTACTOR

R4-1

Active when contact is closed. Action is controlled from transmitter via tram handles.

REVERSE MACHINE LIGHTING

R4-2

Active when contact is closed. Action is controlled from transmitter via either tram handle in reverse.

SPARE OUTPUT #2

R4-3

HEADLIGHTS

R4-4

Active when contact is closed. Action is controlled from transmitter.

PUMP CONTACTOR

R4-5

Active when contact is closed. Action is controlled from transmitter.

LEFT CUTTER CONTACTOR

R4-6

Active when contact is closed. Action is controlled from transmitter.

RIGHT CUTTER CONTACTOR

R4-7

Active when contact is closed. Action is controlled from transmitter.

CONVEYOR FWD CONTACTOR

R4-8

Active when contact is closed. Action is controlled from transmitter.

G005.1-TShoot_RCSysContMiners_In-M

Troubleshooting Guide Table 4. MCU945 Status LED Description (R5 & R6) LED Function

LED Location

Description

WATER FLOW TRIP

R5-1

Active when 120VAC is present. When not present, cutter motors are disabled.

WATER PRESSURE TRIP

R5-2

Active when 120VAC is present. When not present, cutter motors are disabled.

AUX OUTPUT #1 (LATCHED/PUMP)

R5-3

Active when contact is closed. Action is controlled from transmitter.

AUX OUTPUT #2 (MOMENTARY/PUMP)

R5-4

Active when contact is closed. Action is controlled from transmitter.

AUX OUTPUT #3 (MOMENTARY)

R6-1

Active when contact is closed. Action is controlled from transmitter.

AUX OUTPUT #4 (LATCHED PUMP)

R6-2

Active when contact is closed. Action is controlled from transmitter.

AUX OUTPUT #5 (MOMENTARY/PUMP)

R6-3

Active when contact is closed. Action is controlled from transmitter.

AUX OUTPUT #6

R6-4

Active when contact is closed. Action is controlled from transmitter.

AUX OUTPUT #7

R6-5

Active when contact is closed. Action is controlled from transmitter.

AUX OUTPUT #8

R6-6

Active when contact is closed. Action is controlled from transmitter.

SPARE OUTPUT #1

R6-7

PRE-START ALARM

R6-8

Active when contact is closed. Contact will close upon momentary activation provided the pump contact is closed. Action is controlled by the transmitter.

Note: There are no LEDs associated with connector functions R7 through R10.

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Table 5. MCU945 Status LED Description (R11 & R12)

8

LED Function

LED Location

Description

MACHINE STOP

R11-1

Active when 120VAC is present. When not present, indicates that machine stop is pressed. Operation is prevented unless machine stop override from transmitter utilized.

LEFT STOP

R11-2

Active when 120VAC is present. When not present, indicates that left stop is pressed. Operation is prevented unless machine stop override from transmitter utilized.

AC SPARE INPUT #6

R11-3

AC SPARE INPUT #7

R11-4

AC SPARE INPUT #8

R11-5

AC EARTH

R11-6

Active when 120VAC is present. When inactive, problem.

350VAC/DC EARTH

R11-7

Active when 120VAC is present. When inactive, problem.

METHANE MONITOR OK

R11-8

Active when 120VAC is present. When present, indicates that methane monitor is functioning properly and methane levels are within acceptable limits.

METHANE WARNING

R12-1

Active when 120VAC is present.

EMERGENCY TRAM

R12-2

Active when 120VAC is present. When present, indicates that system is in Emergency Tram Mode.

AC SPARE INPUT #9

R12-3

AC SPARE INPUT #10

R12-4

AC SPARE INPUT #11

R12-5

AC SPARE INPUT #12

R12-6

AC SPARE INPUT #13

R12-7

ANY INPUT ON R9

R12-8

Active when 120VAC is present at any input on connector R9.

G005.1-TShoot_RCSysContMiners_In-M

Troubleshooting Guide Table 6. MCU945 Status LED Description (R13 & R14) LED Function

LED Location

FIRE ALARM

R13-1

Active when fire suppression contact is closed. The fire suppression contact, when fire suppression is initiated, will stay active for 10 seconds. Controlled from transmitter.

PRE-START LIGHT

R13-2

Active when Pre-start contact closed. Output will activate upon pump start sequence. Action is controlled by the transmitter.

SPARE DC OUTPUT

R13-3

+12 VDC OUTPUT

R13-4

Indicates +12V I/O have power.

LOW OIL LOCKOUT

R13-5

Active when low oil lockout input sensor is active.

LOW OIL ALARM

R13-6

Active when low oil alarm input sensor is active.

HIGH OIL TEMP ALARM

R13-7

Active when high oil temperature sensor is active.

RIGHT TRAM BRAKE RELEASED

R13-8

Active when 120VAC is present.

LEFT TRAM BRAKE RELEASED

R14-1

Active when 120VAC is present.

TRAM XFMR T-STAT

R14-2

Active when thermostat is below 150C (120VAC is present).

FAN T-STAT

R14-3

Active when thermostat is below 150C (120VAC is present).

PUMP T-STAT

R14-4

Active when thermostat is below 150C (120VAC is present).

RIGHT CUTTER TSTAT

R14-5

Active when thermostat is below 150C (120VAC is present).

LEFT CUTTER TSTAT

R14-6

Active when thermostat is below 150C (120VAC is present).

RIGHT CONVEYOR TSTAT

R14-7

Active when thermostat is below 150C (120VAC is present).

LEFT CONVEYOR TSTAT

R14-8

Active when thermostat is below 150C (120VAC is present).

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Description

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Table 7. MCU945 Status LED Description (R15 to R20) LED Function

LED Location

Description

RADIO RECEIVER TX

R15 TOP

Active when MCU945 transmits out.

RADIO RECEIVER RX

R15 BOT

Active when MCU945 receives packets specific to its ID.

DISPLAY TX

R16 TOP

Active when MCU945 receives packets.

DISPLAY RX

R16 BOT

Active when MCU945 transmits out.

IR PENDENT TX RECEIVED

R17 BOT

Active when MCU945 receives valid packets.

MCU945 TX TO TRACTION DRIVE

R18 TOP

Active when MCU945 transmits out.

MCU945 RX FROM TRACTION DRIVE

R18 BOT

Active when MCU945 receives valid messages.

UNUSED

R19 BOT

Not used at this time.

DOWNLOAD/DEBUG TX

R20-1

Active when MCU945 transmits out.

DOWNLOAD/DEBUG RX

R20-2

Active when MCU945 receives bytes.

Table 8. MCU945 Status LED Description (R21 to R22) LED Function

10

LED Location

Description

GP10

R21

Unused

+5V

R22-1

Indicates when +5V is active. This voltage is required to operate the MCU945.

+12V

R-22-2

Indicates when +12V is active. This voltage is required to operate the MCU945 in normal modes. It is deliberately deactivated in battery mode until required.

UMBILICAL (PENDANT ACTIVITY)

R22-3

Indicates when transmitter is connected to the MCU945 via umbilical cable and is active.

HARDWARE FAILURE (TOGGLE)

Near Rotary Switch

Flashes whenever there is a hardware failure internal to the MCU945.

MODBUS COMM ERROR (TOGGLE)

Near Rotary Switch

IR PENDANT COMM ERROR (TOGGLE)

Near Rotary Switch

WRITE TO EEPROM (TOGGLE)

Near Rotary Switch

G005.1-TShoot_RCSysContMiners_In-M

Troubleshooting Guide

2.4 TX945 Transmitter

Note: Refer to separate documentation for additional information on the TX945 Transmitter. Use Figure 2 as a location reference for the TX945 Transmitter.

Figure 2. TX945 Transmitter Status LEDs Table 9. TX945 Status LED Response Analysis LED Function

Description

BATTERY/UMB MSG

NOTE: THIS LED HAS 2 FUNCTIONS BATTERY Transmitter Mode: A flashing LED means that battery strength is good. A double-blink—pause—double-blink LED means the batteries need to be changed (approx. 24hrs left). The transmitter will run until the batteries are dead, but performance and range will diminish quickly and could be unsafe if trying to operate from a long range. When the LED double-blinks, the batteries should be changed without delay.

Umbilical Message: LED blinks indicating that a message has been sent to the MCU. The blink rate should be steady at 10 times per second.

ERROR

LED does come on briefly after power up. If this LED is ON after power up, the transmitter should be returned for repair.

LINK REQUEST/SHUTDOWN

NOTE: THIS LED HAS 2 FUNCTIONS LINK Request: When the transmitter is connected umbilically, it will attempt to link to the MCU. Shutdown: When the transmitter switches off, this indicates that a shutdown is in progress and power down messages are being sent to the MCU. ** At the same time, one of three LED’s to the right will indicate why the transmitter is powering down: Commanded (Operator initiated), Inactivity or Low Battery (See paragraphs below).

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LED Function

Description

SWITCH ACTIVE/LOW BATTERY

NOTE: THIS LED HAS 2 FUNCTIONS Switch Active: After power up this LED is used to indicate a “stuck switch”.

•

ALL switches must be in their neutral or safe position before the transmitter is allowed to become operational.

•

If after power up (i.e. TX PWR ON depressed) LED lights and stays ON (solid) then there is a “stuck” switch. In this condition, no other switches on the transmitter will be operational.

•

Faulty Condition: The transmitter will send the error condition to the MCU and the system will display which switch is “stuck”. This switch must be replaced before proper operation will resume.

•

After power up, any switch that is operated will result in this LED being solidly ON while the switch is operated. In this manner, all switches can be verified locally at the transmitter.

•

To see if the transmitter switch is being properly read, operate the switch and observe the SW ACTIVE LED.

•

Note that only one switch can be operated at any time as this LED is common for all switches. Also while in normal operation, certain switches are timed to maintain safety features primarily as two handed starts. If for example the ENABLE button is held down for more than 25 seconds, then the transmitter will enter an error mode. If this occurs then all commands will cease to operate and an error code will be sent to the machine.

•

To resume normal operation, the ENABLE button must be released.

Switches that are timed in this manner are ENABLE, SHIFT, TRAM ENABLE, PUMP START, CONV START, CONV REV, and CUTTER START. Note : In normal operation, all of these switches are to be operated for only short periods of time. A constantly held condition would be abnormal and defeat two handed starts and make other enabled functions unsafe. Therefore, these switches are monitored and timed during normal operation to prevent the possibility of a constantly ON switch.

Shutdown via Low Battery: Upon shutdown, this LED will illuminate in conjunction with the SHUTDOWN LED to indicate that the reason the TX shut off was a low battery condition.

12

TRAM ENABLE/INACTIVITY

NOTE: THIS LED HAS 2 FUNCTIONS Tram Enable: Indicates that the tram levers are armed (active) and that any operation of the tram levers will result in machine movement. Conversely, if this LED is OFF, then the tram levers are dead.

Shutdown via Inactivity: Upon shutdown, this LED will light in conjunction with the SHUTDOWN LED to indicate that the reason the TX shut off was inactivity (no switch operation for 5 minutes).

LINK ACK/COMMANDED POWER DOWN

NOTE: THIS LED HAS 2 FUNCTIONS Link Acknowledge: During the TEACH/LEARN process, LED indicates that a link response (acknowledgment) has been received back at the transmitter from the MCU. I f the transmitter was re-linked back to the same MCU (machine), then this LED will flash once.

If this is a new link to a different MCU (machine), then this LED will flash twice.

Shutdown via Power Down: Upon shutdown, this LED will light in conjunction with the SHUTDOWN LED to indicate that the reason the TX shut off was a commanded power down (operated or initiated) as a result of the operator pressing either the MACHINE STOP mushroom head or the TX PWR OFF pushbutton.

G005.1-TShoot_RCSysContMiners_In-M

Troubleshooting Guide LED Function

Description

ERROR

LED does come on briefly after power up. If this LED is ON after power up, the transmitter should be returned for repair.

2.5 RX944 Receiver The RX944 Receiver is approximately 6 inches long and 2 inches high. It is located in the Radio Receiver Case of the 30M Miner. The device runs on 12V via R1-1 and R1-2.

Figure 3. RX944 Receiver Status LEDs Table 10. RX944 Status LED Description LED Function

LED

WATCHDOG

1

Flashes once Per Second to indicate that power has been applied and that internal processor is alive and working.

PRE-AMBLE DETECTED

2

Blinks to indicate that transmitter is on the correct frequency and has been detected. This LED should blink approximately 10 times per second as soon as a transmitter is switched ON in the vicinity of the machine.

VALID MESSAGE

3

Blinks to indicate that valid messages from a transmitter on the correct frequency are being received. Note: This does NOT mean that the transmitter is the serial number that has been “TAUGHT” to the Machine Control Unit. Check top Right Hand Corner of Graphics Display for TX945 Serial Number (See Section 3.0).

LINK RECEIVED

4

Steady On: Indicates that a sufficient number of messages are being received from the TX945 to operate and the system should not drop out.

NOT USED

5-8

Description

Reserved for future use.

2.6 CPS945 The CPS945 Capacitor Backup is approximately 6 inches long and 6 inches high. It is located on the Swing Panel of the Main Control Case in 30M Miners. The device runs on 120VAC via R2-2 and R2-3.

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Figure 4. CPS945 Power Supply Status LEDs Table 11. CPS945 Status LED Response Analysis LED Function

LED

Description

+12VDC OUTPUT ACTIVE

1

Active in Battery Mode.

+5VDC OUTPUT ACTIVE

2

Active in Battery Mode.

120VAC INPUT PRESENT

3

Active when not in Battery Mode.

2.7 DCD100 DC Tram Drive The DCD100 DC Tram Drive is located in the Control Case of the 30M Miner. The device runs on 120VAC via D1-1 and D1-2.

Figure 5. DCD100 DC Tram Drive Status LEDs

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G005.1-TShoot_RCSysContMiners_In-M

Troubleshooting Guide Table 12. DCD100 Status LED Response Analysis LED Function

LED

LOCAL FWD

1

Indicates FWD direction command in LOCAL CTRL.

Description

LOCAL REV

2

Indicates REV direction command in LOCAL CTRL.

UNUSED

3

UNUSED

4

AC PRESENT

AC

Indicates when 120 VAC power is available.

TRANSMIT OUT

TX

Indicates transmission by unit over serial COM port.

RECEIVED IN

RX

Indicates reception by unit over serial COM port.

WATCHDOG

WDG

Indicates unit is active and operating code.

PROPORTIONAL OUTPUT

OUT

Will blink when active. Rate of blinking is directly related to the magnitude of the command.

FORWARD DIRECTION

RT (FWD)

Indicates when commanded output direction is FWD.

REVERSE DIRECTION

LT (REV)

Indicates when commanded output direction is REV.

2.8 CST945 Pendent Drive Controller The CST945 Pendent Remote Control Unit is a handheld controller that connects to the TPI945 receiver/decoder with and umbilical cable. Its primary purpose is to be used as an end-station controller when it becomes necessary to move the machine to a safe location during time when a problem with the MCU945 is indicated. It is usually stored on the miner in a convenient location, disconnected from the MCU until needed.

CST/TPI is an alternate to the MCU control and it works independent of the MCU. • • • •

The CST945 cannot be used unless the MCU is disabled.

12Vdc power to the CST945 is provided by the TPI945 when connected.

The CST945 is active once connected to the machine and the machine selector is in the pendent position.

CST945 MODE LED is lit green when active.

Figure 6. CST945 LEDs

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Table 13. CST945 LED Indicators LED

Name

Description

MODE

Mode

LED blinks green when power is present indicating the unit has power and is on.

Note: For the Tram Enable LED to be on, all tram motion buttons must be

TRME

Tram Enable

in the idle state before the Tram Enable button us depressed.

Default is UNLIT. If all Tram motion buttons are in the idle state and the Tram button is depressed, then the Tram Enable is granted. Enable will be denied if any tram motion button is depressed beforehand.

The LED lights YELLOW indicating the operator has a limited amount of time (Tseconds) in which the tramming buttons can be used.

If the operator uses the tramming buttons while TRME is yellow, tramming remains enabled and the LED will continue to be lit until it senses inactivity beyond its setpoint of Tseconds, in which case it goes out indicating that the four tramming buttons are disabled.

The TRAM enable button must be pressed again to reset the timer to Tseconds, light the TRME yellow LED, and re-enable the tramming buttons.

Note: The TRML LED will only be lit RED when the proper sequencing has TRML

Tram Left

occurred, and a Left Tram motion button is depressed. The LED will remain lit for the duration of the request.

Default for the LED is UNLIT. The TRME LED must be lit YELLOW (Trams properly enabled) for TRML to light RED when the motion button is depressed.

When lit, this indicates directional movements are now granted. The operator can select left TRAM FWD▲ or TRAM REV▼.

Note: The TRMR LED will only be lit RED when the proper sequencing has TRMR

16

Tram Right

occurred, and a Right Tram motion button is depressed. The LED will remain lit for the duration of the request.

Default for the LED is UNLIT. The TRME LED must be lit YELLOW (Trams properly enabled) for TRMR to light RED when the motion button is depressed.

When lit, this indicates directional movements are now granted. The operator can select right TRAM FWD▲ or TRAM REV▼.

G005.1-TShoot_RCSysContMiners_In-M

Troubleshooting Guide

3.0 Alarms, Warnings, and Display Information The purpose of this section is to provide service personnel with the complement of possible alarms, warnings, and information that are designed into the system for troubleshooting purposes. The system is capable of sensing many possible abnormal conditions associated with these message categories. When an abnormal state is sensed, an appropriate message is displayed on all screens for 10 seconds, in addition to being logged (see Section 1). The basic organization of the display screen message banner is provided in Figure 7 and Table 14.

Figure 7. Display Screen Messages Table 14. Display Screen Top Banner General Description Fine #

Description

1

Fault log message, warning message, informational message block.

2

Miner type. For this application, should always read 30M.

3

MCU945 mode.

4

Battery voltage.

5

Transmitter serial number.

6

Commanded input message indication.

7

Messages per second from transmitter.

8

RF signal strength.

9

Active input indicator.

3.1 Coded Alarms and Warnings Alarms and warning codes are distinguished by the prefix letter A and W, respectively.

3.1.1 Alarm Codes Refer to Table 15 for the descriptions of system ALARM codes.

Table 15. Alarm Codes Code #

Description

A001

-120 Vac Loss from MMR

A002

-Pump Shutdown- Left EStop #1 or #2 Activated (R11-2)

A003

-Pump Shutdown- Right Estop #1 or #2 Activated (R11-1)

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Code #

Description

A004

-Transmitter Shutdown- Maximum switch/button active time exceeded

A005

-Error-Internal backplane communication

A006

-CurrentErrorCodeFutureUse

A007

-CurrentErrorCodeFutureUse

A008

-CurrentErrorCodeFutureUse

A009

-120VAC Earth Leakage (EL120)(R9-2)

A010

-Enable PushButton Stuck

A011

-Transmitter shutdown - low battery

A013

-Transmitter shutdown - data link loss

A014

-12VAC Earth Leakage (EL12)(R11-6)

A015

-High Hyd Oil Temperature

A016

-350VAC/DC Earth Leakage (EL350)(R11-7)

A017

-Pump shutdown - Low Low Oil Level Shutdown active for 5 sec.

A018

-Pump shutdown- Tilt Switch Active

A019

-Pump shutdown - Over-temperature (RTD) above 150 C

A020

-Pump shutdown - Pump motor overload

A021

-Pump shutdown - Right Drive Current without Tram Command

A022

-Pump shutdown - Left Drive Current without Tram Command

A023

-Pump shutdown - Pump Inst. Current Trip - 5 Sec to Reset

A024

-Pump shutdown - Pump Phase Imbalance Trip

A025

-Pump shutdown - Pump Low Current - 11 Seconds to Reset

A026

-Pump shutdown - Pump Start Switch held too long

A027

-Pump Start toggle switch stuck

A028

-Conveyor Reverse pushbutton stuck

A029

-Conveyor Start toggle switch stuck

A030

-Conv Shutdown - Rt Motor Jam Current - 5 Sec to Reset

A031

-Conv Shutdown - Lt Motor Jam Current - 5 Sec to Reset

A032

-Conveyor Shutdown - Right Motor Over-temp (RTD)

A033

-Conveyor Shutdown - Left Motor Over-temp (RTD)

A034

-Conveyor Shutdown - Right Motor Overload

A035

-Conveyor Shutdown - Left Motor Overload

A036

-Conv Shutdown - Rt Motor Inst Curr Trip - 5 Sec to Reset

A037

-Conv Shutdown - Lt Motor Inst Curr Trip - 5 Sec to Reset

A038

-Conveyor Shutdown - Right Motor Phase Imbalance Trip

A039

-Conveyor Shutdown - Left Motor Phase Imbalance Trip

A040

-Conv Shutdown - Rt Motor Low Current - 11 Sec to Reset

A041

-Conv Shutdown - Lt Motor Low Current - 11 Sec to Reset

G005.1-TShoot_RCSysContMiners_In-M

Troubleshooting Guide Code #

Description

A042

-Conveyor Shutdown - Conveyor Reverse Switch Operated

A043

-Conveyor Shutdown - Conveyor Motor Current Differential

A044

-Spare Alarm for R12-1 Input

A045

-Conveyor Start Switch held too long

A046

-Conveyor REV JOG Switch held too long

A047

-CurrentErrorCode_FutureUse

A048

-CurrentErrorCode_FutureUse

A049

-CurrentErrorCode_FutureUse

A050

-CurrentErrorCode_FutureUse

A051

-Cutter Shutdown - Right Motor Over-temp (RTD)

A052

-Cutter Shutdown - Left Motor Over-temp (RTD)

A053

-CurrentErrorCode_FutureUse

A054

-CurrentErrorCode_FutureUse

A055

-CurrentErrorCode_FutureUse

A056

-CurrentErrorCode_FutureUse

A057

-CurrentErrorCode_FutureUse

A058

-Cutter Shutdown - Right Motor Overload

A059

-Cutter Shutdown - Left Motor Overload

A060

-Cutter Shutdown - Rt Motor Inst. Curr Trip - 5 Sec to Reset

A061

-Cutter Shutdown - Lt Motor Inst. Curr Trip - 5 Sec to Reset

A062

-Cutter Shutdown - Right Motor Phase Imbalance Trip

A063

-Cutter Shutdown - Left Motor Phase Imbalance Trip

A064

-Cutter Shutdown - Right Motor Low Current - 11 Sec to Reset

A065

-Cutter Shutdown - Left Motor Low Current - 11 Sec to Reset

A066

-Cutter Shutdown - Cutter Disable switch in Disable Position

A067

-Cutter Shutdown - Cutter Motor Current Differential

A068

-Cutter Shutdown - LOW OIL ALARM for 5 sec

A069

-Cutter Shutdown - Cutter Start Switch held too long

A070

-Cutter Shutdown - Low Low Oil Shutdown

A071

-Cutter Shutdown - Water System Flow Trip (R5-3)

A072

-Cutter Shutdown - Right Motor Jam Current - 5 Sec to Reset

A073

-Cutter Shutdown - Left Motor Jam Current - 5 Sec to Reset

A074

-Cutter Start Toggle Switch Stuck

A075

-Spare Alarm for R12-1 Input

A076

-Cutter Shutdown - End of Cutter Gear Case Test Mode

A077

-CurrentErrorCodeFutureUse

A078

-CurrentErrorCodeFutureUse

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Code #

Description

A079

-CurrentErrorCodeFutureUse

A080

-Fan Shutdown - Instantaneous Current Trip - 5 Sec to Reset

A081

-Fan Shutdown - Overload Trip

A082

-Fan Shutdown - Phase Imbalance Trip

A083

-Fan Shutdown - Low Current Trip - 11 Sec to Reset

A084

-Fan Shutdown - Over-temp (RTD)

A085

-Fan Shutdown - Jam Current Trip - 5 Sec to Reset

A086

-CurrentErrorCodeFutureUse

A087

-CurrentErrorCodeFutureUse

A088

-CurrentErrorCodeFutureUse

A089

-CurrentErrorCodeFutureUse

A090

-CurrentErrorCodeFutureUse

A091

-CurrentErrorCodeFutureUse

A092

-CurrentErrorCodeFutureUse

A093

-CurrentErrorCodeFutureUse

A094

-CurrentErrorCodeFutureUse

A095

-CurrentErrorCodeFutureUse

A096

-PLC to Rt Drive COMM Fault (All TRAM commands cleared)

A097

-PLC to Lt Drive COMM Fault (All TRAM commands cleared)

A098

-Machine Voltage Below Allowable Range (<80% Vnom)

A099

-Machine Voltage Above Allowable Range (>117% Vnom)

A100

-CurrentErrorCodeFutureUse

A101

-Right Tram Motor Overload

A102

-Left Tram Motor Overload

A103

-Tram Enable Switch held more than 3 Sec without TRAM

A104

-Tram Enable Switch Stuck

A105

-CurrentErrorCodeFutureUse

A106

-CurrentErrorCodeFutureUse

A107

-CurrentErrorCodeFutureUse

A108

-CurrentErrorCodeFutureUse

A109

-CurrentErrorCodeFutureUse

A110

-CurrentErrorCodeFutureUse

A111

-CurrentErrorCodeFutureUse

A112

-Tram Shutdown - Left Drive Phase A Overcurrent

A113

-Tram Shutdown - Left Drive Phase B Overcurrent

A114

-Tram Shutdown - Left Drive Bus OverVoltage

A115

-Tram Shutdown - Left Drive OverTemperature

G005.1-TShoot_RCSysContMiners_In-M

Troubleshooting Guide Code #

Description

A116

-Tram Shutdown - Right Drive Phase A Overcurrent

A117

-Tram Shutdown - Right Drive Phase B Overcurrent

A118

-Tram Shutdown - Right Drive Bus OverVoltage

A119

-Tram Shutdown - Right Drive OverTemperature

A120

-Right Drive Limited - Loss of Voltage Feedback

A121

-Left Drive Limited - Loss of Voltage Feedback

A122

-CurrentErrorCodeFutureUse

A123

-CurrentErrorCodeFutureUse

A124

-CurrentErrorCodeFutureUse

A125

-CurrentErrorCodeFutureUse

A126

-CurrentErrorCodeFutureUse

A127

-FCR Data Link Loss

A128

-Teach/Learn Successful

A129

-Teach/Learn Failed

A130

-CurrentErrorCodeFutureUse

A144

-Pump Shutdown - 120VAC Earth Leakage (R9-2)

A145

-Cutter Shutdown - Water Pressure Trip (R5-4)

A146

-Tram Shutdown Left Brake Not Released (R5-1)

A147

-Tram Shutdown Right Brake Not Released (R5-2)

A335

-Enable push button stuck on TX

A336

-Tram Enable Button stuck on TX

A337

-Pump Start push button stuck on TX

A338

-Conveyor Start push button stuck on TX

A339

-Cutter Start push button stuck on TX

A348

-Fan Button Stuck on TX

3.1.2 Warning Codes Refer to Table 16 for the descriptions of system WARNING codes.

Table 16. Warning Codes Code

Description

W001

-Conveyor Reverse won't start - Pump Off

W002

-Conveyor Reverse won't start - Right Conveyor Jam

W003

-Conveyor Reverse won't start - Conveyor Stop

W004

-Conveyor Reverse won't start - Right Conveyor Overtemp (RTD)

W005

-Conveyor Reverse won't start - Left Conveyor Overtemp (RTD)

W006

-Conveyor Reverse won't start - Right Conveyor Overload

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IRIS for Continuous Miners in India

Code

Description

W007

-Conveyor Reverse won't start - Left Conveyor Overload

W008

-Conveyor Reverse won't start - Right Conveyor Inst. Trip

W009

-Conveyor Reverse won't start - Left Conveyor Inst. Trip

W010

-Conveyor Reverse won't start - Right Conveyor Low Current

W011

-Conveyor Reverse won't start - Left Conveyor Low Current

W012

-Conveyor Reverse won't start - Right Motor Single Phase

W013

-Conveyor Reverse won't start - Left Motor Single Phase

W014

-Conveyor Reverse won't start - Left Conveyor Jam

W015

-Conveyor Reverse won't start - Differential Trip time not expired

W016

-Conveyor Reverse won't start - time period between fwd/rev not expired

W017

-Pump won't start - Tilt Switch Active

W018

-Pump won't start - Left Estop #1 or #2 is OPEN (R11-2)

W019

-Pump won't start - Right Estop #1 or #2 is OPEN (R11-1)

W020

-Pump won't start - 350VAC/VDC Earth Leakage Detected (R11-7)

W021

-Pump won't start - High Hydraulic Oil Temperature fault

W022

-Pump won't start - Low Low Oil Level Shutdown active for 5 sec (R14-4)

W023

-Pump won't start - Low Current

W024

-Pump won't start - Pump Motor Temp above 150 (140 after trip)

W025

-Pump won't start - Overload trip reset time not expired

W026

-Pump won't start - Inst trip reset time not expired

W027

-Pump won't start - Machine Voltage < 80% Vnom

W028

-Pump won't start - Keyswitch is off

W029

-Pump won't start - 120VAC Earth Leakage Detected (R9-2)

W030

-Pump won't start - Conveyor FWD Start is operated

W031

-Pump won't start - Conveyor REV Start is operated

W032

-Pump won't start - Pump Phase

W033

-Conveyor won't start - Pump Off

W034

-Conveyor Fwd won't start- R Conv Jam trip reset time not expired

W035

-Conveyor won't start - Conveyor Stop

W036

-Conveyor won't start - Right Conveyor Overtemp (RTD)

W037

-Conveyor won't start - Left Conveyor Overtemp (RTD)

W038

-Conveyor won't start - Right Conveyor Overload

W039

-Conveyor won't start - Left Conveyor Overload

W040

-Conveyor won't start - Right Conveyor Instant

W041

-Conveyor won't start - Left Conveyor Instant

W042

-Conveyor won't start - Right Conveyor Low Current

W043

-Conveyor won't start - Left Conveyor Low Current

G005.1-TShoot_RCSysContMiners_In-M

Troubleshooting Guide Code

Description

W044

-Conveyor won't start - Right Phase

W045

-Conveyor won't start - Left Phase

W046

-Conveyor Fwd won't start- L Conv Jam trip reset time not expired

W047

-Conveyor won't start - Differential Trip reset time not expired

W048

-Conveyor won't start - time period between fwd/rev not expired

W049

-Cutter won't start - Pump not running

W050

-Cutter won't start - Right Cutter Overload trip time not expired

W051

-Cutter won't start - Right Cutter Inst trip reset time not expired

W052

-Cutter won't start - Right Cutter Low Current

W053

-Cutter won't start - Right Cutter Overtemp (RTD)

W054

-Cutter won't start - Left Cutter Overtemp (RTD)

W055

-Cutter won't start - Left Cutter Overload trip time not expired

W056

-Cutter won't start - Left Cutter Inst trip reset time not expired

W057

-Cutter won't start - Left Cutter Low Current

W058

-Cutter won't start - Low Low Oil

W059

-Cutter won't start - Water System lacking Flow or Pressure

W060

-Cutter won't start - Differential Trip reset time not expired

W061

-Cutter won't start - Right Phase

W062

-Cutter won't start - Left Phase

W063

-120VAC Loss from MMR

W064

-Cutter won't start - Low Oil

W065

-Fan won't start - cutter must be started first

W066

-Cutter won't start - fan must be started first

W067

-Fan won't start - Fan Overtemp (RTD)

W068

-Fan won't start - Fan Low Current

W069

-Fan won't start - Fan Overload

W070

-Fan won't start - Fan Instant

W071

-Fan won't start - Fan Phase

W072

-Fan won't start - Fan Jam

W081

-Tram won't Start - Left Drive Bus OverVoltage

W082

-Tram won't Start - Right Drive Bus OverVoltage

W083

-Tram won't Start - Left Drive Bus OverTemperature

W084

-Tram won't Start - Right Drive Bus OverTemperature

W085

-Tram - Command without Tram Enable

W086

-Tram - Command without Pump Running

W089

-Tram - Left Tram Overload

W090

-Tram - Right Tram Overload

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IRIS for Continuous Miners in India

Code

Description

W091

-Tram - Left Tram Communication Error

W092

-Tram - Right Tram Communication Error

W093

-Tram won't start - Left Drive Phase A OverCurrent

W094

-Tram won't start - Right Drive Phase A OverCurrent

W095

-Tram won't start - Left Drive Phase B OverCurrent

W096

-Tram won't start - Right Drive Phase B OverCurrent

W097

-System shutdown due to Power Center Trip

W098

-Cutter won't start - Right Cutter Jam

W099

-Cutter won't start - Left Cutter Jam

W105

-Haulage Transformer Over-Temp (RTD)

W106

-Handheld Address Out of Range

W107

-No Active Link Input

W108

-MCU Serial Number out of range

W109

-CutterLower Override due to Right Motor

W110

-Cutter Lower Override due to Left Motor

W111

-Cutter Raise Override due to Right Motor

W112

-Cutter Raise Override due to Left Motor

W113

-12VAC Earth Leakage

W114

-350VAC/DC Earth Leakage

W115

-Water System pressure/flow warning

W116

-Methane Gas detected at Warning Level

W117

-High Hydraulic Oil Temperature Fault

W118

-Tram Transformer T-stat Temperature High

W119

-Fan Motor T-stat Temperature High

W120

-Pump Motor T-stat Temperature High

W121

-Left Cutter Motor T-stat Temperature High

W122

-Right Cutter Motor T-stat Temperature High

W123

-Left Conveyor Motor T-stat Temperature High

W124

-Right Conveyor Motor T-stat Temperature High

W125

-Left Tram Motor Overtemp (RTD)

W126

-Right Tram Motor Overtemp (RTD)

W129

-Pump Shutdown - Pump Stop Operated

W130

-Left Emergency Stop Operated

W131

-Case Emergency Stop Operated

W132

-Conveyor Shutdown - Conveyor Stop Operated

W133

-Cutter Shutdown - Cutter Stop Operated

W134

-Cutter Shutdown - Command Stop

G005.1-TShoot_RCSysContMiners_In-M

Troubleshooting Guide Code

Description

W135

-Low Battery

W136

-Transmitter Shutdown Inactivity Period Expired

W137

-Cutter Shutdown - Keyswitch off

W138

-Switch Active

W139

-Cutter Raise Inhibit Due to Inclinometer

W140

-Cutter Lower Inhibit Due to Inclinometer

W141

-Fwd. Conveyor Inhibit Due to test mode

W142

-Rev. Conveyor Inhibit Due to test mode

W143

-Tram won't start - Right Tram Brake Not Released

W144

-Tram won't start - Left Tram Brake Not Released

W148

-Cutter Start Switch Operated at Start Up

W149

-Ventilation Only Switch Operated at Start Up

W150

-Right Tram Reference Present at Start Up

W151

-Left Tram Reference Present at Start Up

W152

-Right Tram FWD Contact Closed at Power Up

W153

-Right Tram REV Contact Closed at Power Up

W154

-Left Tram FWD Contact Closed at Power Up

W155

-Left Tram REV Contact Closed at Power Up

W156

-Tram Enable Switch Operated at Start Up

W157

-Aux relay 1 won't start - pump off

W158

-Aux relay 2 won't start - pump off

W225

-Cutter won't start - Machine stop override mode

W226

-Conveyor won't start - Machine stop override mode

W229

-Conveyor won't start - Machine stop override mode

W230

-Conveyor won't start - Machine stop override mode

W231

-Conveyor won't start - Machine stop override mode

W236

-Scrubber Fan Stall Current

W237

-Low Oil Level

W238

-Low Low Oil Level Shutdown

W301

-Tram Enable toggle switch stuck in position

W302

-Tram Enable toggle switch stuck in position

W303

-Stab toggle switch stuck in Lower position

W304

-Stab toggle switch stuck in Raise position

W305

-Breaker toggle switch stuck in Reset positon

W306

-Breaker toggle switch stuck in On position

W307

-Conveyor toggle switch stuck in Lower position

W308

-Conveyor toggle switch stuck in Raise position

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IRIS for Continuous Miners in India

Code

Description

W309

-Conv. Swing toggle switch stuck in Left position

W310

-Conv. Swing toggle switch stuck in Right position

W311

-Gath. Head toggle switch stuck in Float position

W312

-Gath. Head toggle switch stuck in Raise position

W313

-Cutter Head toggle switch stuck in Lower position

W314

-Cutter Head toggle switch stuck in Raise position

W315

-Pump toggle switch stuck in Stop position

W316

-Pump toggle switch stuck in Start position

W317

-Fan toggle switch stuck in Off position

W318

-Fan toggle switch stuck in On position

W319

-Dust toggle switch stuck in Off position

W320

-Dust toggle switch stuck in On position

W321

-Fire/Lights toggle switch stuck in Fire position

W322

-Fire/Lights toggle switch stuck in Lights position

W323

-Conveyor toggle switch stuck in Stop position

W324

-Conveyor toggle switch stuck in Start position

W325

-Conveyor Reverse push button stuck

W326

-Cutter toggle switch stuck in Stop position

W327

-Cutter toggle switch stuck in Start position

W328

-Shift push button stuck

W329

-MStop Override push button stuck

W330

-Enable push button stuck

W331

-Tram High push button stuck

W332

-Tram Low push button stuck

W333

-Left Tram lever stuck

W334

-Right Tram lever stuck

W344

-Left Tram Command without enable

W345

-Right Tram Command without enable

W346

-tram enable and left tram simultaneous

W347

-tram enable and right tram simultaneous

W349

-Motor Start before enable

G005.1-TShoot_RCSysContMiners_In-M

Troubleshooting Guide

4.0 Component Identification 4.1 Remote Control System Components The components that make up this system are listed in Table 17. With exception of the TX945, all other components of this radio control system are mounted on the machine and within a methane isolation barrier enclosure. The display may be mounted on the opposite side of the machine and in its own barrier enclosure.

Table 17. System Components Component

Description

MCU945

Custom PLC

RX944

Radio Receiver

TX945

Radio Transmitter

CPS945

Capacitor Backup Power Supply

RDU945

Emergency Pendant Interface

DCD100

DC Tram Drive

Display

Graphics Status Display

CST945

Pendant Drive Controller

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BUCYRUS®

IRIS for Continuous Miners in India

4.2 Remote Control System Components Tie-in The basic components and their interconnections are shown in Figure 8.

Figure 8. Remote Control System Components Layout

28

G005.1-TShoot_RCSysContMiners_In-M

Troubleshooting Guide

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 2008 Cervis, Inc. All rights reserved. Content is subject to change without notice.

2008 Cervis, Inc.

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