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ThismanualisintendedtoprovideGENERALproductinformationfor theModel30M4-NPContinuousMiner.Theillustrations,descriptions andprocedurescontainedinthispublicationapplyonlytoTHISmachine.Bucyrusreservestherighttorevisemodelsanddesignswithout priornotice.
ThisContinuousMinerwasmanufacturedundertheguidelines,proceduresandrequirementsoftheappropriategovernmentregulatoryagencies.
Atthecompletionofthemanufacturingprocess,thisunitwasissuedthe appropriateapprovalnumbersandnameplatesindicatingitmetthe technicalrequirementsoftheseregulatoryagencies.Anychangetothe designorstructureofthisunit,withouttheconsentofBucyrusAmerica, Inc.andtheseregulatoryagencies,oranyrepairorreplacementof partscontrarytoBucyrusAmerica,Inc.’sinstructions,mayinvalidate theseapprovalsandrenderthisunitunsafetooperate.
Strictcompliancewithalllaws,regulationsandpracticesregardingthe safeoperationandmaintenanceofundergroundminingequipmentand strictadherencetotheinstructionsinthismanualisnecessaryforthe personalsafetyofthoseworkingonoraroundthisunit.
Whilethismanualattemptstoanticipatethemostimportantoperations andmaintenanceneedsforthisunit,unforeseencircumstancesmay arisethathavenotbeenaddressedinthismanual.Ifanyconcernsor questionsarise,pleasecontactyourBucyrusAmerica.Inc.Service Representative immediately
Thisworkcontainsinformationprotectedundertradesecretandother intellectualpropertylaws,andisprotectedundertheU.S.Copyright Actof1976,asamended.Thisworkisprovidedunderlicenseandthe licenseisnon-transferable.Distributionandaccessislimitedonlyto authorizedpersonnel.Disclosure,reproduction,distributionorunauthorizedusemaybeaviolationoffederalandstatelawsandmaysubjecttheunauthorizedusertocriminalliability.
1. Aboutthismanual 2. Yoursafety 3. Storageandtransport 5. Operation Aboutthismanual Aboutthismanual Thischapterprovidesimportantinformationmakingiteasierforyouto usethismanual.Itcontainsinformationonthestructureofthemanual andthesymbolsandcharactersused.
Beforestartingtowork Takecaretoensurethattheoperatingmanualavailabletoyouisapplicableforthetypeofequipmentormachineused.
Thisoperatingmanualisintendedfor:
BucyrusModel30M4-NPContinuousMiner
SerialNo.:N/A
andisonlypermittedtobeusedforequipmentofthistype.
Theoperatingmanualmustbeaccessibleatalltimestoallpersons workingonorwiththemachine.Itshould,ifpossible,alwaysbeavailableattheplaceofoperation.
Sendforanewoperationmanualimmediatelyifthepresentmanualis nolongercompleteorhasbecomeillegible.
Whoisthisoperatingmanualintendedfor? Thisoperatingmanualisintendedforthosepersonswhoworkwithor onthemachine.Everypersonworkingonthefaceorintheintersectionbetweenfaceandentryorintheentrymustreadthisoperating manual.
Thisincludespersonswho:
■ operatethemachine
■ areinchargeoftransport
■ performassembly/disassemblywork
■ find/fixfaults
■ performdailyroutineworkatthefaceorintheentry
■ performmaintenancework
■ performrepairwork
supervisorypersonnelwho:
■ initiateand/orsupervisetheactivitiesjustindicated.
Beforestartingtowork Whatisthepurposeofthisoperatingmanual? Thisoperatingmanualisintendedtohelpyouworkefficientlyand safelywithourproduct.Itcontainsimportantinformationonalltheactivitiesrelatedtothemachine.
Readthisoperatingmanualcompletelyandatease.Payspecialattentiontothesafetyinstructions.Trytomemorizetheappearanceandthe meaningofthesafetyandinstructionsymbols.
Ifanydetailsarenotclearlyunderstood,pleasecontactourservicedepartment.Ourserviceaddressisgiveninthechaptertitled“Foryour information”.
Readthechapter“Foryoursafety”withspecialattention.Thechapter containsimportantinformationindicatingpossiblehazards.Observe theinformationgivenandfollowtheproceduralinstructions.
Charactersandsymbolsused Thefollowingcharactersandsymbolsareusedforsafetyinstructions andimportantinformationintheoperatingmanual.
Trytomemorizethesymbolsandtheirmeanings.
DANGER! Pointsinthetextmarkedwiththissymboldrawyourattentionto immediatelyimpendingdanger.Possibleconsequencesare: veryseriousinjuryorevendeath.
WARNING! Thesepointscontaininformationondangeroussituations.Possibleconsequencesare:veryseriousinjuryorevendeath.
CAUTION! Thissymboldrawsattentiontodangeroussituations.Possible consequencesare:lighttomoderatelyseriousinjuriesandmachinedamage.
NOTICE! Pointsinthetextmarkedwiththissymboldrawattentiontoharmfulsituations.Possibleconsequencesare:damagetothemachineordamageintheimmediatevicinity.
IMPORTANT! Pointsinthetextmarkedwiththissymbolcontainusefultipsand informationintendedtofacilitateworkforyou.Theydonotwarn aboutharmfulordangeroussituations.
■ Itemsinlistsaremarkedwithbullets.
– Pointsinsub-listsaremarkedwithalongdashatthestartof theline.
Pointsintextmarkedinthiswaydescribeindividualoperations. Followtheseinstructionsstepbystep.Theywillhelpyoucarryout yourworkfasterandmoreimportantly,safer.
Beforestartingtowork Yoursafety Thischapterprovidesvitalinformationforyoursafety.Payspecialattentiontothischapter.Thesafetyinstructionsandrulesofprocedure willhelpyoutoavoidhazardoussituationsandtoperformthenecessaryworkassafelyaspossible.
Thismachinehasbeenmanufacturedinaccordancewithstateofthe artandgenerallyrecognizedsafetystandardsandregulations. Youandotherscan,nevertheless,beexposedtodangeroussituations e.g.asaresultofenvironmentalinfluences,machinedamageoroperatorerrors.
Donotmakeanyalterationsormodificationswhichcouldimpairthe safeoperationandmaintainabilityofthemachine.Allmodifications andchangesmustbeapprovedbyBucyrusandallappropriateregulatoryagencies.
UseonlyoriginalsparepartsfromBucyrus.Notethattheuseofparts fromothermanufacturerswillvoidthewarranty.
Inadditiontothisoperatingmanualbesuretoalsoobservetherespectivelegalprovisionsandregulationsinyourcountry.
Observethesafetyandaccidentpreventionregulations
■ ofthemine,
■ ofthemine’sinspectors,and
■ oftheminingsupervisoryauthorities.
Readtheoperatingmanualsofthecomponentsrequiredforoperation, e.g.ofgearboxes,electricmotors,etc.,carefullyandthoroughly.Clarifyanyquestions before startingwork.
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training
Personnel Operation Themachinemayonlybeoperatedbyqualified,trainedpersonnel.
Themachineisonlyallowedtobeoperatedbyqualifiedpersonnelwho canprovideproofofhavingbeentrainedonthisunit.
Readingoftheoperationmanual,especiallythechapteronsafety,shall constituteapartofthistraining.
Youmusthaveadequateknowledgeofthe
■ mechanics,
■ hydraulics,and
■ controlengineering andmustbeabletoprovethisknowledge.
Installationandrepair Asafundamentalrule,installationandrepairworkmayonlybecarried outbypersonnelwhohavebeenadequatelytrainedfortheseparticular requirements.
Installationandrepairworkon:
■ safetycomponents(pressurereliefvalves,extinguishers,etc.)
■ theelectrics(motors,controllers,etc.)
■ thehydraulics(controls,cylinders,etc.)
mayonlybecarriedoutbyserviceengineersfromBucyrusorbyspeciallyqualifiedpersonnelofthemine.
Operatingconditions Intendeduse TheContinuousMinerhasbeendesignedandmanufacturedforspecificuses.Intendedusesinclude:
■ extractionofcoal,phosphate,potash,salt,trona,andothermediumhardnessminerals
■ loadingthematerialslistedaboveontoahaulagesystemorshuttle car,ordumpingitontothegroundforloadingatalatertime
■ operationongradesoflessthan10degrees
Unauthorizeduse Applicationsnotexpresslylistedasintendedusesareunauthorized usesandarenotallowedtobeperformedwiththemachine.
■ thetransportofpersons
■ stonedevelopmentorextraction
Bucyrusacceptsnoliabilityforanydamageresultingfromanysuch unauthorizeduse.
Operatingconditions Safetyinstructions Generalrules Alwaysworkwithfullconcentrationandfamiliarizeyourselfwithyour workingenvironment.
Alwayswearyourpersonalprotectiveequipment.Thisalsoincludes earprotectorsasthenoiseemittedbyotherequipmentintheareamay attimesexceed85db(A).
Informyourcolleaguesof
■ yourexactlocation,
■ theworkyouareperforming,and
■ thetimethatyouwillprobablyrequire.
Startthemachineonlywhenitisinagoodandsafeoperatingcondition andallprotectivedevices,e.g.emergencystopdevices,machinestop buttons,coverplates,etc.arecorrectlyinstalled.
Observethesymbolplatesonthemachine.
Pressanemergencystopbuttonimmediatelyintheeventoffaultor irregularitiesinoperation.Reportanyirregularitiestoyoursuperiorso thatnecessarymeasurescanbetakenimmediately.
Disconnect,lockout,andtagthepowersystem,followingallapplicable rulesandregulations,whileperformingmaintenance,inspection,orrepairwork.
Cordonoffyourworkingareawidelyforthemachine.
Neverallowpartsofyourbodytocomebetweenpartswhichcould move,suchase.g.:
■ chains,flights,andchainsprockets
■ pivotpoints
■ crawlerassembliesandconveyors
■ cutterandgatheringheadassemblies
Safetyinstructions Storageandtransport Maintaintheprescribedstorageperiodsandobservetheinstructions forstorage.
Donotstorematerialsorpartsinthetravelwayorinyourworking area.
Informthepersonsinvolvedabouttheintendedtransportrouteandthe anticipateddurationofthetransport.
Ensurethatthetransportsafetydevicesarecorrectlyfitted.
Fixallmovingpartswithtransportlocks.
Neverstandunderunsupportedpartsorsuspendedloads.
Connecttheliftingequipmenttothepointsofattachmentprovidedfor thatpurpose.Observethedifferentloadlimitsoftheattachment points.Also,observetheinstructionsonthetransportsheet.
Onlyusemeansofattachmentwhichareingoodconditionandhave beendesignedfortheloadstobehandled.Forroundcomponentsuse transportstrapsonly;neverusechainsorsteelcablesforthispurpose. Donotdamagethetreatedorpolishedsurfacesofshafts,sealingsurfaces,etc.
Whenusingmobilehandlingsystemsfortransportmakesurethatthe centerofgravityisaslowaspossible.
Pre-startinspection Readthisentiremanualbeforeattemptingtooperatethismachine.
Inspectthemachineandhaveanymalfunctioning,brokenormissing partscorrectedorreplacedbeforeuse.
Verifythatallmaintenancehasbeenperformed.
Verifythatallinstructionandsafetytagsareinplaceandreadable. Theseareasimportantasanyotherequipmentonthemachine.
Installationandstart-up Oninclinedfacessecureallcomponentpartsbychains,e.g.tothe support.
Whenworkingwithoils,greasesandotherchemicalsubstances,observethesafetyregulationsapplicabletotheproduct.SafetyregulationscanbefoundonthecontainerorontheMaterialSafetyData Sheet(MSDS)fortheproduct.
Disposeofcleaningrags,etc.whichhavebeensoiledwithoil,grease orotherchemicalsubstancesinanenvironmentallysafemanner.
Whenstartingupmachine,donotoperateanycontrolslocatedinside theoperator’spitfromoutsidethepit.
Followthestartingprocedureinstructionsintheoperationsmanual. Donotoperateanylevers,pedalsorcontrolsifanyoneisinthered zone.(SeeRedZoneinChapter5ofthismanual)
Operation Operatethemachineonlyifyouhaveaprofoundknowledgeofthe controlelementsandtheirfunctions.Itisnecessarythatyouhave beentasktrainedontherespectiveContinuousMiner.
Beforestart-up,ensurethattherearenopersonsorobstructionsin yourlineoftravelorinthearticulationareawhensteeringtheunit.
Checkthatallprotectivedevicesareinstalledonthemachineandfunctionproperly.
Useextremecautionwhentravelinginclosequartersorincongested orblind-travelareas.
Nevercarrypassengers.Passengersmaybethrownoffthemachine orcrushedbetweenthemachineandoutsideobjects.
Alwaysfollowallsafetyrulesofeachparticularminewhenoperating themachine.
Ifproblemsormalfunctionsareencounteredwhileoperatingtheunit, themachinemustbeproperlyshutdownandtheproblemcorrected immediately.
Safetyinstructions Stopping Alwaysparktheunitonsolid,levelground.Ifthisisnotpossible,park theunitatarightangletotheslopetopreventaccidentalmovementof themachine.
Useproperflags,warningsorbarrierswhenparkinginareasoftraffic.
Maintenanceandrepair Besuretoobservetheprescribedmaintenanceandinspectionintervals.
Informthesupervisorypersonnelandthefacecrewofanymaintenance andrepairoperations.Givetheminformationontheintendedoperationsandtheanticipatedduration.
Beforeattemptinganyrepairs,a DANGER signmustbeattachedtothe appropriatecircuitatthepowerdistributionbox.Itismandatoryunder governingregulationsthatthetrailingcablebeuncoupled,taggedand locked-outfromthepowersourcetoprovidevisualevidencethatthe minerisde-energized.
Secureyourworkingareaoverawiderange,inordertoavoidendangeringotherpersons.
Disconnectthepowerfromthemachinetopreventunauthorizedand unintentionalrestarting.
Protectyourworkareaagainstfallingrocks.
Passdefectivecomponentsremovedonforservicingwithoutdelayin ordertopreventthesepartsbeingreinstalledelsewhere.
Useonlysparepartswhichsatisfythespecifiedtechnicalrequirements. ThisisonlyensuredwithoriginalBucyrusspareparts.Pleasereferto thesparepartslistsorpartscatalogfortheordernumbers.
handlingofhydraulicfluids
maintenance/repair
Safetyinstructions ForraisingtheContinuousMineruseonly:
■ cribblockswithadequateload-holdingcapacity.
■ hoists,jacksorcraneswithadequateload-carryingcapacity.
Avoiddirectcontactbetweentheskinandhydraulicfluids.Hydraulic fluidcanpenetratetheskinandcauseseriousinfection.
Neverusehydraulicfluidforrinsingorcleaning.Hydraulicfluidrepresentsaveryseriousdangertohealth.
Onlypersonswhohaveandcandemonstrateaspecialknowledgeof hydraulicsareallowedtoworkonthehydraulicsystem.
Avoid,wheneverpossible,servicing,cleaningorexaminingthemachineincongestedareas.
Avoid,wheneverpossible,servicingorprovidingmaintenancetothe unitunlesstheappropriatesafetydevicesareplacedwhererecommendedtopreventaccidentalmovementoftheunit.
Donotaltertheelectricalorhydraulicsettingsfromthatindicatedinthis manualorassetatthefactory.
Alwaysreplacedamagedorlostdecalsandmetalinstructionplates. Disconnectthepowerwhenworkingwiththeelectricalsystem,orwhen weldingontheunittopreventelectricalshock.
Alwaysfollowallsafetyproceduresofeachparticularminewhenperformingmaintenance.
Itisimportantthatanyprocedurenotspecificallyrecommendedinthis guidebethoroughlyevaluatedfromthestandpointofsafetybeforeitis implemented.
Someillustrationsinthismanualshowguardsorcoverpanelsremoved forpurposesofclarity.Neveroperateunitwithoutguardsorcoverpanelsinplace.
Carryoutavisualinspectionofallthehydrauliccomponentsatregular intervals.Inparticularcheckthat:
■ thehosesarenotpinchedortrapped.
■ thehoseshavenobubblesorblisters.
■ thehoseoroutersheathsofthehosearenotabnormallyrigidor hard.
■ theoutersheathofthehosesisnotdamaged.
■ theconnectorsaresecurelyinsertedintothesockets.
■ theconnectionsareleak-tight.
Safetyinstructions ____________________________________________ Ensurethatnodirtentersthehydraulicsystemduringrepairwork.Dirt inthehydraulicsystemcancauseseriousdamageinthewholesystem! Flushoutthehydrauliclinesthoroughlybeforeconnecting.
Ifhydraulichosecouplersaredifficulttodisconnectorcannotbedisconnected,thehydrauliclinemaystillbepressurized.Besuretodepressurizethelinebeforedisconnectingcouplers.
Securetheconnectorsofthehydraulicelementsonlywiththeproper couplingclamps.Alwaysfastentheclampscompletelyandwithboth sides.Neverusenails,wireorsimilarmaterialsforsecuring.
Afterfinishingrepairwork,checkallconnectorsandconnectionsfor leaksbeforepressurizingthesystemagain.
Useonlyhydraulichosesapprovedfortheprevailingpressures.
Donotuseanyhydraulichoseswithdamagedconnectorsorwornorings.
Replacehydraulichosesonlywithhosesofthesameorahigherquality.
Nevertrytoholdajumpinghydraulichose.Depressurizethelinein questionimmediately.
Nevertrytorepairdamagedhydraulichoses.
Replacehydraulichosesatthefirstsuspicionofdamage.
installinghydraulichoses
Installthehydraulichosesproperlybehindthebracketsandclamps providedforthem.
Alwaysinstallhydraulichosessothey:
■ alwayshavealittleslack.
Fig.1:Installinghydraulichoses,slack
Safetyinstructions ■ arenottwisted.
Fig.2:Installinghydraulichoses,twisting Right Wrong
■ arenotbentdirectlybehindtheconnections. (distancemin.1.5xnominaldiameter).
Fig.3:Installinghydraulichoses,bending Right Wrong
■ alwayshavealittleslack.
■ arenotkinked.
■ donothavetowithstandtensilestrains.
■ areprotectedagainstthermalradiation.
■ areaccessibleatalltimes.
Screwhydraulichosesintothesocketsonlybyhandandfingertighten. Nevertrytodrivethehydraulichosesinwithatoolasthiswilldamage theconnections.Usetheappropriateamountoftorquetoensurea properhosefit.
Safetyinstructions Wheninstallingthehydraulichoses,ensurethattheycannotbe:
■ tornout,
■ kinked,
■ crushed,
■ drivenoveror
■ twistedbymovementofthemachine.
Fig.4:Installinghydraulichoses,connectionsonmovingparts
Right
Wrong
Storageandtransport Thischaptercontainsimportantinformationonthecorrectstorageand transportoftheContinuousMiner.Storageproceduresaregeneral. Forspecificproceduresforyourenvironment,contactBucyrusEngineering.
Observanceoftheinstructionsandtipswillincreasetheservicelifeand availabilityofthemachine.Youwillalsobeabletocarryoutthetransportworkquickerandmoresafely.Carefulattentiontothepointsin thischapterwillhelpyoutosimplifyyourday-to-daywork.
Storage Componentscoatedwithtemporarycorrosioninhibitorareprotectedfor approximatelysixmonths.
Beforedelivery,thehydraulicfunctionsaretestedandthehydraulic pressuresarepresettoOEMspecifications.
Storageofthemachineandspareparts Storetheequipmentindoorsorcoverwithatarpaulintoprotectagainst directexposuretosunlight.
Protecttheequipmentandallsparepartsstoredoutdoorsagainst moistureanddirt,e.g.usingtarpaulins.
Protectthehydraulicplugconnectorsandtheconnectorsoftheelectricalcableswiththecapsandplugssupplied.
Duringshort-termstorage(approximately4weeks)ofequipmentoutdoors,butattemperaturesabovefreezing,electricalcomponentsneed notberemoved.Suchcomponentsmustbeparticularlyprotected againstexcessivetemperatures,dirt,andmoisture.
Iftheequipmentistobestoredmorethansixmonths,thefollowing lubricationandcorrosioninhibitingproceduresmustbefollowed:
■ Ifthecylinderrodsareexposed,therodsmustbecoatedwitha corrosioninhibitingfluid.
■ Completelyfillthehydraulicoiltankwithoil.
■ Fillallgearcasestothemaximumfilllevel.Thegearcasesmust berotatedmonthlytoensurethattheinteriorofthegearcaseremainslubricated.
■ Lubricateallgreasepoints(seetheMaintenancesectioninChapter5ofthismanual).
■ Theequipmentmustbestoredinawellventilated,dryroom.Do notstoreoutdoors.
Storageandtransport Electroniccomponentsmustbestoredattemperaturesbetween -10°C and55°C(14°Fand131°F).
Thetractiondrivesshouldbestoredat -10to50°C(14to122°F).
Majorproblemswithcondensationcanoccurifadriveisstoredina coldenvironmentandisthentakenintoadeepminewherethetemperatureismuchhigher.Eventhoughthehumiditymaybeatanacceptablelevel,condensationwilloccuronthecolddrive.Slightexposuretoacondensingenvironmentisnotharmfulprovidedthedriveis completelydrybeforeelectricalpowerisapplied.
Afterastorageperiodofapproximatelytwoyears,arandomsample inspectionmustbeperformedtodeterminewhetherthemeasures takenandthemethodofstoragehaspreventeddamage.Onrequest, theinspectioncanbecarriedoutbyBucyrus.
Evenwithproperstorage,sealsandhosesaresubjecttonaturalageing.Donotusethesepartsiftheyhavebeenstoredformorethantwo years.
Instructionsonthestorageofconcentratesforhydraulicfluidscanbe found,ifrequired,inchapter6inthisoperatingmanual.
IMPORTANT! Takecaretoinsurethatnewmaintenancesuppliesarestored separatelyfromexistingstockandthatremovaltakesplaceonthe “firstin,firstout”principle.
Long-termstorageofsparecomponents Ifacomponentistobestoredmorethansixmonths,thehydrauliccomponentmustbecompletelyfilledwithacorrosioninhibitingfluid.Fillthe hollowareasofhydrauliccomponents(e.g.thepistonchambers)in horizontalposition(portsfacingupwards)untiltheystarttooverflow thensealtheportswithplasticorsteelplugs.
Storetheelectricalequipment,electroniccomponents,sparepartsof rubberorplastic – suchassealsandhoses – andhydraulicfluidsonly inclosedroomsattemperaturesof15°Cto25°C(60°Fto77°F).
Refertothemotormanufacturer’sstorageprocedureguideinyourBucyruspartsmanual.
Rotatetheimpeller1-1/4turnoncepermonthtopreventdimplingofthe motorbearingsrollers.
Inordertopreventplasticdeformationofthesealelements,cylinders mustbestoredinanuprightposition.Somecylindersmustberemoved sothattheycanbestoredupright.
Transport Loadunits:dimensionsandweights Observethetransportsheetsforthemachineandspareparts.They containinformationon:
■ dimensions,
■ weights,
■ liftingpoints,etc.
Additionalinformationonthedimensionsandweightscanbefoundin chapter6andintheliftingweightguide(Table1)inthisoperatingsection.Fig.5illustratesthepositionofliftingpointsofthevariousassembliesofthemachine.Fordetailedliftinginstructions,seecomponent hoistinginformation.
WARNING!
Useonlyloadhandlingdevicescomplyingwiththetechnicaland legalregulationsforthetransportofloads.Youcouldbeseriouslyinjuredorevenkilledbyfallingloads.Useonlysuitable loadhandlingdevices.
Table1:Liftingweightsofcontinuousminerassemblies Wheneverpossible,allremovalsshouldbeaccomplishedusinganadjustableliftingbeamwheneverpossible.Allsupportingmembers (chainsandcables)shouldbeparalleltoeachotherandasnearlyperpendicularaspossibletothetopoftheobjectbeinglifted.
Whenitisnecessarytoremoveacomponentonanangle,remember thatthecapacityofaneyeboltdiminishesastheanglebetweenthe supportingmembersandtheobjectincreases.Eyeboltsandbrackets shouldneverbebent.
Whenaneyeboltisprovidedtoliftacomponent,useittoliftonlythat component.
WARNING!
Youcouldbeseriouslyinjuredorkilledasaresultoffallingloads. Donotusetheeyebolttoliftthecomponent and itsrelatedassemblies.
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Storageandtransport _________________________________________ Fig.5:Liftingpoints
Gatheringheadliftingpoints
Bumperliftingpoints Liftingeye (10ton)
Liftingeye (10ton)
Liftingeye (10ton)
Liftingeye (10ton)
Liftingeye (30ton)
Liftingeye (30ton)
Fig.5:Liftingpoints(continued)
Liftingeye (4.5ton)
Liftingeye (4.5ton)
Liftingeye (16ton) (bothsides)
Liftingeye (4.5ton)
(4.5ton)
Conveyorliftingpoints
Cutterheadliftingpoints
Liftingeye
Storageandtransport Beforetransport Beforetransportingtheequipmentattemperaturesbelowfreezing,all hydrauliccomponentsoperatedwithemulsion(HFAEorHFAS)must becompletelydrainedandthenfilledwithacorrosioninhibitor/frostproofingfluid.
Transportofequipmentattemperaturesbetween -21°Cand -40°C(-6° Fand -40°F)isonlypermissiblewhencertainmeasuresweretakento meettheseconditionsatthedesignandmanufacturestages.Nevertheless,theindividualpartsanddevicesofthisequipmentmustnotbe subjectedtosuddenimpactloadsatsuchlowtemperaturesandmay onlybeloadedstaticallyorquasi-statically.
Duringtransportofthisequipmentwithfloor-mountedvehiclesatsuch lowtemperatures,measuresmustalsobetakentoensurethatthe partsanddevicesarenotsubjectedtosuddenimpactloads.Atvery lowtemperaturesandonpoorroads,thetransportvehiclespeedmust thereforebelimitedtoamaximumof25kph(15mph)fortrucktransport.
Electricalandelectroniccomponentsmustbeprotectedagainstharmful environmentalinfluencesbyasuitablepackaging.
Theelectricalcablesremainintheequipment.Theymustbecarefully protectedagainsttransportdamageandsoilingoftheconnections.
Installation Installation Pointstoobservepriortoinstallation
Whoisallowedtocarryoutinstallation?
Installationisonlyallowedtobecarriedoutbypersonnelhavingreceivedadequatetrainingtoperformthistask.
Workon:
■ thesafetycomponents(pressurereliefvalves,fireextinguishing equipmentetc.)
■ theelectricalequipment(controlunits,signalingdevices,etc.)
■ thehydraulicequipment(cylinders,directionalcontrolvalves, hosesetc.)
shouldonlybecarriedoutbyBucyrusserviceengineersorbyspecially trainedpersonnel.
Whichtoolsarerequiredforinstallation?
GeneraltoolsarerequiredtoputtheContinuousMinerintoservice.
Variousitemsofauxiliaryequipmentandmachinesmayberequiredat thepointofinstallation.
Theseinclude:
■ hoistswithadequateliftingcapacity
■ meansofattachmentwithadequateliftingcapacity
■ unloadingdockandcribblocks
■ jackswithadequateliftingcapacity
■ impactwrenches,includingaccessories
toolbox
installationplan
Notesoninstallation CAUTION! SeriousdamagecanbecausedtotheContinuousMinerasaresultofincorrectinstallation.TheunitshouldthereforeonlybeinstalledundertheinstructionofspecialistsfromBucyrus.
BucyrusContinuousMinersareshippedtothecustomersitepercustomerpreference.TheContinuousMinercanbeshippedtothecustomersiteasacompletemachineorincomponentsections.Thisdependsonmineconditions,transportationweightrestrictions/ requirements,orsize/weightrestrictionsatthemine.
IMPORTANT! reassemblyinstructions
Thesequenceofoperationsduringinstallationmustbeadaptedto theindividualconditionsprevailingatthesite.Beforestartingthe workadetailedlistofstepstobetakenwithrespecttotransport andassemblyshouldbepreparedandacorrespondingplanestablished.
Whenassemblyisrequiredaftershipmentofthemachine,theassistanceofspecialistsfromBucyrusisrecommended.Thiswillinsurethat thecorrectinstallation,safetyandmaintenanceproceduresarefollowed.
Pre-installationchecklist NOTICE! Themachinewasinspectedpriortoshipmentfromthefactoryto ensureproperfunctioningandinstallationofallcomponents. However,toensurethatnotransitdamagehasoccurred,thefollowingpre-startupchecksshouldbeperformed:
■ visuallyinspectallcylinders,gearboxes,tanks,andhydraulic componentsforleaksordamage.
■ visuallyinspectallelectricmotorsandelectricalcomponentsfor signsofdamage.
■ checkthefulllengthofthetrailingcable(ifapplicable)fordamage
■ ensurethatthetrailingcableisproperlysuspendedacrossintersectionsandthatthetrailingcableclampattheContinuousMiner issecure
■ cleananyforeignmaterialfromtheconveyorandgatheringpan
■ checkthatallcoversandguardsareinplaceandsecure
■ checkthatalltagsandinstructionlabelsareinplaceandsecure
■ checksafetyprovisionsforoperationalconditiononfiresuppressionsystem
■ visuallyinspectallhydraulichosesandelectricalcablesfordamage
■ startupthemachineandcheckforcorrectoperationofallstop andemergencystopbuttons(bothonthemachineandontherdio remote)
■ afterstartingthemachine,allowthehydraulicsystemtowarmup forfive(5)toten(10)minutesandthencheckhydraulicsystem pressures(refertothehydraulicschematicsuppliedforyourparticularmachineforpressuresettings)
■ checkandoperateallcontrolhandlesandswitchestoensureall machinefunctionsareoperatingproperlyandareinneutralposition
■ checkthetensionoftheconveyorchainandcrawlerchain
machinestopbutton
Safetyfeatures NOTICE! Theoperatormustbecomefamiliarwithallthesafetyfeaturesand theirlocationonthemachinepriortoinstallationoroperation.
Safetyfeaturesinclude:(ReferenceFig.6)
Themachineisequippedwithtwomachinestopbuttons,oneinthepit andoneontheleftsideofthemachine.Themachinestopbuttonsare usedtoshutdownallfunctionscapableofproducingmovementonthe machine.Strikingwithasmallamountofforcewillactuatethemachine stop.
firesuppression(optional) guardsandcovers
Themachinemaybeequippedwithfiresuppression(remote)actuators.Ifequipped,thelocationoftheactuatorsmayvary.Thesuppressionsystem(ifequipped)ispneumaticallyactuatedandextinguishes withdrychemicals.Toactuatethesystemfromtheactuators,pullthe safetypinandstrikedownwardontheplunger.Immediatelyafterthe plungerisstruck,drychemicalwillbedispensedthroughoutthemachine.Thefiresuppressionsystemmustbecompletelyrechargedwith drychemicalsandexpellantsafterithasbeenactuated.
WARNING! Ifafiresuppressionactuatorsisactuated,thesystemmustbe completelyrechargedwithdrychemicalsandexpellants.
Watercanbedirectedtothefirespraynozzles(optional0manually fromafiresprayvalveorviasolenoidfromtheradioremote).If equipped,seeChapter5foroperatinginstructionsandlocationsofthe valves.
IMPORTANT! Thefiresprayvalvemustbemanuallysettothenormalposition beforethedustsuppressionwaterspraysystemcanbeoperated.
CAUTION! Theminesupplywaterpressureatthemachineshouldnotexceed 500psi(34bar)andshouldsupply20gpm(76Lpm)
Themachineisequippedwithguardsandcoverstoreducethepossibilityofpersonnelcomingincontactwithrotatingormovingparts.All guardsandcoversmustbeinstalledandsecurelyfastenedduringoperation.
DANGER! Donotoperatethemachinewithanyoftheguardsorcoversremoved.Youorotherpersonnelcouldbeseriouslyinjuredfrom movingorrotatingparts.
Therearetwocutterboomsafetysupports(Fig.6),oneoneachsideof thecutterboom.Thesupportsareusedtoblockupthecutterboom duringmaintenanceoperations.
conveyorsafetysupports
Therearetwoconveyorsafetysupports,oneoneachsideoftheconveyor.Thesupportsareusedtoblockuptheconveyorduringmaintenanceoperations.
Themachineisequippedwithamethanemonitorthatdetectsthepresenceofmethaneinthemineatmosphere.Whentheminerisbeing poweredup,themonitorlooksformethanebeforeanyotherfunctionis energized.Ifthemethanemonitordetectsalevelofmethanewithina presettolerance,themethanemonitorrelaywillcloseandpowerwillbe suppliedtotheotherfunctionsonthemachine.(Themachinecanhave optionaldualsnifferheadsordualreadouts.)
Theminerwasshippedfromthefactorywithaprotectivecanopy/cab. Ensurethatthecanopy/cabisinplaceandsecureatalltimestoprotect theoperatorfromfallingdebris.
Fig.6:SafetyfeaturesontheContinuousMiner
Machinestop
Machinestop
Radioremoteemergency “STOP”button
Fig.6(continued):SafetyfeaturesontheContinuousMiner
Cutterheadsafety support - installed
Conveyorsafety support - typical bothsides
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Fig.7:OverviewoftheContinuousMiner
Cutterhead assembly
Operator’sstation
Conveyorassembly
Tramassembly
Stabilizershoe
Gatheringpan assembly
Operation Thischaptercontainsimportantinformationontheoperationandmaintenanceofthemachine.Italsoincludesinstructionsonthereplacementofwearparts.
Readthischaptercarefullyandthoroughly.Inparticular,observethe safetyinstructionsinchapter2“Yoursafety”.
Howtooperatethecontinuousminer DANGER! Incorrectoperationendangersyourselfandothers!Incorrectoperationofthemachineisoftenthecauseofveryseriousaccidents!Operatetheunitonlywhenyouhavebeensufficiently trainedonthemachineandhavereadandunderstoodthisoperatingmanual.Shouldanythingbeunclear,pleasecontactyourimmediatesupervisor.
Whoisallowedtooperatethecontinuousminer?
TheContinuousMinerisonlyallowedtobeoperatedbypersonswith adequateknowledgeofthecompletemachine.
Thisalsoincludes:
■ whatsafetydevicesareinstalledonthemachine.
■ wherethesesafetydevicesarelocated.
■ howthesesafetydevicesaretobeoperated.
Whencanoperationbestarted? Operationmustnotbestarteduntilthesafeconditionandproperfunctionofthecompletemachinehasbeencheckedandthedailymaintenanceoperationshavebeencarriedout.
NOTICE! Beforebeginningcuttingoperations,carefullyunloadthetrailing cableprovidingenoughslackandplacingitwhereitallowsadequateclearanceforsafemaneuverabilityoftheminer.
Fig.8:Operator’spit
Controlsandindicators Operator’sstation
Theoperator’spit(Fig.8)islocatedontherighthandsideofthemachine,neartherearbumper.Thecontrolsandindicatorsusedforthe normaloperationofthemachinearelocatedwithinthispit.
“MACHINESTOP” The“MACHINESTOP”button(Fig.9)isalargeredpushbuttonlocatedonthetopleftoftheoperator’scase.Thisisoneoftwo(2)machinestopbuttonslocatedontheminer.Pushing“MACHINESTOP” willshutdownthepumpmotor,causingtheminertoshutdown.Follow thenormalstarupprocedure(SeeStartupprocedureinthischapter) torestartthemachineafterpushing“MACHINESTOP”.
The“MINERMODE”selectorswitch(Fig.9)islocatedtotherightof the“MACHINESTOP”button.Thisswitchhasfour(4)positions:
■ “REMOTE” - Thispositionallowstheminertobeoperatedbyradio remote.Duringnormalminingoperations,theswitchshouldbein thisposition.
■ “PIT” - Thispositionallowstheminertobeoperatedfromtheoperator’spit.
■ “E-TRAM” - Thispositionallowstheminertobetrammedfromthe pendantcontrols.“E-TRAM”isusedintheeventthattheminer cannotbeoperatedin“REMOTE”mode.
■ “GNDCHK” - Placingtheoperationswitchinthegroundcheck positionshouldcausetheminepowercentertotrip,therebyshuttingdownallpowertotheminer.
Thefiresprayvalve(Fig.9)locatedtotheleftofthecontrolcasecan beoperatedmanuallyorbyremote.Tomanuallyoperatethevalve, pullouttoturnonandpushintoturnoff.
The“TRAMBRAKEMODE”switch(Fig9)isusedtoselectthemode ofoperationforthetrambrakes.Whentheswitchisinthe“NORMAL” position,brakeswillbeappliedasconfiguredinthecontrolsystem. Whentheswitchisinthe“MANUALON”position,thebrakesareappliedregardlessofthecontrolsystemconfiguration.
The“TRAMSPEEDSELECTION”switch(Fig.9)isusedtoselectthe maximumtrammingspeedofthemachinewhenthecutterheadisnot cuttingandbothtractiondrivesarehealthy.The“LOW”and“HIGH” speedrangesareadjustablerangesthataresetinthegraphicsdisplay screen.
Whenthecuttersarerunning,themaximumtramspeedwillbegeneratedbythecuttermotorfeedbackfunctioninthecontrolsystem.
Ifonlyonetractiondriveishealthyorifthecontrolsystemreadsboth “LOW”and”HIGH”speedsselected(faultyspeedselectorswitch),the maximumtrammingspeedwillbecreepspeed(25%).
Fig.9:“MACHINESTOP”,“MINERMODE”,“TRAMBRAKE MODE”,“TRAMSPEEDSELECTION”,andfiresprayvalve
“TRAM BRAKE MODE” “TRAM SPEED SELECTION”
Firespray valve
“MACHINE STOP” “MINER MODE”
The“PUMPSTART”button(Fig.10)isusedtoturnonthepumpmotor.Tostartthepumpmotor,pressandhold“PUMPSTART”and “MOTORSTARTENABLE”untilthemotorstarts.Thepumpmotor mustberunningbeforeanyothermotorcanbestarted.
The“PUMPSTOP”button(Fig.10)isusedtoturnoffthepumpmotor. Tostopthepumpmotor,press“PUMPSTOP”.
The“CUTTERSTART”button(Fig10)isusedtostartthecutterhead motors.Tostartthemotors,pressandhold“CUTTERSTART”and “MOTORSTARTENABLE”untilthemotorsstart.
The“CUTTERSTOP”button(Fig.10)isusedtoturnoffthecutter headmotors.Tostopthemotors,press“CUTTERSTOP”.
The“CONVEYORSTART”button(Fig.10)isusedtostarttheconveyorintheforwarddirection.Tostarttheconveyor,pressthe “CONVEYORSTART”and“MOTORSTARTENABLE”buttons.
The“CONVEYORSTOP”button(Fig10)isusedtostoptheconveyor whenitisrunningintheforwarddirection.Tostoptheconveyor,press “CONVEYORSTOP”.
The“MOTORSTARTENABLE”button(Fig.10)isusedwiththe “PUMPSTART”,“CUTTERSTART”and“CONVEYORSTART”buttons tostartthepumpmotor.
The“CONVEYORREVERSEJOG”button(Fig.10)isusedtojogthe conveyorinthereversedirection.Tojogtheconveyorinreverse, pressandhold“CONVEYORREVERSEJOG”.Theconveyorwillcontinuetojoginreverseaslongasthebuttonisheld.Releasingthebuttonwillstoptheconveyor.
Fig.10:“PUMPSTART”,“PUMPSTOP”,“CUTTERSTART”, “CUTTERSTOP”,“CONVEYORSTART”,“CONVEYORSTOP”, “MOTORSTARTENABLE”,and“CONVEYORREVERSEJOG”
circuitbreakers “CONVEYORHOURMETER” “CUTTERHEADHOURMETER”
Therearefour(4)“CONTROLCIRCUITBREAKERS”andsix(6) “MACHINELIGHTING”circuitbreakers(Fig.11)locatedonthecontrol panel.Formoredetailedinformationontheindividualcircuitbreakers, seetheElectricalsectioninthischapter.
The“CONVEYORHOURMETER”(Fig.11)indicatesthehoursofrunningtimefortheconveyor(CLA)motors.
The“CUTTERHEADHOURMETER”(Fig.11)indicatesthehoursof runningtimeforthecuttermotors.
Fig.11:Circuitbreakersandhourmeters
“CUTTERHEAD HOURMETER”
“CONVEYOR HOURMETER” Circuitbreakers
“CLA/PUMP/FAN CIRCUITBREAKER”
The“MAINCIRCUITBREAKER”is ontheleftsideofthebreakercase, whichislocatedbelowtheoperator’scontrolstation(Fig12).Thiscircuitbreakerhasfour(4)positions:"OFF,"tode-energizethemachine's electricalsystemsand"ON,"fornormaloperation,“TRIPPED”whenthe circuitbreakerhastripped,and“RESET”toresetthecircuitbreaker afterithastripped.Themaincircuitbreakershouldbeinthe"OFF" positionbeforethemachineisservicedorshutdown.
The“CLA/PUMP/FANCIRCUITBREAKER”lever(Fig.12)isusedto controlthecircuitbreakerfortheconveyor,pumpandfanmotors.Itis locatedontheleftsideofthebreakercase,whichislocatedbelowthe operator’scontrolstation.Thisbreakermustbeinthe“ON”position beforethemotorswillstart.Toturnthecircuitbreaker“ON”,movethe leverup.Toturnthecircuitbreaker“OFF”,movetheleverdown.Ifthe circuitbreakertrips,Thebreakermustberesetbymovingthelever past“OFF”andthenbacktothe“ON”position.
“TRAMCIRCUITBREAKER” “MAINCIRCUITBREAKER” “CUTTERMOTOR CIRCUITBREAKER” The“TRAMCIRCUITBREAKER”lever(Fig.12)isusedtocontrolthe circuitbreakerforthetrammotors.Itislocatedontherightsideofthe breakercase,whichislocatedbelowtheoperator’scontrolstation. Thisbreakermustbeinthe“ON”positionbeforethetrammotorswill start.Toturnthecircuitbreaker“ON”,movetheleverup.Toturnthe circuitbreaker“OFF”,movetheleverdown.Ifthecircuitbreakertrips, Thebreakermustberesetbymovingtheleverpast“OFF”andthen backtothe“ON”position.
The“CUTTERMOTORCIRCUITBREAKER”is ontherightsideofthe breakercase,whichislocatedbelowtheoperator’scontrolstation(Fig 12).Thecircuitbreakerhasfour(4)positions:"OFF,"tode-energize themachine'selectricalsystemsand"ON,"fornormaloperation, “TRIPPED”whenthecircuitbreakerhastripped,and“RESET”toreset thecircuitbreakerafterithastripped.
Fig.12:Circuitbreakerlevers
“TRAMCIRCUIT BREAKER”
“CUTTERMOTOR CIRCUITBREAKER”
Gaugepanel
Thereisagaugepanel(Fig.13)consistingoffour(4)gaugeslocatedto therightofthecontrolcasethatisusedtomeasurehydraulicandwater pressurethroughouttheminer.
The“MAINPRESSURE”gaugeisusedtomonitorthepressureinthe mainflow - primarypressurecircuit.SeethePrimarypressurecircuitin theHydraulicsectionofthischapterforfurtherinformation.
Thefirstgaugefromtheoperator’sleftonthemiddlerowofgaugesis “PILOTPRESSURE”.Thisgaugeisusedtomonitorthesupplypressureforallpilotfunctions.SeethePilotpressurecircuitintheHydraulic sectionofthischapterforfurtherinformation.
The“MCVPRESSURE”gaugeisusedtomonitorthelowpilotpressure atthe Main Control Valvebank.ThepurposeoftheMCVpilotpressure istoprovidethenecessaryforcetoshiftthecontrolvalveswhenthe solenoidsareenergized.WhentheMCVpilotpressurebecomestoo low,themachineoperationswillbecome“sluggish”.Thisistypicallyan indicationofacloggedpilotfilterandthefiltershouldbechanged.See theMaincontrolvalvepressurecircuitintheHydraulicsectionofthis chapterforfurtherinformation.
The“INTAKEWATERPRESSURE”gaugemonitorsthepressureofthe watergoingintotheminer.SeethewaterpressurecircuitintheWater sectionofthischapterforfurtherinformation.
Fig.13:Gaugepanel
Gaugepanel
“CUTTINGHEAD”controllever
“STAB”controllever
Fig.14:Controllevers
Thefirstleverfromtheoperator’sleftisthe“CUTTINGHEAD”control lever(Fig.14),whichisusedtoraiseandlowerthecutterhead.To lowerthecutterhead,pushtheleverforward,awayfromtheoperator. Toraisethecutterhead,pulltheleverback,towardstheoperator.Positioningtheleverinthecenterpositionwillholdthecutterheadin place.
Thesecondleverfromtheoperator’sleftisthe“CONVEYOR”raise lever(Fig.14),whichcontrolstheverticalpositionoftheconveyor.To raisetheconveyor,pulltheleverback,towardstheoperator.Tolower theconveyor,pushtheleverforward,awayfromtheoperator.
Thethirdleverfromtheoperator’sleftisthe“CONVEYORSWING” controllever(Fig.14),whichisusedtocontrolthehorizontalpositionof theconveyor.Toswingtheconveyorright,pullthelevertotherightof theoperator.Toswingtheconveyorleft,pullthelevertotheleftofthe operator.
Thefourthleverfromtheoperator’sleftisthe“GATHERINGHEAD” controllever(Fig.14),whichisusedtocontrolthepositionofthegatheringhead.Toraisethegatheringhead,pulltheleverbacktowards theoperator.Tofloatthegatheringhead,pushtheleverforward,away fromtheoperator.
Thefifthleverfromtheoperator’sleftisthe“STAB”controllever(Fig. 14),whichcontrolsthepositionofthestabilizershoe.Tolowerthestabilizershoe,pushtheleverforward,awayfromtheoperator.Toraise thestabilizershoe,pulltheleverback,towardtheoperator.
HEAD”
“CONVEYOR” (raise/lower)
“GATHERING HD”
Thereisafootswitch(Fig.15)inthefloorinfrontoftheoperatorcommonlyreferredtoastheman-in-positionswitch.Depressingthefoot switchwillenabletrammingandwillreleasethetrambrakes.This switchmustbeheldinfortrammingtobeactive.
Releasingthefootswitchwilldisabletramming.
Thefirstleverfromtheoperator’sleft(Fig.15)controlsthelefthand crawlerfunctions.Totraminthedirectionofthecutterhead,slowly pushthecontrolleverforward,awayfromtheoperator.Totraminthe directionoftheconveyorendoftheminer,slowlypullthelevertoward theoperator.
Thesecondleverfromtheoperator’sleft(Fig.15)controlstheright handcrawlerfunctions.Totraminthedirectionofthecutterhead, slowlypushthecontrolleverforward,awayfromtheoperator.Totram inthedirectionoftheconveyorendoftheminer,slowlypullthelever towardtheoperator.
Thetram/steeringcontrolleversareusedfortrammingandpositioning themachine.Totramthemachineinastraightdirectiontowardsthe cutterheadendofthemachine,pushbothtramcontrolleversforward, awayfromtheoperator.Totramthemachineinastraightdirection towardstheconveyorendofthemachine,pullbothtramcontrollevers back,towardtheoperator.
Tosteerleftinthedirectionofthecutterhead,pushtherighttramcontrolforward(awayfromtheoperator)whilethelefttramcontrolleveris intheneutralposition.Fortighterturns,pullthelefttramcontrollever back(towardstheoperator)whiletherighttramcontrolleverispushed forward(awayfromtheoperator).
Tosteerrightinthedirectionofthecutterhead,pushthelefttramcontrolforward(awayfromtheoperator)whiletherighttramcontrolleveris intheneutralposition.Fortighterturns,pulltherighttramcontrollever back(towardstheoperator)whilethelefttramcontrolleverispushed forward(awayfromtheoperator).
Fig.15:Tramcontrollevers
Footswitch
“LEFTTRAM” “RIGHTTRAM”
methanemonitordisplay
Themethanemonitordisplay(Fig.16)islocatedbehindoperator’spit. Consultthemanufacturer’sinformationregardingthesetup,operation, andmaintenanceofthemethanemonitoringsystem.
IMPORTANT! Itistheresponsibilityofthecontinuousminerowner/operatorto knowandfollowalllawsandregulationsregardingmethanemonitoringrequirements,including,butnotlimitedto,dailyoperation, maintenance,andtesting.
Fig.16:Methanemonitordisplay
“METHANE MONITOR” display location
“MACHINESTOP”
scrubberjetpump pressuregauge
scrubbersprays pressuregauge
Leftsidecontrolsandindicators(Fig.17)
Thereisa“MACHINESTOP”buttonlocatedontheleftrearsideofthe machine.Thereareatotaloftwo(2)machinestopbuttonslocatedon theminer.Pushing“MACHINESTOP”willshutdownthepumpmotor, causingtheminertoshutdown.Followthenormalstarupprocedure (SeeStartupprocedureinthischapter)torestartthemachineafter pushing“MACHINESTOP”.
Thereisaseriesofmanuallyoperatedwatervalvesonthelefthand sideofthemachine(Fig.17):
The“WASHDOWNHOSE”valveisusedtoturnonwatertothewashdownhose.
The“FIRESPRAY”valveisusedtomanuallyturnonwatertothefire sprays.
The“BACKFLUSHSTRAINERVALVEB”isusedtomanuallybackflush thestrainer.Valves“A”and“C”mustbeclosedwhenvalve“B”isopen.
The“SUMPWASHOUTVALVEC”isusedtomanuallysupplywaterto thesumpwashout.Valves“A”and“B”mustbeclosedwhenvalve“C” isopen.
Thegaugeisusedtomonitortheoutputpressureofthescrubberjet pump.
Thisgaugeisusedtomonitorscrubberspraypressure.
Fig.17:Leftsidecontrolsandindicators
“BACKFLUSH STRAINER VALVEB”
“SUMP WASHOUT VALVEC”
“FIRE SPRAY”
Jetpump “VALVEA”
Scrubberjetpump pressuregauge
Scrubbersprays pressuregauge
“WASHDOWN HOSE”
“EMERGENCY STOP”
controlmodule(hub)
Machinecontrolsystem Anmulti-componentsystemisusedtocontrolvariousaspectsofthe machineandconsistsofthefollowingmaincomponents:
■ Powersupply
■ Controlmodule(hub)
■ Input/Outputmodules
■ Radiosremote
■ Graphicsdisplay
Thefollowinginformationispresentedasageneralguidetothecapabilitiesandfunctionsofthecontrolsystem.Beforeattemptingtooperate,service,ortroubleshoottheContinuousMiner,trainingmustbe completed.Foradetaileddescriptionofcomponentlocations,please seetheBucyruspartsbookforyourmachine.
Thereisa24VDCpowersupplylocatedinsidethecontrollerthatprovidespowertothecontrolandinput/outputmodulesinthecontrolsystem.
Thecontrolmodule,alsoknownasthehub,isthe“brain”ofthecontrol systemandislocatedinsidethecontroller.Theapplicationsoftware forthemachineisstoredonthecontrolmodule.Whenthesystemis poweredup,thesoftwareisusedtocontrolthemachine.Itmonitors inputsandcontrolsoutputstoothermodules.
input/output(I/O)modules
Basedontheparameterssetandtheinputreceived,thecontrolsystem hastheabilitytoissueerrormessages,faultmessages,and/orshutdownthemachine powersupply
Input/Outputmodules,locatedinthecontroller,areusedtoreaddata fromandsendcommandstothefollowingmachinefunctions:
■ Cuttermotors(leftandright)
■ Gatheringheadmotors(leftandright)
■ Scrubbermotor
■ Pumpmotor
■ Hydraulicoillevel
■ Methanemonitoring
radioremote (remotecontrol)
Theradioremote(Fig.18)isusedtocontrolthecontinuousminerduringnormalminingoperations.
WARNING!
Radioremotecontrolsystemsaredangerous.Thecontinuous mineroperatorcannotoperatearemotesystemuntilheisproperlytrainedintheoperationofthesystem.Remotecontrolsystemssometimeshaveautomaticfeaturesofwhichuntrainedoperatorsandworkersarenotaware.
Fig.18:Radioremote(typical)
Theradioremotehasthefollowingcontrolbuttons: IMPORTANT!
Foroperatinginstructions,includingstarting,shuttingdown, tramming,andmining,usingtheremotecontrol,seetheOperatingproceduressectionofthischapter.
Table1:Radioremotebuttons(typical)
Button Primaryfunction Secondaryfunction
TramForward
- Tramsbothtracks forward.
TramReverse
- Tramsbothtracksin reverse.
EmergencyStop
- Shutsdownallremote functions.
FireExtinguisher (optional)
- Pushandholdtoincrease speedwhentraveling forward.
- Pushandholdtodecreasespeedwhentravelinginreverse.
- Pushandholdtoincrease speedwhentravelingin reverse,
- Pushandholdtodecreasespeedwhentravelingforward.
Whenpressedwith “SHIFT”,tripsthepilot relay.
None
Lights
- Whenpressedwith “SHIFT”,turnsthe headlightson.
Menu
- Usedtoaccessthe menuscreen
Lights
Turnstheheadlights off.
Remote
- Whenpressedwith “SHIFT”,returnsfromthe menuscreen
Notinuse. Notinuse.
Stab
- Operatesthestab raisesolenoid.
ATRSUp(optional)
- Whenpressedwith “SHIFT”,operatesthe ATRSraisesolenoid.
Table1:Radioremotebuttons,continued
Button Primaryfunction Secondaryfunction
Pan
- Operatesthegathering headraise.
Shear
- Operatesshearup solenoid.
TramLeftForward
- Tramslefttrackforward.
TramLeftReverse
- Tramslefttrackin reverse.
PanExtend(optional)
- Whenheldwith“SHIFT”, operatesplowextend solenoid.
ShearExtend
- Whenheldwith“SHIFT”, operatesthecutterextend solenoid.
- Pushandholdtoincrease speedwhiletravelling forward.
- Pushandholdtodecrease speedwhentravelingin reverse.
- Pushandholdtoincrease speedwhiletravelling reverse.
- Pushandholdtodecrease speedwhentraveling forward. Notinuse. Notinuse.
Stab
- Operatesstablower solenoid.
Pan
- Operatesgathering headfloat.
ShearDown
- Operatessheardown solenoid.
TramRightReverse
- Tramsrighttrackin reverse
ATRSDown(optional)
- Whenpressedwith “SHIFT”,operatesthe ATRSdownsolenoid.
PanRetract(optional)
- Whenpressedwith “SHIFT”,operatesplow retractsolenoid.
Retract
- Whenpressedwith ‘SHIFT”,operatesplow retractsolenoid.
- Pushandholdtoincrease speedwhiletravelling reverse.
- Pushandholdtodecrease speedwhentraveling forward.
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