CAT Bucyrus Continuous Miner 30M4-NPIndia Operation and Maintenance Manual (1)

Operation and Maintenance Manual Bucyrus - Continuous Miner Model - 30M4-NP India Doc. No.: A6474X326

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

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

Internet: www.bucyrus.com

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This manual is intended to provide GENERAL product information for the Model 30M4-NP 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 o, 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 laws, regulations and practices regarding the safe operation and maintenance of underground mining equipment and strict adherence to the instructions in this manual is necessary for the personal safety of those working on or around this unit.

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

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

© BUCYRUS AMERICA, INC.

ALL RIGHTS RESERVED

________________________________________________ Table of contents

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

2. Your safety

© BUCYRUS AMERICA, INC.

Your safety .............................................................................. 2.3 Personnel............................................................................. 2.4 Operation ........................................................................ 2.4 Installation and repair...................................................... 2.4 Operating conditions ............................................................ 2.5 Intended use ................................................................... 2.5 Unauthorized use............................................................ 2.5 Safety instructions................................................................ 2.7 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..............................................2.26

3. Storage and transport Storage and transport ............................................................ 3.3 Storage ................................................................................ 3.3 Storage of the machine and spare parts......................... 3.3 Long-term storage of spare components........................ 3.4 Transport.............................................................................. 3.5 Hoisting of heavy components........................................ 3.6

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

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Table of contents _________________________________________________

Operation ................................................................................. 5.3 How to operate the Continuous Miner ................................. 5.3 Who is allowed to operate the Continuous Miner ........... 5.3 When can operation be started?..................................... 5.3 Controls and indicators ........................................................ 5.4 Machine control system ......................................................5.17 Red zone.............................................................................5.33 Safety precautions for underground operation ...................5.36 Tramming safety rules ........................................................5.36 Emergency stop from a machine stop button .....................5.37 Starting procedure ..............................................................5.38 Shutdown procedure...........................................................5.41 Tramming the miner............................................................5.42 Cutter head operation .........................................................5.44 Conveyor operation.............................................................5.45 Typical cutting sequence ....................................................5.46 Mining operations................................................................5.48 Mechanical assemblies.......................................................5.53 Hydraulic system.................................................................5.59 Water system ......................................................................5.97 Electrical system ............................................................... 5.111 Instructions on the maintenance....................................... 5.147 Important notes ............................................................ 5.147 Before maintenance..................................................... 5.147 Torque values .............................................................. 5.149 Lubricants, fluids and capacities .................................. 5.149 Specific lubrication and maintenance instructions ............ 5.155 Every shift .................................................................... 5.155 Every third shift (daily) ................................................. 5.158 Weekly ......................................................................... 5.165 Monthly......................................................................... 5.170 Every three months ...................................................... 5.176 Every six months.......................................................... 5.182 Instructions on the adjustment procedures....................... 5.185 Pilot pressure circuit relief/reducing valve ................... 5.187 Direction control valve (main control and cutter head) 5.189 Multi-purpose valve ...................................................... 5.194 Conveyor chain tension pressure ................................ 5.195 Tram track .................................................................... 5.196 Tail shim....................................................................... 5.201 Conveyor chain tension ............................................... 5.204

_________________________________________________________________ Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

5. Operation

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© BUCYRUS AMERICA, INC.

Replacement of wear parts............................................... 5.205 Cutter head (boom) assembly ..................................... 5.205 Cutter head assembly removal/installation ............. 5.206 Shear cylinder ......................................................... 5.210 Center cutter drum .................................................. 5.215 End cutter drum....................................................... 5.218 Drum drive motor .................................................... 5.221 Drum drive gear case.............................................. 5.226 Gathering head assembly ............................................ 5.229 Gathering head assembly removal/installation ....... 5.230 Gathering head drive motor .................................... 5.235 Gathering head gear case ...................................... 5.238 Gathering head foot shaft ....................................... 5.241 CLA ......................................................................... 5.244 CLA tip replacement................................................ 5.246 Gathering head lift cylinder ..................................... 5.247 Crawler assembly ........................................................ 5.251 Tram motor.............................................................. 5.252 Tram case ............................................................... 5.257 Crawler chain .......................................................... 5.262 Tram track front idler ............................................... 5.266 Tram brakes ............................................................ 5.269 Conveyor assembly ..................................................... 5.274 Conveyor chain ....................................................... 5.275 Conveyor assembly removal/installation ................ 5.279 Discharge conveyor ................................................ 5.282 Tail roller ................................................................. 5.287 Troubleshooting procedures ............................................. 5.290 Typical hydraulic problems .......................................... 5.291 Contaminants in hydraulic systems ............................. 5.292 Specific hydraulic circuits............................................. 5.293 General safety procedures for shutdown..................... 5.297 Excessive noise ........................................................... 5.298 Excessive heat ............................................................. 5.299 Incorrect flow................................................................ 5.300 Incorrect pressure ........................................................ 5.301 Faulty operation ........................................................... 5.302 Restarting checklist...................................................... 5.303 Bearings ....................................................................... 5.304 Control system ............................................................. 5.305 MCU Status LEDs ................................................... 5.306 Transmitter LEDs .................................................... 5.312 Radio receiver LEDs ............................................... 5.315 Capacitor backup power supply LEDs .................... 5.316 Emergency tram pendant LEDs.............................. 5.318 Alarms, warnings, and display information ............. 5.319 Alarm codes ............................................................ 5.320 Warning codes ........................................................ 5.325

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Table of contents _________________________________________________ 6. Technical data Technical data ......................................................................... 6.3 Tightening torques................................................................ 6.5 Permissible data................................................................... 6.7 Lubrication fluids and greases......................................... 6.7

7. For your information

© BUCYRUS AMERICA, INC.

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

_________________________________________________________________ Bucyrus – Model 30M4-NP Continuous Miner

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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. It contains information on the structure of the manual and the symbols and characters used.

Before starting to work applicable operating manual machine type

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

This operating manual is intended for: Bucyrus Model 30M4-NP Continuous Miner Serial No.: N/A and is only permitted to be used for equipment of this type.

© BUCYRUS AMERICA, INC.

new operation manual

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

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

Who is this operating manual intended for?

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

This includes persons who: ■

operate the machine

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are in charge of transport

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perform assembly/disassembly work

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find/fix faults

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perform daily routine work at the face or in the entry

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perform maintenance work

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perform repair work

supervisory personnel who: ■

initiate and/or supervise the activities just indicated.

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

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

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

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

safety

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

© BUCYRUS AMERICA, INC.

service

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

Try to memorize the symbols and their meanings.

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

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

© BUCYRUS AMERICA, INC.

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

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

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

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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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Before starting to work ________________________________________

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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

This machine has been manufactured in accordance with 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.

alterations

Do not make any alterations or modifications which could impair the safe operation and maintainability of the machine. All modifications and changes must be approved by Bucyrus and all appropriate regulatory agencies.

© BUCYRUS AMERICA, INC.

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

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

Observe the safety and accident prevention regulations

further operating manuals

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of the mine,

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of the mine’s inspectors, and

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of the mining supervisory authorities.

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

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Personnel ___________________________________________________ Personnel Operation training

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

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

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

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mechanics,

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hydraulics, and

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control engineering

and must be able to prove this knowledge.

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

Installation and repair work on: ■

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

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the electrics (motors, controllers, etc.)

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the hydraulics (controls, cylinders, etc.)

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

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© BUCYRUS AMERICA, INC.

You must have adequate knowledge of the

_________________________________________ Operating conditions Operating conditions Intended use The Continuous Miner has been designed and manufactured for specific uses. Intended uses include: ■

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

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

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operation on grades of less than 10 degrees

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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stone development or extraction

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

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Operating conditions __________________________________________

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___________________________________________ Safety instructions Safety instructions General rules general

noise emissions

Always work with full concentration and familiarize yourself with your working environment.

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).

Inform your colleagues of

© BUCYRUS AMERICA, INC.

safety equipment

symbol plates

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your exact location,

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the work you are performing, and

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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, machine stop buttons, cover plates, etc. are correctly installed.

Observe the symbol plates on the machine.

emergency stop

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

lock-out and tag

Disconnect, lockout, and tag the power system, following all applicable rules and regulations, while performing maintenance, inspection, or repair work.

working area

Cordon off your working area widely for the machine.

moving parts

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

chains, flights, and chain sprockets

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pivot points

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crawler assemblies and conveyors

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cutter and gathering head 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 to the points of attachment provided for that purpose. Observe the different load limits of the attachment points. Also, observe the instructions on the transport sheet.

Only use means of attachment which are in good condition and have been designed for the loads to be handled. For round components use transport straps only; never use chains or steel cables for this purpose.

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

mobile handling equipment

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

Pre-start inspection operation

Read this entire manual before attempting to operate this machine.

inspection

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

maintenance instruction and safety tags

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.

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© BUCYRUS AMERICA, INC.

means of attachment

___________________________________________ 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. Safety regulations can be found on the container or on the Material Safety Data Sheet (MSDS) for the product.

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

© BUCYRUS AMERICA, INC.

controls

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

starting procedures

Follow the starting procedure instructions in the operations manual.

red zone

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

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 Continuous Miner.

before start-up

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

protective devices

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

traveling

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

passengers

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

safety rules

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

problems and malfunctions

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

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Safety instructions ____________________________________________ Stopping 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.

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

trailing cable uncoupled and locked and tagged out

securing

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

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

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

Protect your work area against falling rocks.

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

original parts

Use only spare parts which satisfy the specified technical requirements.

This is only ensured with original Bucyrus spare parts. Please refer to the spare parts lists or parts catalog for the order numbers.

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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 lifting

handling of hydraulic fluids

For raising the Continuous Miner use only: ■

crib blocks with adequate load-holding capacity.

■

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

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

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

maintenance/repair

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

© BUCYRUS AMERICA, INC.

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

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

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

Always replace damaged or lost decals and metal instruction plates.

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

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

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

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 sheaths 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.

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

Flush out the hydraulic lines thoroughly before connecting. permissible hoses

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

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

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

Use only hydraulic hoses approved for the prevailing pressures.

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

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

Never try to repair damaged hydraulic hoses.

Replace hydraulic hoses at the first suspicion of damage. installing hydraulic hoses

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

Always install hydraulic hoses so they: ■

always have a little slack.

Fig. 1: Installing hydraulic hoses, slack Right

Wrong

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© BUCYRUS AMERICA, INC.

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

___________________________________________ Safety instructions ■

are not twisted.

Fig. 2: Installing hydraulic hoses, twisting Right

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Wrong

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

© BUCYRUS AMERICA, INC.

Fig. 3: Installing hydraulic hoses, bending Right

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always have a little slack.

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are not kinked.

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do not have to withstand tensile strains.

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are protected against thermal radiation.

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are accessible at all times.

Wrong

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

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

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

torn out,

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kinked,

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crushed,

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driven over or

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twisted by movement of the machine.

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

© BUCYRUS AMERICA, INC.

Right

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________________________________ 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 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.

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.

© BUCYRUS AMERICA, INC.

WARNING! Do not use the eyebolt to lift the component AND its related assemblies.

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.

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 following pre-startup 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.

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

DANGER! Do not operate the machine with any of the guards or covers removed. You or other personnel could be seriously injured from moving or rotating parts. ______________________________________________________________ A6474X326

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Overview of safety instructions _________________________________ Chapter 5: Operation DANGER! Incorrect operation endangers yourself and others! Incorrect operation of the machine is often the cause of very serious accidents! Operate the unit only when you have been sufficiently trained on the machine and have read and understood this operating manual. Should anything be unclear, please contact your immediate supervisor.

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

WARNING! Before operating any controls make sure no one is in the red zone (see Red zone in this chapter). Do not operate any controls from outside the operator’s pit.

WARNING! Do not open/disconnect cutter motors while motors are running.

Opening the disconnect does not remove all 4160V from the entire machine, just the cutter motors.

WARNING! Read all instructions carefully before attempting to start or operate the machine. Failure to read and understand all operating instructions before starting the continuous miner could result in serious injury or death to the operator or persons around the machine or cause damage to the machine.

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

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

WARNING! Before starting the machine, make sure that no one is in the red zone (Fig. 22 through Fig. 24).

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© BUCYRUS AMERICA, INC.

DANGER! The continuous miner is designed to be operated from within the operator’s pit. Do not attempt to operate the controls and levers located in the operator’s pit from outside the pit. Severe injury or death may result.

________________________________ Overview of safety instructions NOTICE! In extremely cold weather, allow motors and gear cases to idle.

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

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

After training, which includes reading and understanding the Controls and Indicators section of this chapter, and becoming familiar with the locations and functions of all machine controls, the operator is ready to operate the continuous miner. An experienced operator should monitor a new operator’s indoctrination to the starting procedure.

© BUCYRUS AMERICA, INC.

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

WARNING! Visually check for other personnel and verbally shout a warning before starting this machine. Make sure all personnel are completely clear of the machine and it’s components and check that the area is clear before starting the machine.

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

WARNING! Tramming requires cooling water to the tram motors. Failure to cool the motors will result in motor damage and premature failure.

WARNING! Never start cutter head motors under a load. Starting motors under load may result in motor damage or premature failure.

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

IMPORTANT! Both cutter motors do not start at the same time. There is a preset timed delay between the left cutter motor starting and the right cutter motor starting.

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

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Overview of safety instructions _________________________________ CAUTION! Always ensure operator safety while operating the machine. Be alert for hazardous conditions and take corrective action as necessary. Failure to be alert and correct hazardous situations may result in serious injury.

IMPORTANT! Care should be taken not to stall cutters or conveyor during cutting operations. Severe damage to motors and gear boxes could occur if cutters or conveyor are repeatedly stalled.

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

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

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

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

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

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

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

_________________________________________________________________ 2.18 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

IMPORTANT! Tram is limited in the forward direction while the cutters are running with the cutter head feedback circuit. As the cutter head begins to cut the material from the face, the sump speed will automatically slow the tram down to prevent over sumping the machine.

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

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

© BUCYRUS AMERICA, INC.

DANGER! The area under and around the raised cutter head is dangerous.

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

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

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

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

DANGER! Never run the conveyor without the needle valve closed. Injury or death may occur.

IMPORTANT! To ensure against leakage on the brake shaft seal, It is important that the tank connection from the brake cooling outlet is unimpeded. This seal should not be exposed to pressures above 4 bar (65 psi).

WARNING! This section is intended only to familiarize the user with the electrical components of the continuous miner. Electrical maintenance should only be performed by a qualified electrician with knowledge of the functions of the components involved.

WARNING! Before removing any cover from an electrical case or attempting any maintenance or troubleshooting, the main power must be disconnected and locked out at the main power center.

______________________________________________________________ A6474X326 VTSV/00 2.19

Overview of safety instructions _________________________________ IMPORTANT! Hang trailing cables to prevent damage from moving equipment!

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

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

WARNING! Opening the cutter motor disconnect switch on the front of the 4160 case will remove power to the cutter motors only. The trailing cable and the machine will remain energized. To de-energize the machine, the pilot disconnect switch, “PILOT DISC”, must be turned to “OFF” or the “POWER STOP” button must be activated.

WARNING! Closing the cutter motor disconnect switch on the front of the 4160 case will remove power to the cutter motors only. The trailing cable and the machine will remain energized. To de-energize the machine, the pilot disconnect switch, “PILOT DISC”, must be turned to “OFF” and the “POWER STOP” button must be activated.

WARNING! Before performing maintenance on the machine the power must be turned off, the pilot must be disconnected, and the trailing cable must be unplugged. Follow all regulations for lockout/tagout procedures. Accidental machine movement or electrical shock can result in serious injury or death to you or other personnel.

WARNING! Do not move any hydraulic control lever unless you are certain that everyone is completely clear of any machine movement. Accidental machine movement can cause serious injuries or even death to you or the maintenance person.

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.

_________________________________________________________________ 2.20 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

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

________________________________ Overview of safety instructions 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.

WARNING! Observe the safe working load limits of all blocking devices. You could be seriously injured or killed by falling loads.

WARNING! Use extreme caution when inspecting for leaks with the machine running. Unexpected machine movement, or contact with moving parts, could result in injury.

© BUCYRUS AMERICA, INC.

NOTICE! If the gear case is scheduled for oil drain and refill, obtain the oil sample prior to the oil change.

IMPORTANT! Always collect oil samples using a siphon pump. Do not remove the drain plug and collect oil by allowing it to run out into the bottle.

IMPORTANT! Always use the collection hose provided with each bottle. Always discard hose immediately following collection of the oil and do not use it for the next sample. To do so will contaminate the next sample with oil from the previous sample.

IMPORTANT! For motor bearings that require high temperature lithium complex grease (Spec. 100-15), Bucyrus provides a special “button” style lubrication fitting (Fig. 116) to prevent the accidental use of multipurpose lithium complex grease at these locations.

NOTICE! Incorrect grease or over greasing of the electric motor may cause serious damage to the motor. Follow the greasing procedure outlined above.

IMPORTANT! Always use the proper tools when adjusting valve cartridges.

IMPORTANT! Do not start any motors - CLA, cutter head, pump, or traction motors - until all pressures are set. Start the pump motor as directed.

WARNING! Never rely on the load holding valve as a means of supporting the cutter or conveyor boom while making repairs. Severe injury or death could result.

______________________________________________________________ A6474X326 VTSV/00 2.21

Overview of safety instructions _________________________________ IMPORTANT! Reference the Hydraulic section in this chapter for individual circuit information. Always refer to the hydraulic schematic in your Bucyrus America, Inc. parts manual for your miner.

WARNING! Two people are required to adjust pressure settings. One person will make the adjustments while the second person must remain at the machine stop at all times during the adjustment procedure.

Failure to do so may result in serious injury or death.

IMPORTANT! The main inlet relief is set higher than the port reliefs and will only relieve if a spike occurs in the system or if the port relief does not function properly. This provides protection of the main pump section, A2.

CAUTION! Do not adjust the main inlet relief over 207 bar (3,000 psi). Destruction of the valve bank and the main pump could result.

CAUTION! Always be alert for any unintended machine movement.

WARNING! Keep body parts clear of machine while in raised position or serious injury could result.

WARNING! Always allow function to bottom out and stop moving before adjusting any pressure.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load of all blocking devices.

WARNING! Follow all Federal and mine lockout/tagout regulations and procedures. Failure to do so could result in machine damage or serious injury or death to personnel CAUTION! Shims must be inserted completely into the idler slide channel. A shim that is not correctly seated on the idler slide channel’s inside surface provides uneven support that can cause idler slant. A slanted idler can cause uneven wear and stress on the tram track and can cause improper operation of or damage to the tram system.

_________________________________________________________________ 2.22 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

WARNING! Always allow cylinder functions to bottom out (stop moving) before adjusting any pressure. Pressure adjustments will only be accurate when the cylinder is in this condition.

________________________________ Overview of safety instructions IMPORTANT! Check that the shims are correctly seated on the idler slide channel’s inside surface by looking at the channel’s inside surface from the opposite side of the miner through the space between the gathering head and the idler assembly.

CAUTION! Disassembly and assembly procedures listed in this section are specialized and, as such, should only be performed by qualified personnel.

© BUCYRUS AMERICA, INC.

WARNING! Failure to follow all applicable regulations regarding lockout/ tagout procedures may result in machine damage or serious injury or death of personnel.

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 under load, the load will fall. Machine damage or serious injury or death to personnel may result.

WARNING! Do not use your fingers to check the alignment of the rod bearing in the clevis. Shifting of the parts could result in serious injury.

IMPORTANT! In addition to the shear cylinders, the stabilizer and gathering head can be used to adjust the cutter boom’s position to allow easier installation of the cutter boom pivot pins.

IMPORTANT! Before detaching these three (3) lugs, tag the wires to make reconnection easier.

WARNING! Power should not be reconnected to the miner while the motor power cable is disconnected. Damage to the miner or personal injury or death could result.

WARNING! Law requires that mining equipment electrical components must be inspected by a certified electrician before the equipment can be operated.

WARNING! This procedure involves attaching an electrical power cable to a motor. The trailing cable must be disconnected and locked and tagged out to safely perform this operation. Follow all Mine, State, and Federal lockout/tagout procedures. Failure to do so may result in serious injury or death.

______________________________________________________________ A6474X326 VTSV/00 2.23

Overview of safety instructions _________________________________ IMPORTANT! A certified electrician must inspect all work and check for permissibility.

IMPORTANT! During the removal of the cap screws that secure the gear case to the frame, it may be necessary to adjust the blocking under the gear case. Ensure that the gear case is securely blocked at all times and that it does not shift as it is unbolted.

WARNING! Stand clear of the miner and the gear case while tramming the miner. You could be seriously injured or killed by falling loads.

CAUTION! Use care when tramming the miner away from the gear case.

While each cutter motor is supported by a bracket at the rear of the motor, excessive bumping could cause the motor to fall.

IMPORTANT! Make sure that the lower section of the conveyor chain is free of the foot shaft so that when the miner is trammed away from the gathering head, the chain will pull free of the return deck.

NOTICE! When the gathering head was removed, the lower length of the conveyor chain was pulled free of the gathering head. This end of the conveyor chain must be brought forward when the miner is trammed to the gathering head.

DANGER! All personnel must stay clear of the miner while it is tramming and being aligned with the gathering head assembly. Standing under the cutter head or in the path of the miner while it is tramming may result in severe injury or death.

CAUTION! To avoid injury while relieving tension off of the conveyor chain, wear proper personal protective equipment, to include, at a minimum, safety glasses and gloves.

IMPORTANT! Position the foot shaft so that it’s sprocket will engage the conveyor chain links when the chain is reconnected.

WARNING! Do not reconnect the trailing cable to the miner while the power cable is disconnected from the motor. Serious injury or death may occur.

_________________________________________________________________ 2.24 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

WARNING! Do not attempt to start the cutter head motors. You could be seriously injured or killed.

________________________________ Overview of safety instructions WARNING! The end of the chain, just forward of the separation point, should be blocked. Personnel should stay clear of the chain during separation to avoid injury when the chain is disconnected.

IMPORTANT! Be sure that the grousers are in the correct direction before installing the chain into the machine. Check the parts book for your machine to verify the correct direction.

© BUCYRUS AMERICA, INC.

WARNING! Be sure all conveyor components are correctly installed and that the conveyor chain is properly engaged by the foot shaft before starting the miner.

WARNING! Some procedures must be carried out with the cover of the electrical controller removed and some procedures require the controller to be energized during the tests. It is extremely important that you take all necessary precautions to prevent accidental electrical shock while working within the controller. An certified electrician must supervise and inspect all work performed.

______________________________________________________________ A6474X326 VTSV/00 2.25

Overview of safety instructions _________________________________ Chapter 6: Technical data IMPORTANT! The technical data listed in this chapter is for stock machines only. Customer specials may not be listed.

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.

IMPORTANT! The lubrication fluids and greases listed in the same table can be mixed. Other products may only be used if the supplier can guarantee that they are equivalent.

Differently composed fluids and greases must not be mixed as this may change the consistency, i.e. the mixture can become thinner so that the lubrication effect is not sufficient. It may also be dangerous to use lubricating greases and fluids having the same specification base but different origins.

In case of doubt, the manufacturer of the lubrication to be used should be contacted as to the compatibility of the lubrication in question.

IMPORTANT! Bucyrus America, Inc. expressly point out that the approval of the listed products relates only to the pure technical use in our mechanical and hydraulic systems. The responsibility for the constituents used in the hydraulic concentrates lies solely with the respective manufacturer.

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

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

_________________________________________________________________ 2.26 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

IMPORTANT! Use a calibrated torque wrench for accuracy!

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Storage and transport

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________________________________________ Storage and transport

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

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

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

Storage corrosion protection

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

© BUCYRUS AMERICA, INC.

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

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

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

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

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

short-term storage

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

long-term storage

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

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

■

Completely fill the hydraulic oil tank with oil.

■

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

■

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

■

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

______________________________________________________________ A6474X326 VTSV/00 3.3

Storage and transport _________________________________________ machine electrical components traction drives

Electronic components must be stored at temperatures between -10° C and 55° C (14° F and 131° F).

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

random sample inspection

After a storage period of approximately two years, a random sample inspection must be performed to determine whether the measures taken and the method of storage has prevented damage. On request, the inspection can be carried out by Bucyrus America, Inc.

natural aging

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

HFA fluids

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.

Long-term storage of spare components hydraulic components

If a component is to be stored more than six months, the hydraulic component must be completely filled with a corrosion inhibiting fluid. Fill the hollow areas of hydraulic components (e.g. the piston chambers) in horizontal position (ports facing upwards) until they start to overflow then seal the ports with plastic or steel plugs.

miscellaneous components

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

motors

Refer to the motor manufacturer’s storage procedure guide in your Bucyrus America, Inc. parts manual.

fan assembly

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

plastic deformation

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

_________________________________________________________________ 3.4 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

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

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

dimensions,

■

weights,

■

lifting points, etc.

© BUCYRUS AMERICA, INC.

Additional information on the dimensions and weights can be found in chapter 6 and in the lifting weight guide (Table 1) in this operating section. Fig. 5 illustrates the position of lifting points of the various assemblies of the machine. For detailed lifting instructions, see component hoisting information.

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

Table 1: Lifting weights of continuous miner assemblies Description

Approximate Weight

Tractor Frame

80,000 lbs

Gathering Head

23,158 lbs

Chain & Conveyor

17,000 lbs

Support Frame

50,500 lbs

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

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

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

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

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

______________________________________________________________ A6474X326 VTSV/00 3.5

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.

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

electronic components

Electrical and electronic components must be protected against harmful environmental influences by a suitable packaging.

The electrical cables remain in the equipment. They must be carefully protected against transport damage and soiling of the connections.

_________________________________________________________________ 3.6 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

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

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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.

© BUCYRUS AMERICA, INC.

Work on: ■

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

■

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

■

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

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

Which tools are required for installation? tool box

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

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

These include: ■

hoists with adequate lifting capacity

■

means of attachment with adequate lifting capacity

■

unloading dock and crib blocks

■

jacks with adequate lifting capacity

■

impact wrenches, including accessories

______________________________________________________________ A6474X326 VTSV/00 4.3

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

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

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

reassembly instructions

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

_________________________________________________________________ 4.4 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

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

__________________________________________________ Installation Pre-installation check list

© BUCYRUS AMERICA, INC.

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

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

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

■

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

■

check the full length of the trailing cable (if applicable) for damage

■

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

■

clean any foreign material from the conveyor and gathering pan

■

check that all covers and guards are in place and secure

■

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

■

check safety provisions for operational condition on fire suppression system

■

visually inspect all hydraulic hoses and electrical cables for damage

■

start up the machine and check for correct operation of all stop and emergency stop buttons (both on the machine and on the transmitter)

■

after starting the machine, allow the hydraulic system to warm up for five (5) to ten (10) minutes and then check hydraulic system pressures (refer to the hydraulic schematic supplied for your particular machine for pressure settings)

■

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

■

check the tension of the conveyor chain and crawler chain

______________________________________________________________ A6474X326 VTSV/00 4.5

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

machine stop button

The machine is equipped with four machine stop buttons, two on each side of the machine. The machine stop buttons are used to shut down all functions capable of producing movement on the machine. Striking with a small amount of force will actuate the machine stop.

fire suppression (optional)

The machine may be equipped with fire suppression (remote) actuators. If equipped, the location of the actuators may vary. The suppression system (if equipped) is pneumatically actuated and extinguishes with dry chemicals. To actuate the system from the actuators, pull the safety pin and strike downward on the plunger. Immediately after the plunger is struck, dry chemical will be dispensed throughout the machine. The fire suppression system must be completely recharged with dry chemicals and expellants after it has been actuated.

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

Water can be directed to the fire spray nozzles (optional) manually from a fire spray valve or via solenoid from the remote transmitter. If equipped, see Chapter 5 for operating instructions and locations of the valves.

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

CAUTION! The mine supply water pressure at the machine should not exceed 500 psi (34 bar) and should supply 20 gpm (76 Lpm)

guards and covers

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

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

cutter boom safety supports

There are two cutter boom safety supports (Fig. 6), one on each side of the cutter boom. The supports are used to block up the cutter boom during maintenance operations.

_________________________________________________________________ 4.6 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

Safety features include: (Reference Fig. 6)

__________________________________________________ Installation Fig. 6: Safety features on the Continuous Miner

Machine stop

© BUCYRUS AMERICA, INC.

Machine stop

Machine stop

Machine stop

______________________________________________________________ A6474X326 VTSV/00 4.7

Installation___________________________________________________ Fig. 6 (continued): Safety features on the Continuous Miner

© BUCYRUS AMERICA, INC.

Cutter head safety support - installed

Cutter head safety support - typical both sides

_________________________________________________________________ 4.8 Bucyrus – Model 30M4-NP Continuous Miner

__________________________________________________ Installation Fig. 7: Overview of the Continuous Miner

Conveyor assembly

Cutter head assembly

Operator’s station

Tram assembly

Gathering pan assembly

© BUCYRUS AMERICA, INC.

Stabilizer shoe

______________________________________________________________ A6474X326 VTSV/00 4.9

© BUCYRUS AMERICA, INC.

Installation___________________________________________________

_________________________________________________________________ 4.10 Bucyrus – Model 30M4-NP Continuous Miner

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Operation

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________________________________________________________________

_________________________________________________________________

___________________________________________________Operation

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

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

How to operate the continuous miner

© BUCYRUS AMERICA, INC.

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

Who is allowed to operate the continuous miner?

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

This also includes: ■

what safety devices are installed on the machine.

■

where these safety devices are located.

■

how these safety devices are to be operated.

When can operation be started?

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

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

______________________________________________________________ A6474X326 VTSV/00 5.3

Operation____________________________________________________ Controls and indicators Operator’s station DANGER! The Continuous Miner is radio remote controlled during production operations. Manual operation via controls at the operator’s station is not permitted for production operation. Manual operation is for troubleshooting and maintenance under supported roof only. Tramming via the Emergency tram pendant is only permitted in situations when the radio remote system is inoperable. operating the Continuous Miner with manual or pendant controls under unsupported roof may result in severe injury or death.

The operator’s station (Fig. 8) is located on the right hand side of the machine, near the rear bumper.

Fire spray valve

Switches

“MACHINE STOP”

Horn

View panel

“START/ STOP”

View panel

Circuit breakers

Hour meters

Gauge panel

Circuit breaker reset handles (power)

_________________________________________________________________ 5.4 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

Fig. 8: Operator’s station

___________________________________________________Operation “MACHINE STOP”

“MINER MODE”

© BUCYRUS AMERICA, INC.

“350 VOLT”

“120 VOLT”

The “MACHINE STOP” button (Fig. 9) is a large red push button located on the top left of the operator’s case. This is one of four (4) machine stop buttons located on the miner. Pushing “MACHINE STOP” will shut down the pump motor, causing the miner to shut down. Follow the normal star up procedure (See Start up procedure in this chapter) to restart the machine after pushing “MACHINE STOP”.

The “MINER MODE” selector switch (Fig. 9) is located to the right of the “MACHINE STOP” button. This switch has two (2) positions: ■

“REMOTE” - This position allows the miner to be operated by radio remote. During normal mining operations, the switch should be in this position.

■

“OFF/E-TRAM” - This position allows the miner to be trammed from the pendant controls. “E-TRAM” is used in the event that the miner cannot be operated in “REMOTE” mode.

The “350 VOLT” switch is used to check ground in the 350 volt circuit.

The switch has three (3) positions: ■

“NORMAL MODE” - The switch should be in this position during normal operation of the machine.

■

“GND CHK” - When the switch is turned to this position, the 350V circuit will be grounded, causing the machine to shutdown.

■

“RESET” - The 350V circuit must be reset after it has been grounded. To reset the circuit, turn the switch to the “RESET” position.

The “120 VOLT” switch is used to check ground in the 120 volt circuit.

The switch has three (3) positions: ■

“NORMAL MODE” - The switch should be in this position during normal operation of the machine.

■

“GND CHK” - When the switch is turned to this position, the 350V circuit will be grounded, causing the machine to shutdown.

■

“12 VOLT”

“RESET” - The 120V circuit must be reset after it has been grounded. To reset the circuit, turn the switch to the “RESET” position.

The “12 VOLT” switch is used to check ground in the 12 volt circuit.

The switch has three (3) positions: ■

“NORMAL MODE” - The switch should be in this position during normal operation of the machine.

■

“GND CHK” - When the switch is turned to this position, the 350V circuit will be grounded, causing the machine to shutdown.

■

“RESET” - The 12V circuit must be reset after it has been grounded. To reset the circuit, turn the switch to the “RESET” position.

______________________________________________________________ A6474X326 VTSV/00 5.5

Operation____________________________________________________

fire spray valve

The “MACHINE LIGHTING” switch is used to control the area and head lights on the machine. The switch has four (4) positions: ■

“OFF” - When the switch is in the “OFF” position, all lights on the machine are off.

■

“AREA LIGHTS” - Turning the switch to the “AREA LIGHTS” position will turn on the area lights only.

■

“HEAD LIGHTS” - Turning the switch to the “HEAD LIGHTS” position will turn on the head lights only.

■

“ON” - Turning the switch to the “ON” position turns on both the area and head lights.

The fire spray valve (Fig. 9) located to the left of the control case can be operated manually or by remote. To manually operate the valve, pull out to turn on and push in to turn off.

Fig. 9: “MACHINE STOP”, switches, and fire spray valve “MACHINE STOP”

“MINER MODE”

“350 VOLT”

“120 VOLT”

“12 VOLT”

“MACHINE LIGHTING”

Fire spray valve

_________________________________________________________________ 5.6 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

“MACHINE LIGHTING”

___________________________________________________Operation “PRESTART WARNING” horn “START/STOP” switch

circuit breakers

The “PRESTART WARNING” horn (Fig. 10) will sound before the pump motor starts running and when tramming is enabled.

The “START/STOP” switch (Fig. 10) is used to connect/disconnect power to the miner at the main power center.

There are four (4) “CONTROL CIRCUIT BREAKERS” and four (4) “MACHINE LIGHTING” circuit breakers (Fig. 10) located at the top of the control panel. For more detailed information on the individual circuit breakers, see the Electrical section in this chapter.

“CONVEYOR HOUR METER”

The “CONVEYOR HOUR METER” (Fig. 10) indicates the hours of running time for the conveyor (CLA) motors.

“CUTTER HEAD HOUR METER”

The “CUTTER HEAD HOUR METER” (Fig. 10) indicates the hours of running time for the cutter motors.

Fig. 10: Horn, start/stop switch, circuit breakers, and hour meters “START/STOP” switch

Circuit breakers

© BUCYRUS AMERICA, INC.

“PRESTART WARNING” horn

“CONVEYOR HOUR METER”

“CUTTER HEAD HOUR METER”

______________________________________________________________ A6474X326 VTSV/00 5.7

view panels

There are two (2) view panels located on the front of the control case (Fig. 11). The view panels can be used to view components located on the front of the swing panel. .

“CUTTER MOTOR CIRCUIT BREAKER”

The “CUTTER MOTOR CIRCUIT BREAKER” lever (Fig. 11) is used to control the circuit breaker for the cutter motors. This breaker must be in the “ON” position before the cutter motors will start. To turn the circuit breaker “ON”, move the lever to the right. To turn the circuit breaker “OFF”, move the lever to the left. If the circuit breaker trips, The breaker must be reset by moving the lever past “OFF” and then back to the “ON” position.

“TRAM CIRCUIT BREAKER”

The “TRAM CIRCUIT BREAKER” lever (Fig. 11) is used to control the circuit breaker for the tram motors. This breaker must be in the “ON” position before the tram motors will start. To turn the circuit breaker “ON”, move the lever to the right. To turn the circuit breaker “OFF”, move the lever to the left. If the circuit breaker trips, The breaker must be reset by moving the lever past “OFF” and then back to the “ON” position.

Fig. 11: Viewing panels and circuit breaker levers “CUTTER MOTOR CIRCUIT BREAKER”

View panel

View panel

“TRAM CIRCUIT BREAKER”

_________________________________________________________________ 5.8 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

Operation____________________________________________________

___________________________________________________Operation Gauge panel There is a gauge panel (Fig. 12) consisting of twelve (12) gauges located to the right of the control case that is used to measure hydraulic and water pressure throughout the miner.

“MAIN PRESSURE”

© BUCYRUS AMERICA, INC.

“LOAD SENSING PRESSURE”

The first gauge from the operator’s left on the top row of gauges is “MAIN PRESSURE”. This gauge is used to monitor the pressure in the main flow - primary pressure circuit. See the Primary pressure circuit in the Hydraulic section of this chapter for further information.

The second gauge from the operator’s left on the top row of gauges is “LOAD SENSING PRESSURE”. This gauge monitor the pressure in the load sensing circuit of the main valve bank.

“GH FLOAT PRESSURE”

The third gauge from the operator’s left on the top row of gauges is “GH FLOAT PRESSURE”. This gauge is used to monitor the pressure in the gathering head circuit during gathering head float operations. See the Gathering head raise/hold/float-lower circuit in the Hydraulic section of this chapter for more information.

“SHEAR DOWN PRESSURE”

The fourth gauge form the operator’s left on the top row of gauges is “SHEAR DOWN PRESSURE”. The gauge is used to monitor the pressure of the cutting head cylinder circuit during shear down operations.

See the Cutter head raise/lower circuit in the Hydraulic section of this chapter for more information.

“PILOT PRESSURE”

The first gauge from the operator’s left on the middle row of gauges is “PILOT PRESSURE”. This gauge is used to monitor the supply pressure for all pilot functions. See the Pilot pressure circuit in the Hydraulic section of this chapter for further information.

“CONVEYOR CHAIN TAKE-UP PRESSURE”

The second gauge from the operator’s left on the middle row of gauges is “CONVEYOR CHAIN TAKE-UP PRESSURE”. This gauge is used to monitor the pressure of the automatic conveyor chain tensioner. See the Conveyor take-up circuit in the Hydraulic section of this chapter for further information.

“HIGH SPEED RAISE ACTIVATION PRESSURE”

The third gauge from the operator’s left on the middle row of gauges is “HIGH SPEED RAISE ACTIVATION PRESSURE”. This gauge monitors the pressure of the high speed cutter head raise circuit. See the High speed cutter head raise circuit in the Hydraulic section of this chapter for further information.

“BRAKE COOLING PRESSURE”

The fourth gauge from the operator’s left on the middle row of gauges is “BRAKE COOLING PRESSURE”. This gauge monitors the pressure in the brake cooling circuit. See the Brake control valve circuit in the Hydraulic section of this chapter for further information.

“ACCUMULATOR PRESSURE”

The first gauge from the operator’s left on the bottom row of gauges is “ACCUMULATOR PRESSURE”. This gauge monitors the pressure of the accumulator. See the Dust-scrubber-fire sprays circuit in the Hydraulic section of this chapter for further information.

______________________________________________________________ A6474X326 VTSV/00 5.9

Operation____________________________________________________ “OUTBY WATER FILTER PRESSURE”

The second gauge from the operator’s left on the bottom row of gauges is “OUTBY WATER FILTER PRESSURE”. This gauge monitors the pressure across the outby water filter. See the Water section of this chapter for further information.

“SUMP DUMP JET PUMP PRESSURE”

The third gauge from the operator’s left on the bottom row of gauges is “SUMP DUMP JET PUMP PRESSURE”. This gauge monitors the water pressure at the scrubber sump jet pump. See the Scrubber screen backflush sprays circuit in the Water section of this chapter for further information.

“SCRUBBER SPRAY PRESSURE”

The fourth gauge from the operator’s left on the bottom row of gauges is “SCRUBBER SPRAY PRESSURE”. This gauge monitors the water pressure of the scrubber sprays. See the Dust/cooling water circuit in the Water section of this chapter for further information.

Fig. 12: Gauge panel 1

6

2

7

3

4

8 © BUCYRUS AMERICA, INC.

5

1.

2.

3.

4.

5.

6.

9

10

“MAIN PRESSURE” “LOAD SENSING PRESSURE” “GH FLOAT PRESSURE” “SHEAR DOWN PRESSURE” “PILOT PRESSURE” “CONVEYOR CHAIN TAKE-UP PRESSURE

7.

8.

9.

10.

11.

12.

11

12

“HIGH SPEED RAISE ACTIVATION PRESSURE” “BRAKE COOLING PRESSURE” “ACCUMULATOR PRESSURE” “OUTBY WATER FILTER PRESSURE” “SUMP DUMP JET PUMP PRESSURE” “SCRUBBER SPRAY PRESSURE”

_________________________________________________________________ 5.10 Bucyrus – Model 30M4-NP Continuous Miner

___________________________________________________Operation Hydraulic valve bank The manually operated valve bank (Fig. 13) is a six section valve bank located to the right of the control case and is used to operate the hydraulic cylinder on the miner during maintenance and troubleshooting while under supported roof.

© BUCYRUS AMERICA, INC.

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

“GATHERING HD”

The first lever from the operator’s left, “GATHERING HD”, controls the hydraulic cylinders that raise and lower the gathering head. To raise the gathering head, push the lever away from the operator. To float the gathering head, pull the lever toward the operator.

“CONVEYOR” (right/left)

The second lever from the operator’s left, “CONVEYOR” (right/left), controls the conveyor swing cylinders. To swing the conveyor boom to the left, push the lever away from the operator. To swing the conveyor boom to the right, pull the lever toward the operator.

“CONVEYOR” (raise/lower)

The third lever from the operator’s left, “CONVEYOR” (raise/lower), controls the hydraulic cylinders that raise and lower the conveyor boom. To raise the conveyor, pull the lever toward the operator. To lower the conveyor, push the lever away from the operator.

“STABILIZER”

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

“CUTTER HEAD”

The fifth lever from the operator’s left, “CUTTER HEAD”, controls the hydraulic cylinders that raise and lower the cutter head. To raise the cutter head, pull the lever toward the operator. To lower the cutter head, push the lever away from the operator. Positioning the lever in the center (neutral) position, will hold the cutter head in place.

“CUTTER HEAD HS”

The sixth lever from the operator’s left, “CUTTER HEAD HS”, controls the hydraulic cylinders that raise the cutter head; this valve section will only raise (not lower) the cutter head. High speed (HS) cutter head raise should only be used when positioning the cutter head, not while cutting.

WARNING! High speed cutter head raise should only be used when positioning the cutter head, not while cutting. Using the high speed cutter head function while cutting will result in machine damage.

______________________________________________________________ A6474X326 VTSV/00 5.11

Operation____________________________________________________ Fig. 13: Hydraulic valve bank “CONVEYOR” (right/left)

“CONVEYOR” (raise/lower)

“STABILIZER”

“CUTTER HEAD”

“CUTTER HEAD HS”

© BUCYRUS AMERICA, INC.

“GATHERING HD”

_________________________________________________________________ 5.12 Bucyrus – Model 30M4-NP Continuous Miner

___________________________________________________Operation “VENTURI OIL TANK FILL CONTROL VALVE”

The “VENTURI OIL TANK FILL CONTROL VALVE”, located behind a cover on the front right side of the machine (Fig. 14), is used in conjunction with the “CONVEYOR” lower function to power fill the hydraulic oil tank. To power fill: IMPORTANT! In order to avoid damaging the pump, the oil level in the tank must be above the suction strainer before using the power fill function.  Manually open the Venturi oil tank fill control valve.  Engage the conveyor lower function by pushing the “CONVEYOR” raise/lower lever away from the operator.  After filling the tank, close the Venturi oil tank fill control valve.

© BUCYRUS AMERICA, INC.

“HYD OIL FILL HAND PUMP”

“MACHINE STOP”

The “HYD OIL FILL HAND PUMP” is located on the right front side of the machine (Fig. 14) and is used to manually pump hydraulic oil into the hydraulic oil tank.

The “MACHINE STOP” button (Fig. 14) is a large red push button located on the front right side of the machine. This is one of four (4) machine stop buttons located on the miner. Pushing “MACHINE STOP” will shut down the pump motor, causing the miner to shut down. Follow the normal star up procedure (See Start up procedure in this chapter) to restart the machine after pushing “MACHINE STOP”.

Fig. 14: “VENTURI OIL TANK FILL CONTROL VALVE”, “HYD OIL FILL HAND PUMP”, and “MACHINE “VENTURI OIL TANK FILL CONTROL VALVE”

“HYD OIL FILL HAND PUMP”

“MACHINE STOP”

______________________________________________________________ A6474X326 VTSV/00 5.13

Operation____________________________________________________ Left side controls and indicators (Fig. 14) “MACHINE STOP”

The are two “MACHINE STOP” buttons located on the left side of the machine, on is located near the back and one near the front of the machine. There are a total of four (4) machine stop buttons located on the miner. Pushing “MACHINE STOP” will shut down the pump motor, causing the miner to shut down. Follow the normal star up procedure (See Start up procedure in this chapter) to restart the machine after pushing “MACHINE STOP”.

“MANUAL SCRUBBER WATER”

The “MANUAL SCRUBBER WATER” valve is used to manually turn on water to the scrubber.

“WASHDOWN HOSE”

The “WASHDOWN HOSE” valve is used to turn on water to the washdown hose.

“MANUAL SCRUBBER BACKFLUSH SPRAYS”

The “MANUAL SCRUBBER BACKFLUSH SPRAYS” valve is used to manually turn on the water to the scrubber backflush sprays.

“FIRE SPRAY”

The “FIRE SPRAY” valve is used to manually turn on water to the fire sprays.

“BACKFLUSH STRAINER VALVE B”

The “BACKFLUSH STRAINER VALVE B” is used to manually backflush the strainer. Valves “A” and “C” must be closed when valve “B” is open.

“COOLING/DUST-SCRUBBER MANIFOLD WATER”

The “COOLING/DUST-SCRUBBER MANIFOLD WATER” valve is used to manually turn on the water to the manifold.

“SUMP WASHOUT VALVE C”

The “SUMP WASHOUT VALVE C” is used to manually supply water to the sump washout. Valves “A” and “ B” must be closed when valve “C” is open.

scrubber jet pump pressure gauge scrubber sprays pressure gauge

The gauge is used to monitor the output pressure of the scrubber jet pump.

This gauge is used to monitor scrubber spray pressure.

_________________________________________________________________ 5.14 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

There is a series of manually operated water valves on the left hand side of the machine (Fig. 14):

___________________________________________________Operation Fig. 14: Left side controls and indicators

“MANUAL SCRUBBER WATER”

“WASHDOWN HOSE”

“MANUAL SCRUBBER BACKFLUSH SPRAYS”

“FIRE SPRAY”

“MANUAL COOLING/ DUST WATER”

“BACKFLUSH STRAINER VALVE B”

“COOLING/ DUSTSCRUBBER MANIFOLD WATER”

“SUMP WASHOUT VALVE C”

© BUCYRUS AMERICA, INC.

“EMERGENCY STOP”

“VALVE A”

Scrubber jet pump pressure gauge

Scrubber sprays pressure gauge

______________________________________________________________ A6474X326 VTSV/00 5.15

Operation____________________________________________________ Controls and indicators - bumper view screen

The view screen (Fig. 15) is located on the right side of the bumper.

For information regarding the view screen, please see the Machine control system section of this chapter.

methane monitor display

The methane monitor display (Fig. 15) is located on the right side of the bumper, below the graphics display. Consult the manufacturer’s information regarding the setup, operation, and maintenance of the methane monitoring system.

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

© BUCYRUS AMERICA, INC.

Fig. 15: Graphics and methane monitor displays

Graphics display

Methane monitor display

_________________________________________________________________ 5.16 Bucyrus – Model 30M4-NP Continuous Miner

___________________________________________________Operation Machine control system IMPORTANT! The following information is presented as a general guide to the capabilities and functions of the control system. Before attempting to operate, service, or troubleshoot the Continuous Miner, training must be completed. For a detailed description of component locations, please see the Bucyrus parts book for your machine.

© BUCYRUS AMERICA, INC.

An multi-component system is used to control various aspects of the machine and consists of the following main components:

MCU

radio receiver

radio transmitter

■

MCU (Motor Control Unit )

■

Radio receiver

■

Radio transmitter (remote control)

■

Back up power supply

■

Emergency tram pendant

■

DC tram drive

■

Pendant drive controller

■

View screen

■

Infrared (IR) remote

The Main Control Unit (MCU) is a device used to automate monitoring and control of the machine. See the Bucyrus parts book for your machine for the correct part number for the MCU. The radio receiver receives the signal from the radio transmitter (remote control) and communicates that signal to the PLC. The radio transmitter (Fig. 16) allows the operator to control the continuous miner from a remote location. The transmitter send a signal to the radio receiver, which is mounted on the machine.

Machine operations are hand operated using the eight (8) push buttons, thirteen (13) toggle switches, two (2) tram levers, and a machine stop button. There are also six LEDs on the transmitter to provide operator feedback.

______________________________________________________________ A6474X326 VTSV/00 5.17

Operation____________________________________________________ Fig. 16: Transmitter

“MACHINE STOP”

“TX POWER ON”

“TX POWER OFF”

Operator feedback LEds

“SHIFT”

“MSTOP OVR”

“ENABLE”

“HIGH”

“CUTTER START-STOP”

“CONVEYOR REVERSE”

“CONVEYOR START-STOP”

“FIRELIGHTS”

“DUST ON-OFF”

“FAN START-STOP” “PUMP START-STOP”

Left tram lever

Right tram lever

“TRAM ENABLE”

“BREAKER ON-RESET”

“CONVEYOR RAISE-LOWER”

“CONV SWING LEFT-RIGHT”

“GATH HD FLOAT-RAISE”

“CUTTER HEAD RAISE-LOWER”

_________________________________________________________________ 5.18 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

“LOW”

___________________________________________________Operation The transmitter power on button, “TX PWR ON” , is a push button used to turn the transmitter on.

“TX PWR OFF”

The transmitter power off button, “TX PWR OFF”, is a push button used to turn the transmitter off. Pushing this button initiates a shutdown sequence on the machine that will shut off the pump motor, thereby shutting off all motors on the machine. The transmitter will issue this command twenty (20) times before it turns off.

“MACHINE STOP”

The emergency machine stop button, “MACHINE STOP”, is a large red button in the upper left corner of the transmitter. Pushing this button will immediately shutdown the machine.

“ENABLE”

The “ENABLE” button is used in conjunction with other switches and performs no operation on its own. Any switch that requires the use of the “ENABLE” button will have its function marked in green lettering. If this button is held during start up, an error is generated and displayed on the view screen. If held on for more than fifteen (15) seconds, an error is generated and shutdown codes are sent.

“CUTTER”

The cutter motor start/stop switch, “CUTTER”, is used to start and stop the cutter motors.

© BUCYRUS AMERICA, INC.

“TX PWR ON”

Cutter “START” requires the “ENABLE” button to be pressed simultaneously. If the switch is held for more than fifteen (15) seconds, an error occurs and the transmitter issues standard motor shutdown commands and displays the error on the view screen.

Moving the lever forward to the “STOP” position will shutdown the cutter motors. The display will show “CUTTER STOP”. If held during start up, an error is generated and displayed on the view screen.

“CONVEYOR”

The conveyor motor start/stop switch, “CONVEYOR”, is used to start and stop the conveyor motors. When the conveyor motor is started, the conveyor will run in the forward direction.

“START” requires the “ENABLE” button to be pressed simultaneously.

If the switch is held for more than fifteen (15) seconds, an error occurs and the transmitter issues standard motor shutdown commands and displays the error on the view screen.

Moving the lever forward to the “STOP” position will shutdown the conveyor motors.

“CONVEYOR REVERSE”

To run the conveyor in reverse, the “ENABLE” button and “CONVEYOR START” switch must be held in while “CONVEYOR REVERSE” is pressed. An error is displayed on the view screen if this button is pressed during transmitter start up. If held for more than fifteen (15) seconds, and error message will be generated.

______________________________________________________________ A6474X326 VTSV/00 5.19

“FIRE”

The “FIRE” switch will activate the fire suppression system on the machine. If held during start up, an error is generated and displayed on the view screen.

“LIGHTS”

The “LIGHTS” switch is used to activate and deactivated the lights.

This is a latched function. The lights turn on when the toggle switch is pushed and released. The lights turn off when the switch is pushed again. If held during start up, and error is generated and displayed on the view screen.

“DUST”

The dust sprays are turned on and off with the “DUST ” switch. To turn the dust sprays on, move the switch to the “ON” position. To turn the sprays off, move the switch to the “OFF” position. If held in either position, “ON” or “OFF”, during start up, an error will be generated and displayed on the view screen.

“FAN”

The fan (scrubber) is turned on and off with the “FAN” switch. To turn the fan on, move the switch to the “ON” position. To turn the fan off, move the switch to the “OFF” position. If held in either position, “ON” or “OFF”, during start up, an error will be generated and displayed on the view screen.

“PUMP START”

The “PUMP START” switch starts the pump motor. This switch requires the “ENABLE” button to be pressed before the switch is activated. The switch must be held in the “START” position for 0.5 seconds before the transmitter will transfer the command. IF the switch is held for more than fifteen (15) seconds, an error occurs, the transmitter will issue standard motor shut down commands, and an error displays on the view screen.

“PUMP STOP”

The “PUMP STOP” switch turns off the pump motor. If held during start up, an error is generated and displayed on the view screen.

“CUTTER HEAD”

The cutter head is raised and lowered with the “CUTTER HEAD” switch. To raise the cutter head, move the switch to the “RAISE” position. To lower the cutter head, move the switch to the “LOWER” position. If the switch is held in either position during start up, an error is generated and displayed on the view screen.

“GATH HEAD”

The gathering head position is controlled with the “GATH HEAD” switch. To raise the gathering head, move the switch to the “RAISE” position. To float the gathering head, move the switch to the “FLOAT” position. If the switch is held in either position during start up, an error is generated and displayed on the view screen.

“CONV SWING”

The “CONV SWING” switch controls the horizontal position of the conveyor. To swing the conveyor to the left, move the switch to the “LEFT ”. To swing the conveyor to the right, move the switch to the “RIGHT ” position. If the switch is held in either position during start up, an error is generated and displayed on the view screen.

_________________________________________________________________ 5.20 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

Operation____________________________________________________

___________________________________________________Operation

© BUCYRUS AMERICA, INC.

“CONVEYOR”

The conveyor vertical position is controlled with the “CONVEYOR” switch. To raise the conveyor, move the switch to the “RAISE” position. To lower the conveyor, move the switch to the “LOWER” position.

If the switch is held in either position during start up, an error is generated and displayed on the view screen.

“BREAKER” (optional)

The “BREAKER” switch (optional) is used to turn on or reset the main circuit breaker, “CB1”. To turn on the breaker, move the switch to the “ON” position while pressing the “ENABLE” button. To reset the breaker, move the switch to the “RESET” position while pressing the “ENABLE” button.

“STAB”

The “STAB” switch is used to raise and lower the stabilizer shoe. To raise the stabilizer, move the switch to the “RAISE” position. To lower, move the switch to the “LOWER” position.

“MSTOP OVR”

The machine stop override button, “MSTOP OVR”, requires the “ENABLE” button to be press to be activated. This button will override the machine stop buttons on the left side of the miner. To override a machine stop button, the “ENABLE” button must be pressed then “MSTOP” must be pressed and held whild the pump is started and during tramming.

tram “LOW”

The tram “LOW” button will put the miner in low tram speed. This is the default tram speed when the miner is energized.

tram “HIGH”

The tram “HIGH” button will put the miner in high tram speed and is activated by pushing the button.

______________________________________________________________ A6474X326 VTSV/00 5.21

Operation____________________________________________________ Operator feedback LEDs The operator feedback LEDs (Fig. 17) are located in the upper left hand corner of the transmitter.

“BATTERY/UMB MSG”

The battery/umbilical message LED, “BATTERY/UMB MSG”, blinks different ways, depending on mode of operation. When in transmitter mode (“REMOTE” on the “MINER MODE” switch), the LED indicates general battery condition. A rapid blink indicates a relative full battery and a slow blink indicates a relatively weak battery. Two blinks followed by a long pause followed by two blinks indicated approximately 8 hours of battery life remains. This pattern will continue, indicating that fresh batteries are needed.

When in umbilical mode (“ETRAM” on the “MINER MODE” switch), the LED blinks at a steady ten times per second indicating that a message has been sent to the MCU.

“ERROR”

The “ERROR” light indicates the general health of the transmitter. The LED should turn on briefly at power up. When the LED is on after power up, it indicates an internal error within the transmitter and the transmitter should be replaced.

“LING REQ/SHUTDOWN”

When the transmitter is connected as an umbilical, it will attempt to link to the MCU (see teach/learn in the operating procedures in this chapter). The link request/shutdown (“LINK REQ/SHUTDOWN” LED will blink for each link request sent to the MCU. Whe the transmitter is switched off, the LED serves a second purpose in that it indicates a shutdown is in progress and power down messages are being sent to the MCU. During power down, on of three other LEDs will indicate why the transmitter is powering down: Commanded (operator initiated), Inactivity, or Low battery.

_________________________________________________________________ 5.22 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

Fig. 17: Operator feedback LEDs

___________________________________________________Operation “SW ACTIVE/LOW BATT”

This LED is used after power up to indicated a stuck switch. All switches must be in their neutral position before the transmitter is allowed to become operational. If, after the transmitter power button is pressed, this LED is on and stays solidly illuminated, it is indicating a stuck switch. No other switches on the transmitter will be functional.

The transmitter will send the error condition to the MCU and the stuck switch will be displayed. The indicated switch must be put in proper position before operations can resume.

© BUCYRUS AMERICA, INC.

After power up, any switch that is operated will result in the LED being solidly on while the switch is being operated. Note that certain switches are timed to maintain safety features, primarily two handed starts. If one of these switches is held in the on position for longer than fifteen (15) seconds, the transmitter will enter error mode. All commands will cease to operate and an error code will be sent to the MCU. The timed switches are: “ENABLE”, “SHIFT”, “TRAM ENABLE”, “PUMP START”, “CONV START”, “CONV REV”, and “CUTTER START”.

If, during shutdown, the LED illuminates in conjunction with the “SHUTDOWN” LED, it indicates that a low battery was the reason the transmitter shut off.

“TRAM ENABLE/INACTIVITY”

The “TRAM ENABLE/INACTIVITY” LED has two functions. If the LED is on during normal operations, it indicates that the tramming function is enabled and any operation of the tram levers will result in machine movement. If the LED is off, the tram levers are not active.

If this LED is illuminated in conjunction with the “SHUTDOWN” LED, it indicates that the transmitter was shutdown due to inactivity (no switch was operated for the last five (5) minutes).

“LINK ACK/CMD’D POWR”

The link acknowledged/commanded power down, ‘LINK ACK/CMD’D POWR”, LED has two functions. If the LED is illuminated during the teach/learn process (see operating procedures in this chapter), it indicates that a link response (acknowledgement) has been received at the transmitter from the MCU. If the transmitter was re-linked to the same MCU (machine), this LED will flash one time. If this is a new link to a different MCU (machine), the LED will flash two times.

If, during shutdown, the LED illuminates in conjunction with the “SHUTDOWN” LED, it indicates that the transmitter was shut off with by a commanded power down (either the “MACHINE STOP” or “TX POWER OFF” button was pressed).

______________________________________________________________ A6474X326 VTSV/00 5.23

Operation____________________________________________________ pendant controls

The machine can be operated using a pendant control (Fig. 18) connected to the miner by an umbilical cable. This control is used in the event that the transmitter (remote control) cannot communicate with the control system..

The pendant controller allows limited operation of the machine: tramming and pump motor activation to provide hydraulic power to raise or lower the cutting head.

In order to use the pendant, it must be connected to the machine via a pigtail. After plugging in the umbilical cord, the machine mode of operation switch must be rotated to the “ETRAM” .

© BUCYRUS AMERICA, INC.

Fig. 18: Pendant controls

_________________________________________________________________ 5.24 Bucyrus – Model 30M4-NP Continuous Miner

___________________________________________________Operation Pendant functions “MACHINE STOP”

Depressing the “MACHINE STOP” button will immediately stop all motors.

“PUMP START/ENABLE”

The “PUMP START/ENABLE” button is used with the “PUMP ON” button to start the pump motor.

“PUMP ON”

The “PUMP ON” button is used to turn on and off the pump motor.

When pressed by itself, “PUMP ON” will turn off the pump motor.

When used in conjunction with “PUMP START ENABLE”, “PUMP ON” will start the pump motor:  Press and hold the “PUMP START/ENABLE” button.  Press the “PUMP ON” button. Hold both buttons in until the pump starts (approximately one second).

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 Release the buttons.

“TRAM”

Press “TRAM” to activate the tramming function. Once “TRAM” is pressed, the “TRME” LED lights yellow for a preprogrammed number of seconds. If tram buttons are not used within this programmed time period, the LED extinguishes and tramming is disabled.

“TRAM FWD”

After pressing “TRAM ENABLE”, press the right “TRAM FWD” button to tram the right track forward, press the left “TRAM FWD” button to tram the left track forward, or press both “TRAM FWD” buttons together to tram both tracks forward.

“TRAM REV”

After pressing “TRAM ENABLE”, press the right “TRAM REV” button to tram the right track in reverse, press the left “TRAM REV” button to tram the left track in reverse, or press both “TRAM REV” buttons together to tram both tracks in reverse.

“CUTTER RAISE”

When pressed, the “CUTTER RAISE” button raises the cutter head.

The pump motor must be on for this button to be active.

“CUTTER LOWER”

When pressed, the “CUTTER LOWER” button lowers the cutter head.

The pump motor must be on for this button to be active.

LED lights

There are four (4) LED lights across the top of the pendant: “MODE”: LED blinks green when power is present, indicating the unit has power and is on.

“TRME”: Yellow LED indicates that tram action is enabled.

“TRML”: Red LED indicates that tram left command is being sent.

“TRMR”: Red LED indicates that tram right command is being sent.

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Operation____________________________________________________ infrared (IR) remote

The handheld IR remote (Fig.19) is used to interface with the view screen from a remote location. The remote allows navigation through the screens and has the capability of changing attribute values on single variable screens.

Fig. 19: IR remote

“SET” “MENU” “LINK” “PAGE UP” “PAGE DOWN” “DOWN”

IR remote functions “LINK” LED

The “LINK” LED flashes red when the remote is active (turned on). The remote will automatically power down after thirty (30) seconds of inactivity to conserve power. Any button press enables (powers on) the remote when it is inactive.

“PAGE UP” button

The “PAGE UP” button moves to the preceding menu from the current menu.

“PAGE DOWN” button

The “PAGE DOWN” button moves to the following menu from the current menu.

“UP” button

The “UP” button increments the selected menu attribute value. The “SET” button must be pressed immediately after adjusting the attribute value for the system to store the change in memory.

“DOWN” button

The “DOWN” button decreases the selected menu attribute value. The “SET” button must be pressed immediately after adjusting the attribute value for the system to store the change in memory.

“SET” button “MENU” button

The “SET” button sets the new value shown on the display.

The “MENU” button is used to access the default menu on the view screen.

_________________________________________________________________ 5.26 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

“UP”

___________________________________________________Operation view screen

There is a protected view screen (Fig. 19)with a menu system located on the right rear bumper of the machine. The operator navigates through the menus using the yellow “SHIFT” button on the transmitter in conjunction with the switches marked with yellow labels or by using the IR remote.

Fig. 19: View screen display location

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Graphics display

The default menu is the “REMOTE RUNTIME STATUS” menu (Fig. 20). This menu graphically displays all motor currents and temperatures using color changing bar graphs that indicate whether the values are high or low.

Fig. 20: Default menu (typical)

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Operation____________________________________________________

transmitter ID

The transmitter ID is the identification number of the transmitter from which the system is receiving messages.

LED

The green LED indicates when a valid command is being transmitted.

“BATTERY”

“BATTERY” indicates the voltage of the transmitter battery. Low battery voltage is indicated by red battery text. The battery should be changed if the text is red.

“RF SIGNAL”

The “RF SIGNAL” indicator shows the relative strength of the signal. A low value indicates that the miner is approaching a point where signal loss can occur.

IMPORTANT! A low signal indications does not mean there is a loss of information transmitted to the miner; as a digital signal, it will either work or not work. The “RF SIGNAL” indicator shows a potential problem and that transmitter troubleshooting is required. If a low signal is shown when the transmitter is held near the antenna, check the antenna cabling and then check the transmitter for low power output.

“MSG/SEC”

“MSG/SEC” is a diagnostic tool. There should be eight (8) to twelve (12) messaged displayed per second (MSG/SEC) when there is an active command. If the transmitter is idle for one (1) second, the number decreases to four (4) to seven (7) message per second. If there is interference from another transmitters, the number of messages decrease and the displayed value will be smaller.

Fig. 21: Transmitter status area (typical) Transmitter ID

LED

“RF SIGNAL” indicator

“BATTERY”

“MSG/SEC”

_________________________________________________________________ 5.28 Bucyrus – Model 30M4-NP Continuous Miner

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The transmitter status area (Fig. 21) is located in the upper right corner of all menus. This area contains the following:

___________________________________________________Operation fault and error messages

The machine displays faults and errors that occur during operation.

Only faults that cause a motor to shutdown are logged to memory.

Error messages are displayed on a red background on the main display (Fig. 22). The transmitter cannot be used until the condition that generated the error message is corrected.

Fault messages are stored and are available for later viewing on the “FAULT LOG” menu (Fig. 23).

Fig. 22: Error message (typical)

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Error message

Fig. 23: Fault log (typical)

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Operation____________________________________________________ “MINER OVERVIEW” display

The “MINER OVERVIEW” screen (Fig. 24) gives a graphical overview of motor currents and temperatures, machine voltage, tram transformer temperature, and MCU temperature.

motor monitoring displays

There are separate monitoring screens for the pump motor, fan motor, cutter motors, CLA motors, and the tram motors (Fig. 24).

The individual screens provide motor history in one minute intervals.

Color bars display current and temperature for each motor (except for the pump and fan motors, where there is only one each). The current and temperature are also displayed in numerical values on the bottom The graph at the bottom of the screen displays %FLA (Full Load Amps) reading in one minute intervals from left to right.

_________________________________________________________________ 5.30 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

Fig. 24: “MINER OVERVIEW” (typical)

___________________________________________________Operation

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Fig. 24: Motor monitoring displays (typical)

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Operation____________________________________________________ “I/O STATUS PAGE”

There are four (4) input/output (I/O) status monitoring pages (Fig. 25).

Items will be marked in green if a response has been provided to that situation (ex. The box beside “TRANSMITTER ACTIVE” box is green on “PAGE 2” to indicate that the transmitter was communicating with the miner.

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Fig. 25: “I/O STATUS PAGE”

_________________________________________________________________ 5.32 Bucyrus – Model 30M4-NP Continuous Miner

___________________________________________________Operation Red zone There are many dangers present when working in or around a continuous miner. The miner operator most make sure he is fully positioned inside the operator’s pit (if equipped) at all times during operation. He must be aware of all personnel working in the area where the miner is being operated. The miner is especially dangerous when it is being maneuvered during mining operations. The miner is capable of slewing when turning, especially when the crawlers are split. The discharge conveyor can also swing. In each of these cases, anyone in the vicinity is in danger of being hit, or worse yet, run over by the machine.

Equally dangerous is the possibility of someone being pinned against the rib by the miner.

Some typical situations dangerous to the miner operator or anyone working in the vicinity are illustrated on the following pages. The danger area, or red zone, is indicated by alternating red and white diagonal stripes (Fig. 23).

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Fig. 23: Red zone

Tramming the miner (Fig. 24) from one place to another, especially maneuvering around intersections. This illustrates that the operator should not place anyone between the miner and the rib.

Beginning the first sump (Fig. 24) in a new cut. The miner is against the left rib and the discharge conveyor is swung toward the center of the entry ready for the haulage car. All personnel must stay clear of the discharge conveyor and the rear of the miner.

Fig. 24: Red zones

Tramming the miner red zone

Beginning 1st sump red zone

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Operation____________________________________________________ Sumping in the left hand side of the cut (Fig. 25). As the miner penetrates the face, new unsupported roof is being exposed. Personnel must stay clear of the haulage vehicle at the rear of the miner as it approaches the miner and while it is loading.

Repositioning the miner for the right hand cut (Fig. 25). Because the miner is backing out and turning in close quarters, personnel must stay behind the miner to be safe.

Sumping in the right hand cut (Fig. 25). Again, personnel must stay away from the face where the newly-exposed roof is unsupported, as well as staying clear of the haulage vehicle while it approaches and loads.

© BUCYRUS AMERICA, INC.

Fig. 25: Red zones

Sumping on the left hand side red zone

Repositioning miner for right hand cut red zone

Sumping in the right hand cut red zone

_________________________________________________________________ 5.34 Bucyrus – Model 30M4-NP Continuous Miner

___________________________________________________Operation Crosscut red zones (Fig. 26). Beginning and completing crosscuts requires a lot of maneuvering of the miner and loading the haulage vehicle while at awkward positions. Crosscuts also result in newlyexposed unsupported roof. Respecting a red danger zone is important to personnel safety in these conditions.

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

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

Fig. 26: Crosscut red zones

Beginning a right hand crosscut red zone

Right hand crosscut development

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Operation____________________________________________________ Safety precautions for underground operation

■

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

■

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

■

This machine must be maintained following all applicable laws and regulations.

■

Make a visual check of the continuous miner before energizing.

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

■

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

Tramming safety rules ■

Communicate your intentions to the workmen affected by the movement of the continuous miner.

■

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

■

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

■

Position the cutter and gathering head for tramming.

■

Position the stabilizer shoe and booms for tramming.

■

Position your body completely inside the operator's pit, facing the intended direction of travel.

■

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

_________________________________________________________________ 5.36 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

In addition to the preceding instructions for operating the continuous miner, observe the following special precautions after the machine is taken underground.

___________________________________________________Operation

Emergency stop from Machine Stop buttons There are four machine mounted stop buttons that can be pressed at any time to shut down all motors and functions. Two buttons are mounted on the left side of the machine and two are mounted on the right side. There are also machine stop buttons located on the transmitter and the tram pendant.

To shut down the machine using any machine stop:  Press and hold the machine stop button.

© BUCYRUS AMERICA, INC.

The control system will shut down all functions and motors.

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Operation____________________________________________________ Starting procedure WARNING! Read all instructions carefully before attempting to start or operate the machine. Failure to read and understand all operating instructions before starting the continuous miner could result in serious injury or death to the operator or persons around the machine or cause damage to the machine.

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

WARNING! Before starting the machine, make sure that no one is in the red zone (see Red zone in this chapter).

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

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

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

After training, which includes reading and understanding the Controls and Indicators section of this chapter, and becoming familiar with the locations and functions of all machine controls, the operator is ready to operate the continuous miner. An experienced operator should monitor a new operator’s indoctrination to the starting procedure.

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

WARNING! Visually check for other personnel and verbally shout a warning before starting this machine. Make sure all personnel are completely clear of the machine and it’s components and check that the area is clear before starting the machine.

_________________________________________________________________ 5.38 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

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

___________________________________________________Operation The first time a transmitter is used to operate a machine, it must be connected to the machine by an umbilical and linked to the machine by a Teach-Learn process. If the transmitter was the last transmitter to operate the machine, the Teach-Learn process can be skipped.

Teach-Learn Process  Assure that the trailing cable plug and socket are coupled tightly.  Assure that all circuit breakers are in the closed position.   Turn the transmitter to reveal the umbilical cord port located on the side of the unit (Fig. 80). The port has a black cap that protects it and enables it as a radio transmitter.

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Fig. 80: Umbilical cord port

Port cap

Umbilical cord port

Detached port cap

 Unscrew the black cap and remove the black cap/plug. Store the cap in a secure location.

IMPORTANT! The transmitter will not work with the plug inserted and the cap screwed onto the port.

______________________________________________________________ A6474X326 VTSV/00 5.39

Operation____________________________________________________  Attach the umbilical cord to the port. The port is keyed so that the plug pins will only align when the plug is properly positioned. Once the plug is properly aligned, screw the knurled retainer on the port (Fig. 81).

Fig. 81: Connected umbilical cord Knurled retainer

 Press the “TX PWR ON” button to turn the transmitter on. The “UMB MSG” (umbilical message) LED and the “LINK REQ” (link request) LED will flash. The “LINK ACK” (link acknowledged) LED will then flash once to verify that the serial number provided by the MCU matches that in it’s memory or will flash twice for logging a new machine serial number into it’s memory.  The handheld can now be used as an end station (with the umbilical cord still attached) or as a remote transmitter (umbilical cord detached). To use as a remote transmitter, the port cap must be reattached.

Pump motor start After the transmitter has completed the teach-learn procedure, or if the transmitter was the last transmitter to control the machine, the following procedure is used to start the pump motor.  Press the “ENABLE” button in the top right corner of the transmitter.  Press the “PUMP” toggle switch to the “START” position and hold for 0.5 seconds. If the switch is held in the “ON” position for more than 15 seconds, the transmitter will issue an error and the pump motor will not start. An error message will display on the graphics display.

_________________________________________________________________ 5.40 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

Connected umbilical cord

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

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 Move the “CONV STOP” switch to the “OFF” position. The conveyor motors should shut down immediately.  Tram the miner to an area of well supported roof. Park the machine in its designated parking area out of traffic and on flat, solid ground.

If it is not possible to park the machine on flat ground, park the machine at a right angle to the slope.  Lower the cutter head to the floor.  Lower the conveyor and gathering head.  Turn off the pump motor by moving the “PUMP” switch to the “OFF” position. The pump motor should shutdown immediately.  Disconnect and lockout the trailing cable following all regulatory agency rules and regulations.

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Operation____________________________________________________ Tramming the miner NOTICE! The continuous miner has skid type steering: it is capable of turning within its own limits.

WARNING! Tramming requires cooling water to the tram motors. Failure to cool the motors will result in motor damage and premature failure.   Ensure that the pump motor is running (see Starting procedure in this chapter).   Ensure that the stabilizer shoe is away from the mine floor.

 Ensure adequate clearance at all times while tramming machine.

Be aware of people, equipment, and cables.  Push the “TRAM ENABLE” switch to activate tramming. The tram levers must be activated within three (3) seconds of tramming or the tram function will be disabled. The “TRAM ENABLE” switch will then have to be pushed again. When tramming is active, the tram enable, “TRAM ENBL”, LED should be lit.  Use the tram control levers to tram the miner. The farther the lever is moved, the faster tramming.

Tram direction  Push both tram levers forward to tram the miner straight forward or pull both levers back to tram the miner straight in reverse.  To make a right turn, press the left tram lever forward and pull the right lever back.  To make a left turn, press the right tram lever forward and pull the left lever back.

Tram speed control There are three (3) tramming speeds available: Sump: The lowest speed - sump is used while digging into the coal face. This speed is automatically engaged when the miner comes into contact with the coal face. It is also automatically selected when one tram is used alone or when the trams are operated in different directions.

_________________________________________________________________ 5.42 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

 Raise cutter boom to best possible position to allow clearance from roof, ribs, and floor and raise gathering head away from the mine floor. Adjust conveyor boom to best possible position to allow clearance from roof, walls, and floor.

___________________________________________________Operation Low tram: Default speed on start up. To switch from high tram to low tram, push the “LOW” tram button on the transmitter.

High tram: Selected by pressing the “HIGH” tram button on the transmitter.

The relationship between lever position and speed can be seen on the graphics display in the area labeled “TRACTION FT/MIN” (Fig. 82).

The tram control signals from the transmitter can also be seen on this screen.

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Fig. 81: Tram speed/lever relationship shown on graphics display

Traction lever to speed relationship

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

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

 Ensure that the pump motor is running (see Start procedure in this chapter) as the cutter motors will not run if the pump motor is not running.   Press the “ENABLE” button and move the “CUTTER” switch to the “START” position simultaneously. The cutter motors should start immediately.

To stop the cutter motors   Move the “CUTTER” switch to the “STOP” position. The cutter motors should stop immediately.

_________________________________________________________________ 5.44 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

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

___________________________________________________Operation

 Conveyor motors To start the conveyor motors in forward  Place conveyor boom in desired position.  Warn ALL CLEAR before starting the conveyor.

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

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 Ensure that the pump motor is running (see Start procedure in this chapter) as the conveyor motors will not start if the pump motor is not running.   Press the “ENABLE” button and move the “CONVEYOR” switch to the “START” position simultaneously. The conveyor motors should start immediately.

To stop the conveyor motors - conveyor forward  Move the “CONVEYOR” switch to the “STOP” position. The conveyor motors should shutdown immediately.

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

WARNING! Warn ALL CLEAR before starting the conveyor. Failure to do so may result in serious injury or death.  Ensure that the pump motor is running (see Starting procedure in this chapter). The conveyor motors will not start if the pump motor is not running.   Activate the following switches simultaneously: “ENABLE” switch, “CONVEYOR” switch in the “START” position, and the “CONVEYOR REVERSE” switch. If any of the switches are released, the conveyor will stop.

______________________________________________________________ A6474X326 VTSV/00 5.45

Operation____________________________________________________ Typical cutting sequence CAUTION! Always ensure operator safety while operating the machine. Be alert for hazardous conditions and take corrective action as necessary. Failure to be alert and correct hazardous situations may result in serious injury.

IMPORTANT! Care should be taken not to stall cutters or conveyor during cutting operations. Severe damage to motors and gear boxes could occur if cutters or conveyor are repeatedly stalled.

 Position conveyor so it doesn't hit the roof, walls, other equipment or any other obstacle. Never operate the conveyor in its fully limited position, right left, up, or down. If in the fully limited position and contacting any obstacle, damage could occur.  Start the gathering head and conveyor. Do not start machine in face or with excessive material in the gathering head.  Engage tram and adjust for speed and direction.  Start cutter head prior to contacting area to cut.  Raise cutter head to desired mining height.  Engage tram in the forward position.

IMPORTANT! Tram is limited in the forward direction while the cutters are running with the cutter head feedback circuit. As the cutter head begins to cut the material from the face, the sump speed will automatically slow the tram down to prevent over sumping the machine.  Continue to sump until the desired depth of cut is achieved. The depth of the sump will depend on the type of material being cut, the diameter of the cutter drum, and bit lacing.  Release tram levers.  Lower the rear stabilizer to the floor to provide stability if necessary.

Do not lower the shoe enough to raise the rear of the machine. If the shoe is lowered too far the machine will not sump into the face properly.

_________________________________________________________________ 5.46 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

 Ensure that the pump motor is running (see Start up procedure in this chapter).   Place gathering head in the float position.

___________________________________________________Operation  Shear down (lower cutter head). The shear down rate is controlled by a shear down relief valve to limit the hydraulic pressure being applied to the cylinders. This is an adjustable feature and can be easily changed as mining conditions change.   Note: if this step is required, it will be necessary to first raise the floor stabilizer. To maintain smooth, level floor conditions, it may be necessary to tram the machine backward approximately 914 mm (36 inches)., thus trimming ridges and smoothing the floor.

This may or may not be necessary each cut sequence depending on mine conditions.   Repeat this procedure to desired depth of cut.  Turning crosscuts is accomplished by making a series of partial cuts (sumps) until the machine can be turned to the desired angle.

Relocating the miner

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 Ensure rear stabilizer is raised from the floor.  Position cutter boom so as to prevent it from hitting roof, ribs, or floor.  Raise gathering head.  Lower conveyor boom down and position so it will not hit roof, ribs, floor or any other equipment or obstacles.  Ensure that trailing cable out of the path of travel.  Ensure there is enough clearance when relocating to avoid damage to machine and ensure operator safety.  Be alert to any people, obstacles, or other machines.  Know the position of fellow workers.  Engage tram in desired direction and speed.

______________________________________________________________ A6474X326 VTSV/00 5.47

Operation____________________________________________________ Mining operations It is presumed that the operator of this machine is experienced in continuous mining techniques. This section of the manual will present some basic rudiments of continuous miner mining operations, but should not be considered in any way as a complete how-to of mining techniques. It is recognized that each mine will have their own methods and techniques which work best for them.

One of the keys to good productivity with a continuous miner is to know the correct depth of sump which, when the cutting cycle is completed with shear-down, gives enough mined material to adequately fill one haulage vehicle.

The following discussion outlines the various steps of an efficient continuous miner mining cycle.

Preparation of the face for the next cut The first view in Fig. 27 shows a continuous miner approaching a freshly cut face. The operator has the cutter head lowered to prepare for making a 50 mm to 75 mm (2 inch to 3 inch) deep sump cut at the bottom of the face. This is done to make clearance for the gathering head blade when the miner is sumping at the top of the face. In this manner, the miner can make a deeper sump into the top of the face.

The next view in the figure shows the miner having made a 762 mm (30 inch) sump cut at the bottom of the face. The operator will now back the miner out of the cut and raise the cutter head to the mine roof.

In the final view, the operator has backed out of the bottom cut and raised the cutter head to the roof, positioning the miner for making a top sump.

_________________________________________________________________ 5.48 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

Another important factor is to do as much advance cutting as possible, while awaiting the haulage vehicle, to load up the gathering head pan.

When the vehicle arrives, the gathering head can then work at maximum efficiency to load out the accumulated mined material while the remainder of the cutting cycle is being completed.

___________________________________________________Operation Fig. 27: Preparation of the face for the next cut

© BUCYRUS AMERICA, INC.

Approaching a freshly cut face

762 mm (30”) sump cut at the bottom of the face

Positioning for top sump

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Operation____________________________________________________ The next face cut Having cut bottom clearance for the gathering head blade, the operator can now make a deep sump at the top such as a full drum diameter as shown in the first view of Fig. 28. He can commence his down-cut until his gathering head pan is full. Optimally, all this is being done while awaiting the next haulage car so that maximum loading rate can be achieved when the car arrives.

While loading the haulage car, the operator completes the down-cut to the mine bottom as shown in the second view of Fig. 28.

Depending on the depth of the top sump, a small cusp of material will be left behind the drum on the mine bottom. This cusp is removed by backing the miner out of the face a small distance while the cutter head is running.

Using the stabilizer shoe The stabilizer shoe is located under the rear deck of the main frame and beneath the conveyor. It is hinged at its front edge and is lowered by a hydraulic cylinder.

The stabilizer shoe serves two purposes: ■

To elevate the rear of the miner for maintenance work.

■

To provide stability, if necessary, during sumping.

■

To provide a higher down-cut force at the coal while shearing down during mining operations.

Fig. 29 illustrates the advantage of the stabilizer shoe in the down-cut application.

Fig. 28: The next face cut

Miner sumps in at top and begins down cut

Miner completes down cut with small cusp remaining

_________________________________________________________________ 5.50 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

The miner is now in a similar position as that shown in the first view of Fig. 27 and the operator can proceed with the next cutting cycle.

___________________________________________________Operation The miner is shown in the middle of its shearing down cycle in Fig. 29.

Without the stabilizer shoe deployed, the machine will tend to rock back on the rear of the crawlers. The distance from the miner’s center-ofgravity to the rear of the crawlers is noted as “Lever Arm w/o Stab Shoe”.

Conversely, with the stabilizer shoe deployed, the miner will now tend to rock back on the shoe, providing a longer lever arm. In the case of this miner, the lever arm with the stabilizer shoe down is more than twice the lever arm without the stabilizer shoe, thus doubling the down force available for shearing down. This increase in down-cut force will improve the speed and efficiency of the shear down portion of the cutting cycle.

© BUCYRUS AMERICA, INC.

Fig. 29: Effect of using stabilizer shoe on down cut force

Downcut Force Machine Weight

Lever Arm W/O Stab Shoe Lever Arm With Stab Shoe

Shearing up and down Most Continuous Miners have their center-of-gravity located forward of the center of the crawler footprint. This weight distribution makes the miner inherently more effective in shearing down rather than up because shearing down takes advantage of the miner’s weight to maximize down-cut force.

Shearing only downward requires the cutter head to be raised without cutting during each mining cycle, and a non-productive dead time is introduced in the mining cycle.

An alternative particularly useful in softer, easier cutting seams is to shear both up and down while advancing, thus maximizing the time spent actually cutting material in the total cycle. This sequence is illustrated in Fig. 30.

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Operation____________________________________________________ The first view in Fig. 30 shows the miner having sumped in at the top of the face. If the operator intends to shear down and up, the depth of sump should be no more than half a drum diameter; otherwise, a cusp will be left at the bottom or top after shearing, which will require trimming.

The second view shows the miner in the middle of the down cut.

Having completed the down cut, the third view shows the miner sumped in about half a drum diameter at the mine bottom.

Finally, the last view shows the miner in the middle of the up cut. The technique of successively shearing up and down is particularly productive when the miner is working in conjunction with a continuous haulage system.

© BUCYRUS AMERICA, INC.

Fig. 30: Shearing up and down

Miner shearing down

Miner sumping in at mine bottom

Miner shearing up

_________________________________________________________________ 5.52 Bucyrus – Model 30M4-NP Continuous Miner

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

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

Main Chassis

© BUCYRUS AMERICA, INC.

The main chassis of the machine (Fig. 31) is a heavy duty box type structure of high-strength steel that provides the following: ■

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

■

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

■

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

■

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

■

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

Fig. 31: Main Chassis Water valves

Conveyor raise cylinder clevis

Cutter head pivot

Gather head cylinder clevis

Oil tank

Rear bumper plate

Cutter head cylinder clevis

Crawler idler guides

Gathering head cylinder clevis Main controller case

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Mechanical assemblies ________________________________________ Gathering head assembly The gathering head assembly (Fig. 32) is attached to the main chassis at right and left hand pivot points. The assembly is articulated around these pivot points to adjust the gathering head for uneven floor conditions and when tramming the miner. The independent pivots allow removal of the gathering assembly without disturbing the cutting head or discharge conveyor.

■

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

■

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

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

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

Fig. 32: Gathering head assembly

Gear case and pot assembly (under cover)

Foot shaft

Lift cylinder

Motor (behind cover)

CLA

___________________________________________________________________ 5.54 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

The gathering head assembly includes:

_______________________________________ Mechanical assemblies Conveyor assembly The conveyor assembly (Fig. 33) is attached to the main chassis at right and left hand independent pivot points. The conveyor is articulated vertically around these pivot points to assist in optimum loading into a haulage vehicle. Independent pivots allow removal of the conveyor assembly without disturbing the cutting head or gathering head components.

© BUCYRUS AMERICA, INC.

The conveyor assembly includes the following: ■

An intermediate conveyor structure that includes the right and left hand pivot points for attaching to the main chassis, upper mounting clevises for the two conveyor raise cylinders, and a horizontal pivot arrangement at the rear for mounting the rear conveyor subassembly.

■

A rear conveyor subassembly that includes: –

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

–

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

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

Fig. 33: Conveyor assembly Intermediate conveyor section

Conveyor swing cylinder location Chassis pivot points

Rear conveyor section

Tail roller shaft

Conveyor pivot pin

Conveyor chain tensioning cylinder

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Mechanical assemblies ________________________________________ Traction drive system

■

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

■

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

■

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

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

–

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

–

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

The traction drive control system provides the operator with the capability to run either right or left hand crawler chain in forward or reverse independently for maximum maneuverability (for example, the miner may be pivoted about its central vertical axis). Both drive trains are equipped with fully enclosed, multiple disc, fail safe, hydraulic flushed parking brakes that are spring applied and hydraulically released.

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

Fig. 34: Traction drive system

Idler roller

Crawler track

Electric motor

Drive gear case

___________________________________________________________________ 5.56 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

The traction drive system (Fig. 34) provides the mobility for mining operations and for tramming from place to place. It includes:

_______________________________________ Mechanical assemblies Stabilizer shoe A stabilizer shoe (Fig. 35), located beneath and at the rear of the tractor frame, may be lowered to anchor the back end of the machine and provides a greater downward thrust of the cutter head for hard-cutting while preventing backward creep of the miner. The stabilizer shoe is raised and lowered hydraulically by a double acting cylinder that moves the shoe bracket up or down.

© BUCYRUS AMERICA, INC.

Fig. 35: Stabilizer shoe

Stabilizer shoe

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Mechanical assemblies ________________________________________ Cutting head assembly The cutting head assembly (Fig. 36) is attached to the main chassis at right and left hand independent pivot points around which the assembly is articulated for vertical ranging cutting. The independent pivots allow removal of the cutting head assembly without disturbing the gathering head or conveyor components.

■

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

■

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

■

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

The cutting head assembly is raised and lowered by two (2) heavy duty hydraulic cylinders mounted to the main chassis at their lower ends and to the main longitudinal structural members of the cutting head support frame at their upper ends. These cylinders enable the cutting head assembly over a predesigned range (see the general arrangement drawing for you machine for dimensions).

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

Fig. 36: Cutting head assembly

Cutter head pivot

Cutter head cylinder

Cutter head motor

Cutter head gear case

Cutter head drum assembly

___________________________________________________________________ 5.58 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

The cutting head assembly consists of the following:

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

Fig. 37 gives an overview of hydraulic cylinders located on the 30M4NP Continuous Miner. Fig. 38 shows the location of other hydraulic components.

This section gives general descriptions of the hydraulic components used on the miner along with typical schematics for hydraulic functions.

The schematics in this section are general; always refer to the hydraulic schematic in your Bucyrus America, Inc. parts manual supplied with your machine.

Operation considerations

© BUCYRUS AMERICA, INC.

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

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

■

maintaining a sufficient oil level in the tank;

■

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

■

changing filters and fluids at prescribed intervals.

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

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

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Hydraulic ____________________________________________________ Fig. 37: Cylinder locations

Gathering head raise cylinder

Conveyor raise cylinder

Cutter head raise cylinder

Gathering head raise cylinder

Gathering head cylinder

Cutter head raise cylinder © BUCYRUS AMERICA, INC.

Cutter head raise cylinder

Conveyor raise cylinder Conveyor raise cylinder

Stabilizer shoe cylinder

Stabilizer shoe cylinder Stabilizer shoe cylinder

Conveyor swing cylinder

Conveyor chain take-up cylinder

Conveyor swing cylinder Conveyor chain take-up cylinder Conveyor chain take-up cylinder

_________________________________________________________________ 5.60 Bucyrus – Model 30M4-NP Continuous Miner

___________________________________________________ Hydraulic Fig. 38: Hydraulic component location

© BUCYRUS AMERICA, INC.

Valve, check Y-strainer

Hand pump Valve, relief Filter, pressure Filter, return Filter, pilot

Pump

Breather

Pump, jet Valve, ball Accumulator

Oil level switch

Valve, brake control with manifold

Valve, pressure reducing Valve, control (6-unit)

Breather

Valve, brake control with manifold

Switch, pressure

Valve, flow control (2)

Hydraulic pressure switch Gauge, pressure - 160 psi Gauge, pressure - 600 psi (2) Gauge, pressure - 1000 psi Gauge, pressure - 4000 psi (5) Filter, bypassing pilot Valve assembly, solenoid manifold

_____________________________________________________________ A6474X326 VTSV/00 5.61

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

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

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

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

_________________________________________________________________ 5.62 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

Graphic symbols denote the type of function a component performs but do not necessarily sh ow i ts s hap e or c ons tr ucti on . T hes e schematic symbols are used to trace the system flow from the reservoir to the actual work being performed and then back to the reservoir.

The symbols used are shown individually with a functional description where needed. The study of these symbols helps in understanding the system and thereby aids in troubleshooting the system.

___________________________________________________ Hydraulic How to read a hydraulic schematic All valves are shown in the neutral position on the hydraulic schematics.

To follow oil flow through a system, visually imagine the valve spool shifting as shown in Fig. 40.

Fig. 40: Oil flow through a spool

MAIN PRESSURE

PILOT PRESSURE

SOLENOID A

SOLENOID B

© BUCYRUS AMERICA, INC.

PORT A IS ACTIVATED BY ENERGIZING SOLENOID A. THE SOLENOID WILL SHIFT THE 3-WAY PILOT VALVE WHICH WILL HYDRAULICALLY SHIFT THE MAIN SPOOL ALLOWING FLOW TO PORT A. SEE FIGURE 2

A (RAISE)

PORT B IS ACTIVATED BY ENERGIZING SOLENOID B. THE SOLENOID WILL SHIFT THE 3-WAY PILOT VALVE WHICH WILL HYDRAULICALLY SHIFT THE MAIN SPOOL ALLOWING FLOW TO PORT A. SEE FIGURE 3

B (LOWER)

TO TANK

FIGURE 1 STABLIZER RAISE/LOWER SECTION OF TYPICAL MAIN CONTROL VALVE. CURRENTLY SHOWN IN NEUTRAL POSITION.

MAIN PRESSURE

PILOT PRESSURE

MAIN PRESSURE

PILOT PRESSURE

SOLENOID A

SOLENOID B

TO TANK

A (RAISE)

A (RAISE)

B (LOWER)

B (LOWER)

TO TANK

FIGURE 2

FIGURE 3

PORT A ACTIVATED

PORT B ACTIVATED

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Hydraulic ____________________________________________________ accumulator

An accumulator (Fig. 41) is essentially a fluid pressure storage chamber in which the potential energy of a fluid under pressure can be stored against a compressible force of a gas to do useful work.

The stored fluid is readily available to perform a given task when called upon by the requirements of the system in which it is used.

breather

A breather (Fig. 41) permits air to move in and out of the oil tank reservoir to maintain atmospheric pressure.

cylinders

Cylinders (Fig. 41) are bored and honed steel tubes enclosing a piston connected to a rod that extends out the end of the cylinder.

Working surfaces are ground and finely finished, with seals and gaskets incorporated to prevent leakage. Fig. 37 illustrates the location of the hydraulic cylinders on the miner.

Fig. 41: Accumulator and cylinder hydraulic symbols

Accumulator

Cylinder, single acting with external spring

Breather

Cylinder, single acting

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

Cylinder, double acting

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

Cylinder, single acting with dry pocket

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

_________________________________________________________________ 5.64 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

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

___________________________________________________ Hydraulic filters

Filters and strainers (Fig. 42) are designed to protect a hydraulic oil system from harmful levels of particulate contamination. High levels of contaminants accelerate wear of components, cause improper functioning, and add to system sluggishness. Other problems such as seizure of parts, higher temperatures due to increased fluid friction, leakage, and loss of control may occur. Contamination also contributes to oxidation and chemical breakdown of the fluid.

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

© BUCYRUS AMERICA, INC.

When a non by-passing filter element starts clogging with trapped particles, the radio system/solenoid functions will slow down, indicating it is time to change the element. For filter element maintenance and changing schedules, see the Maintenance section in this chapter.

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

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

Fig. 42: Filter hydraulic symbols

Filter, bypassing

Filter, non-bypassing

Filter, non-bypassing with CFX30 valve

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Hydraulic ____________________________________________________

orifice

A flow meter (Fig. 43) is a visual device which indicates the volume of fluid passing through it per unit of time.

An orifice (Fig. 43) is a device that restricts flow.

pressure/return manifold

A pressure manifold (Fig. 43) has one inlet port and many outlet ports to supply flow to many circuits. A return manifold has many inlet ports and only one outlet port for flow to return to tank. Note: You can have the same part number for a pressure or return manifold.

pressure gauge

A pressure gauge (Fig. 43) is a visual device used to indicate the pressure in a hydraulic or water circuit.

pump

The purpose of a pump (Fig. 43) is to produce flow; it does not pump pressure. Pressure is caused by a resistance to flow. All system components have some resistance to flow. Hydraulic cylinders, which power machine functions, are the major components causing this resistance.

Each circuit is protected by a relief valve so that the pressure in the system will not exceed the rating of its components. To ensure that everything works correctly and in proper sequence, relief valve pressure settings closely match the load requirements.

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

quick disconnect female/male coupling

A quick disconnect (Fig. 43) is a coupling which can quickly join or separate lines.

Fig. 43: Hydraulic symbols

Flow meter

Orifice

Pressure gauge

Pressure/return manifold

Pump, hydraulic three section

Pump, jet

Quick disconnect male half coupling

Quick disconnect female half coupling

_________________________________________________________________ 5.66 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

flow meter

___________________________________________________ Hydraulic Valves The hydraulic symbols for the different types of valves are given in Fig. 44. ball valve check valve

© BUCYRUS AMERICA, INC.

directional control valve

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

A valve that allows fluid flow in one direction only.

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

flow control valve

A valve with a primary function of controlling flow rate.

flow control valve with internal check

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

load holding valve (load lock valve) (overcenter valve)

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

A load holding valve locks a load in any position without allowing drift. It may provide static overload relief and thermal expansion relief with open-center control valves, as are on the cutter head raise circuit, or be combined with an atmospheric relief, as on the conveyor raise circuit of the miner. Cartridge style valves allow installation directly into the cylinder.

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

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

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

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

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

There are no adjustments required on the load holding valves.

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

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

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

relief valve

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

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

Some relief valves are atmospheric. These valves are used for overpressure protection only. Should the preset pressure be reached, they discharge oil into the air. An example of this is on the conveyor raise circuit where the pressure is set to relieve at 3,000 psi, which is well above expected operating pressures.

_________________________________________________________________ 5.68 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

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

___________________________________________________ Hydraulic There are a number of relief valves in the hydraulic system that are set for individual sub-circuit protection (conveyor elevation, gathering head, etc.). Each pump section also has a main relief valve for protection against over-pressurization. The main hydraulic pump section is typically set at 3,000 psi. The pilot section is typically set at 600 psi. If your system has 3 pump sections, consult your system schematic (in your Bucyrus Parts Manual) for the auxiliary pump section relief valve setting.

© BUCYRUS AMERICA, INC.

For relief valve adjustment procedures, see the Adjustment section of this chapter. shuttle valve

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

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

Each section of the main control valve is piloted by a solenoid valve that is mounted adjacent to that particular section. Reduced pilot pressure is supplied to these 3-way valves to control the main spool inside the larger working section of the directional control valve. Energizing the solenoid opens the pilot valve to allow the pilot pressure to move the spool in the proper direction to achieve the desired function of the directional control valve.

solenoid valve (with radio option)

These 3-way valves are used to supply reduced pilot pressure that controls a number of functions on the machine. These functions include the control of hydraulically piloted water valves for the Dust/Cooling, Fire, and Scrubber spray system circuits.

_____________________________________________________________ A6474X326 VTSV/00 5.69

Hydraulic ____________________________________________________ Fig. 44: Valve hydraulic symbols

Check valve

Flow control valve

Flow control valve with internal check

Pressure reducing/ relieving valve Multipurpose valve

Shuttle valve

Relief valve

_________________________________________________________________ 5.70 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

Ball valve

___________________________________________________ Hydraulic Abbreviations and terms Cavitation: Briefly, cavitation means that air bubbles are forming in the liquid that is being pumped. These bubbles are usually formed in the suction line of a pump when an obstruction causes the suction pressure (which is a vacuum) to go significantly below atmospheric pressure. The actuall pressure at which these bubbles form is dependent on the rank fluid level and the integrity of the seal on the suction line components. When these air bubbles are compressed in the pump gears, they can cause surface pitting, corrosion, and/or erosion. These bubbles can also coalesce to create erratic operation or water hammer problems.

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

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

© BUCYRUS AMERICA, INC.

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

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

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

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

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

PSI (psi): Pounds per square inch (unit of pressure) Open center circuit: A circuit in which flow through the system and back to the oil tank reservoir is open in neutral. Example: the main flow-primary pressure circuit.

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

_____________________________________________________________ A6474X326 VTSV/00 5.71

Hydraulic ____________________________________________________ Hydraulic pump assembly circuit Hydraulic power for all of the hydraulically actuated functions originates with the pump assembly (Fig. 45). This pump utilizes three working sections designated as follows: A1 (primary pressure circuit), A2 (high speed cutter head raise circuit), and A3 (pilot pressure circuit). Oil is supplied from the oil reservoir through a suction line and a locking ball valve (optional) to the pump inlet ports.

Pump A1 - Primary pressure circuit Hydraulic pump gear section A1 powers the primary pressure circuit.

The A1 gear section is rated at 31.4 gpm at a pressure of 2,800 psi (143 Lpm at 193 bar). This open-center circuit supplies oil flow to the Main Control Valve (MCV). The MCV operates the conveyor raise, conveyor swing, stabilizer (stab) shoe, gathering head cylinders, cutter head raise cylinders. From the pump, oil enters a 10 micron bypassing pressure filter and continues to the MCV, whose main relief valve is set at 3,046 psi (210 bar).

For a more detailed description of this circuit, please refer to the individual circuit descriptions later in this section.

_________________________________________________________________ 5.72 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

Fig. 45: Hydraulic pump circuit

___________________________________________________ Hydraulic Pump A2 - High speed cutter head raise circuit Hydraulic pump gear section A2 powers the high speed cutter head raise circuit. The A2 gear section is rated at 23.7 gpm at a pressure of 2,000 psi (108 Lpm at 138 bar)). This open-center circuit supplies oil flow to the manually controlled, pilot-operated cutter head directional control valve. From the pump, oil continues to the high speed cutter head raise section of the main control valve, whose main relief valve is set a 2,046 psi (210 bar).

For a more detailed description of this circuit, please refer to the individual circuit descriptions later in this section.

Pump A3 - Pilot pressure circuit

© BUCYRUS AMERICA, INC.

Hydraulic pump gear section A3 powers the pilot pressure circuit. The A3 gear section is rated at 8.1 gpm at a pressure of 600 psi (371 Lpm at 41 bar)). Pilot pressure is maintained by a relief valve. This closed center circuit supplies oil to all pilot functions on the machine including: ■

Hydraulic conveyor chain take-up section of multi-purpose valve

■

Pilot supply manifold supplying: –

Dust/fire/scrubber solenoid manifold

–

Brake control valve

–

Gathering head raise/hold/float-lower circuit on multi-purpose valve

From the pump, oil enters a 10 micron by-passing pressure filter and splits to supply the hydraulic conveyor chain take-up circuit and a 3 micron non by-passing pressure filter. The oil continues from the 3 micron non-bypassing filter to supply the pilot supply manifold.

For a more detailed description of these circuits, please refer to the individual circuit descriptions later in this section.

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Hydraulic ____________________________________________________ Tank Ports All three pump circuits described above pass through a 10 micron bypassing return filter before returning to tank (hydraulic reservoir).

There are two main connections to the tank; one on the left hand side of the machine (T-14) and one on the right hand side of the machine(T7). The schematic shown in Fig. 46 shows the tank connections for the tank manifolds. Each tank manifold is equipped with a breather. The left hand side tank tower is equipped with a float switch to detect low fluid level in the reservoir.

The schematic shown in Fig. 46 is typical for tank port connections.

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

© BUCYRUS AMERICA, INC.

Fig. 46: Tank port connections

_________________________________________________________________ 5.74 Bucyrus – Model 30M4-NP Continuous Miner

___________________________________________________ Hydraulic Main Control Valve (MCV) The Main Control Valve (MCV) consists of a series of directional control valves assembled in a row. This row of valves is commonly referred to as a valve bank. The MCV directs fluid flow to perform a specific function of work that transforms hydraulic energy into mechanical energy.

Control may be initiated manually or electrically (through the solenoid pilot valve).

The MCV (Fig. 39) is located on the right side of the machine.

© BUCYRUS AMERICA, INC.

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

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

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

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

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

■

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

■

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

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Hydraulic ____________________________________________________ Fig. 39: Main control valve GATHERING HEAD

CONVEYOR SWING

CONVEYOR RAISE

STABILIZER

CUTTER HEAD 2

PORT B RELIEF ADJUST PILOT PRESSURE PRV

PORT A RELIEF ADJUST (CUTTER HEAD ONLY)

MAIN RELIEF ADJUST

PRESSURE AT PORT A/A1

59.75

31°

31° PORT B RELIEF ADJUST (CUTTER HEAD ONLY)

CUTTER HEAD 2

PRESSURE AT PORT B/B1

PORT B RELIEF ADJUST

PILOT PRESSURE PRV MAIN RELIEF ADJUST

59.75

PRESSURE AT PORT A/A1

59.75

31°

31°

PRESSURE AT PORT B/B1

_________________________________________________________________ 5.76 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

59.75

___________________________________________________ Hydraulic Main control valve circuit The main control valve circuit is powered by hydraulic pump gear section A1. The A1 gear section is rated at 143 Lpm at 193 bar (31.4 gpm at 2,800 psi). This circuit supplies oil flow to the main control valve. The main control valve operates the gathering head, conveyor raise and swing, stabilizer, and cutter head cylinders.

From the pump, oil enters a 10 micron by-passing pressure filter and continues to the main control valve, whose relief is set at 210 bar (3,045 psi).

The auxiliary pressure circuit is powered by hydraulic pump gear section A2. The A2 gear section is rated at 108 Lpm at 138 bar (23.7 gpm at 2,000 psi). This circuit supplies oil to the high speed cutter head raise section of the main control valve. The relief on this valve section is set at 210 bar (3,045 psi).

© BUCYRUS AMERICA, INC.

Oil from both the primary and auxiliary circuits exits the main control valve and passes through a 10 micron by-passing return filter before entering the oil reservoir.

The schematic shown in Fig. 40 is typical. Always refer to the schematic in the Bucyrus parts book for your machine.

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Hydraulic ____________________________________________________

Z

Z

T T

M

M

LS LS R1 P1

P

R

_________________________________________________________________ 5.78 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

Fig. 40: Main control valve circuit

___________________________________________________ Hydraulic Cutter head raise/lower circuit DANGER! The area under and around the raised cutter head is dangerous.

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

© BUCYRUS AMERICA, INC.

Oil is supplied by hydraulic pump section A1 through a 10-micron bypassing pressure filter to the cutter head working section of the main control valve. By manual or remote solenoid control, the valve spool allows oil to enter the cutter head cylinder circuit. The cutter head cylinder is a double acting cylinder with a load holding cartridge. There are two (2) cutter head cylinders, one on each side of the machine.

To manually raise the cutter head (extend cylinders) raise the valve’s handle. Remote operation is achieved by energizing the cutter head raise solenoid (CHU). Oil goes to port “P2” and continues to the extend port of the cylinders, free flowing through the check valve of the load holding cartridge, to extend the cylinders. The cutter head raise circuit is protected by a port relief that is set at 2,800 psi (207 bar).

The anti-chatter/maintenance section of the multipurpose valve has three primary functions: ■

It provides back pressure against the shear cylinder pistons when shearing down to prevent the machine from climbing the face (raising the machine off of the ground).

■

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

■

It allows for bypassing of the counterbalance valve to eliminate the back pressure against the shear cylinder pistons. This provides the maximum pressure differential between the two sides of the shear cylinders which allows the machine to be raised off the ground (jack-knifed).

Note:

To jack-knife the miner, the stabilizer shoe is first lowered. The cutter head is then lowered with the maintenance valve opened in the anti-chatter/maintenance section of the multipurpose valve. At this point, the machine can be inspected, adjustments can be made to the crawler tracks, and the tram voltage can be adjusted. See stabilizer shoe circuit in this section.

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

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

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

Oil is supplied to the high speed cutter head raise section of the main control valve by hydraulic pump section A2. By manual or remote solenoid control, the valve spool directs oil to the high speed cutter head raise circuit. This circuit is protected by an inlet relief set at 3,046 psi (210 bar).

To manually select the high speed cutter head raise, pull the valve’s handle. Remote operation is achieved by energizing the high speed raise solenoid. Oil is directed through a check valve to the high speed cutter head raise section of the main control valve.

The schematic shown in Fig. 48 is a typical cutter head circuit with high speed raise. Always refer to the schematic in the Bucyrus parts book for your machine.

_________________________________________________________________ 5.80 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

High speed cutter head raise

___________________________________________________ Hydraulic

© BUCYRUS AMERICA, INC.

Fig. 48: Cutter head circuit with high speed raise

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Hydraulic ____________________________________________________ Conveyor raise/lower circuit Oil is supplied by hydraulic pump section A1 through a 10-micron bypassing pressure filter to the conveyor raise/lower working section of the main valve control. By manual or remote solenoid control, the valve spool allows oil to enter the conveyor raise/lower cylinder circuit. The conveyor raise/lower cylinder is a single acting cylinder with a relief valve and a pilot operated check valve on the extend port. There are two (2) conveyor raise/lower cylinders.

To manually lower the conveyor (retract the cylinders), lower the valve’s handle. Remote operation is achieved by energizing the conveyor lower (CD) solenoid. Oil is directed to the pilot port on the pilot operated check valve on the cylinders. This “pilots” the check valve open and allows oil to exit the cylinders through the main control valve and return to tank through a 10-micron bypassing return filter to tank. The conveyor lower circuit is protected by a port relief that is set at 97 bar (1,400 psi).

The schematic shown in Fig. 49 is a typical conveyor raise/lower circuit schematic. Always refer to the schematic in the Bucyrus parts book for your machine.

_________________________________________________________________ 5.82 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

To manually raise the conveyor (extend the cylinders), raise the valve’s handle. Remote operation is achieved by energizing the conveyor raise (CU) solenoid. Oil free flows through pilot operated check valves to the extend port of the cylinders. The conveyor raise circuit is protected by a port relief that is set at 124 bar (1800 psi).

___________________________________________________ Hydraulic

© BUCYRUS AMERICA, INC.

Fig. 49: Conveyor raise/lower

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Hydraulic ____________________________________________________ Conveyor swing circuit Oil is supplied by hydraulic pump section A1 through a 10-micron bypassing pressure filter to the conveyor swing working section on the main control valve. By manual or remote solenoid control, the spool allows oil to enter the swing circuit. The conveyor swing cylinder is a double-acting cylinder. The range on the cylinder will allow the conveyor tail to move 45 degrees off the centerline of the machine in both directions. The descriptions below for left and right movement are based on an individual standing at the rear of the machine looking forward to the cutter head.

To manually move the conveyor to the left (retract the cylinder), lower the valve’s handle. Remote operation is achieved by energizing the conveyor swing left (CSL) solenoid. Oil free flows to the retract port of the cylinder. The conveyor swing left circuit is protected by a port relief that is set at 125 bar (1,800 psi).

When extending or retracting, the oil from the opposite port exits the cylinders and passes through the main control valve and returns to tank through a 10-micron bypassing return filter.

The schematic shown in Fig. 50 is a typical conveyor swing cylinder circuit. Always refer to the schematic in the Bucyrus parts book for your machine.

_________________________________________________________________ 5.84 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

To manually move the conveyor to the right (extend the cylinder), raise the valve’s handle. Remote operation is achieved by energizing the conveyor swing right (CSR) solenoid. Oil free flows to the extend port of the cylinder. The conveyor swing right circuit is protected by a port relief that is set at 125 bar (1,800 psi).

___________________________________________________ Hydraulic

© BUCYRUS AMERICA, INC.

Fig. 50: Conveyor swing cylinder circuit

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Hydraulic ____________________________________________________ Stabilizer shoe cylinders circuit Oil is supplied by hydraulic pump section A1 through a 10-micron bypassing pressure filter to the stabilizer shoe working section of the main control valve. By manual or remote solenoid control, the valve spool allows oil to enter the stabilizer shoe circuit. The stabilizer shoe cylinder is a double-acting cylinder. There are two stabilizer shoe cylinders on the machine.

To manually lower the stabilizer shoe (extend the cylinders), lower the valve’s handle. Remote operation is achieved energizing the stabilizer lower solenoid (SSD). Oil flows to the extend port of the cylinders.

The stabilizer lower circuit is protected by a port relief that is set at 2,800 psi (193 bar). When extending or retracting, the oil from the opposite port exits the cylinders and passes through the main control valve and returns to tank through a 10-micron bypassing return filter.

Note:

To jack-knife the miner, the stabilizer shoe is first lowered. The cutter head is then lowered with the maintenance valve opened in the anti-chatter/maintenance valve section of the Multipurpose valve. At this point, the machine can be inspected, adjustments can be made to the crawler tracks, and the tram voltage can be adjusted.

See cutter head circuit description in this section.

The schematic shown in Fig. 51 is a typical stabilizer shoe cylinders circuit. Always refer to the schematic in the Bucyrus parts book for your machine.

_________________________________________________________________ 5.86 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

To manually raise the stabilizer shoe (retract the cylinder), raise the valve’s handle. Remote operation is achieved by energizing the stabilizer raise (SSU) solenoid. Oil flows to the retract port of the cylinders. The stabilizer raise circuit is protected by a port relief that is set at 1,400 psi (97 bar).

___________________________________________________ Hydraulic

© BUCYRUS AMERICA, INC.

Fig. 51: Stabilizer shoe cylinders circuit

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Hydraulic ____________________________________________________ Gathering head raise/hold/float-lower circuit Oil is supplied by hydraulic pump A1 through a 10 micron by-passing pressure filter to the gathering head working section of the main control valve. By manual or remote solenoid control, the valve spool allows oil to enter the gathering head raise/hold/float-lower circuit. The gathering head cylinder is a single acting cylinder. There are two (2) gathering head cylinders, one on each side of the machine.

At any time while raising the gathering head, the operator can stop the gathering head pan by centering the handle on the valve (or deenergizing the solenoid) and the pan will hold in position. The gathering head raise circuit is protected by a port relief that is set at 1,800 psi (124 bar) when in the raise and hold position.

To put the gathering head pan in the float-lower mode, lower the valve’s handle. Remote operation is achieved by energizing the gathering head down (GHD) solenoid. This vents the port labeled “V” on the gathering head float section of the Multipurpose valve to tank and allows control of the gathering head lower via the valves in the block. Counterbalance valve VR is set to relieve at 1,200 psi (83 bar) to allow the gathering head to drift down at a controlled rate of speed. This valve is adjustable and the rate of retract speed for the cylinders can be increased by decreasing the pressure setting of the valve.

Conversely, the retract speed for the cylinders can be decreased by increasing the pressure setting of the valve. When in the float-lower condition, the cylinders carry some of the gathering head pan weight to prevent the gathering head leading edge from digging into the soft bottom of the mine. This condition also moves the machine’s center of gravity forward when mining.

The relief valve in the gathering head float section of the Multipurpose valve is set to relieve at 1,800 psi (124 bar). This valve is marked with a stamped “CR” on the manifold block. This fixed setting will relieve pressure directly to the tank in the event of a forced movement of the gathering head. This can occur if the cutter head is lowered onto a raised gathering head pan or by some other external force. The “CR” valve will relieve pressure in the circuit regardless of the position of the control valve (raise, hold or float-lower).

The pilot pressure supply for the gathering head float comes from hydraulic pump A3 through a 3 micron non by-passing filter, to the “pilot” port of the gathering head float section of the Multipurpose valve.

The pilot pump provides make-up oil for the gathering head cylinders when the pan goes over uneven terrain and raises quickly and extends the gathering head cylinders at a rapid rate.

_________________________________________________________________ 5.88 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

To manually raise the gathering head pan (extend the cylinder), raise the valve’s handle. Remote operation is achieved by energizing the gathering head up solenoid (GHU). Oil free flows through the check valve in counterbalance valve in the gathering head float section of the Multipurpose valve and is directed to both cylinder extend ports. The counterbalance valve is marked with a stamped “VR” on the Manifold block.

___________________________________________________ Hydraulic This temporary condition can create high demand for pilot oil. An orifice is located in the pilot supply circuit of the Multipurpose valve to prevent the pilot demand from reducing the pilot pressure to the point where the main control valve may not have sufficient pilot pressure to shift when the solenoids are energized. If this demand were to be too great, it is possible to experience a momentary loss of radio control of the machine. If the counterbalance valve (“VR”) is set to a pressure below the pilot pressure setting, it will create a path for the pilot pressure to return to tank and may result in loss of pilot pressure.

© BUCYRUS AMERICA, INC.

This orifice is protected from contamination by an upstream filter. A downstream check valve keeps system pressure from entering the pilot pressure lines. An adjustable needle valve allows for the bleeding off of pressure for maintenance. This needle valve is to remain closed except for performing maintenance. A gauge port is incorporated into the valve block for maintenance and troubleshooting.

Each single acting gathering head raise cylinder is equipped with a dry pocket to provide additional stroke beyond its normal hydraulic stroke.

This feature provides protection in the event that the gathering head is trammed into an obstruction forcing it to raise beyond its hydraulic stroke limit.

The schematic shown in Fig. 52 is a typical gathering head circuit. Always refer to the schematic in the Bucyrus parts book for your machine.

_____________________________________________________________ A6474X326 VTSV/00 5.89

Hydraulic ____________________________________________________

© BUCYRUS AMERICA, INC.

Fig. 52: Gathering head circuit

_________________________________________________________________ 5.90 Bucyrus – Model 30M4-NP Continuous Miner

___________________________________________________ Hydraulic Pilot pressure circuit descriptions

© BUCYRUS AMERICA, INC.

Pilot pressure is supplied by hydraulic pump section A3 as described in this section. The following functions are controlled using pilot pressure: ■

hydraulic tension conveyor chain take-up

■

gathering head float circuit, and

■

all solenoid valves, which control –

the scrubber

–

dust sprays

–

fires sprays

–

fall main control valve functions

–

parking brakes

The pilot gear section A3 is rated at 8.1 gpm at 600 psi (37L at 41 bar).

From the pump section A3, oil enters a 10-micron by-passing pressure filter and circuit relief valve set at 600 psi (41 bar). Oil then flows to the hydraulic tension conveyor chain take-up and a 3-micron non bypassing pressure filter. The oil continues to the pilot pressure manifold where the oil separates to the accumulator, all solenoid valves, and the gathering head float circuit.

The schematic shown in Fig. 53 is a typical pilot pressure circuit. Always refer to the schematic in the Bucyrus parts book for your machine.

Fig. 53: Pilot pressure circuit

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Hydraulic ____________________________________________________ Hydraulic conveyor chain take-up section of multipurpose valve Oil flows from the 10 micron by-passing pilot pressure filter to the “In” port of the hydraulic conveyor chain take-up section of the Multipurpose valve and “Out” to the two conveyor chain take-up cylinders. The conveyor chain take-up section consists of a check valve to hold pressure in the circuit and a pressure reducing/ relieving cartridge maintain a constant pressure of 200 psi in the circuit. The reducing/ relieving valve reduces pilot pressure to 200 psi and relieves any pressure spikes caused by forces acting against the conveyor of the miner.

An adjustable needle valve allows for the bleeding off of pressure for maintenance. This needle valve is to remain closed except for performing maintenance. A gauge port is incorporated into the valve block for maintenance and troubleshooting.

The schematic shown in Fig. 54 is a typical conveyor chain take up circuit. Always refer to the schematic in the Bucyrus parts book for your machine.

Fig. 54: Conveyor chain take-up circuit

_________________________________________________________________ 5.92 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

DANGER! Never run the conveyor without the needle valve closed. Injury or death may occur.

___________________________________________________ Hydraulic Brake control valve Pilot oil is supplied to the pressure port of the brake control valve manifold. The brake control valve is a 3 way, 2 position solenoid operated, spring return valve that hydraulically pilots a higher flow 3 way 2 position valve. When the solenoid is de-energized, the brake control pressure is vented to tank which engages the brake. Energizing the solenoid applies pilot pressure to the pistons inside the brake which disengages (releases) the brake. The brake pressure required to fully release the brake is 34 bar (510 psi). A pressure switch is connected to the “GA” port of the brake control valve to monitor the brake pressure. Refer to the electrical section for control details of the pressure switch.

The schematic shown in Fig. 55 is a typical brake circuit. Always refer to the schematic in the Bucyrus parts book for your machine.

© BUCYRUS AMERICA, INC.

Fig. 55: Brake circuit

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Hydraulic ____________________________________________________ Dust-scrubber-fire sprays hydraulic circuit This circuit is used to activate the dust sprays, the scrubber sprays, and the fire sprays. Pilot oil is supplied to the pressure port of the solenoid manifold. The manifold is connected to an accumulator that is pre-charged with nitrogen to 400 psi. The difference between the pilot circuit pressure of 600 psi and the accumulator pressure of 400 psi provides a volume of oil to allow for remote operation of the fire suppression when the pump is not operational. There is a gauge for monitoring the accumulator pressure, which should closely track the pilot pressure.

If the accumulator pressure falls below 450 psi, shutdown the machine and call for maintenance.

When the dust or scrubber spray solenoid cell is de-energized, the hydraulic pilot valve shifts back to its neutral position, which vents the hydraulic pilot pressure on the water control valve. This venting allows the water control valves to return to their normally closed positions.

The spool in the fire spray water valve has a detent spool which keeps the water valve open if the battery backup dies. This water valve must be manually rest to reset the deluge fire spray circuit.

The schematic shown in Fig. 56 is a typical dust-scrubber-fire sprays circuit. Always refer to the schematic in the Bucyrus parts book for your machine.

_________________________________________________________________ 5.94 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

The three solenoids in the manifold operate in the same manner.

When the solenoid coil is energized, it shifts the spool, allowing oil to travel to a 2 way/2 position water valve. The spool in the water valve is shifted, allowing water to pass through it.

___________________________________________________ Hydraulic

© BUCYRUS AMERICA, INC.

Fig. 56: Dust-scrubber-fire sprays hydraulic circuit

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© BUCYRUS AMERICA, INC.

Hydraulic ____________________________________________________

_________________________________________________________________ 5.96 Bucyrus – Model 30M4-NP Continuous Miner

______________________________________________________ Water Water system overview A water supply to the miner is required for the following purposes: ■

cooling water for motors, control case, and transformer

■

water for dust suppression and air scrubber

■

water for fire suppression

■

water for washdown hoses

© BUCYRUS AMERICA, INC.

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

minimum flow rate of 20 gpm for cooling

■

total flow rate - based upon customer dust plan

■

minimum pressure of 250 psi (dynamic)

■

maximum pressure of 500 psi

Bucyrus offers straight, left hand, right hand, or bidirectional cutter head spray manifolds.

The water circuits described in this section are for a typical Bucyrus 30M4 miner. The circuit for your machine may vary depending on your dust pan and unique requirements. Always refer to the schematic in the Bucyrus parts book for your machine.

______________________________________________________________ A6474X326 VTSV/00 5.97

Water _______________________________________________________ Fig. 57: Water component locations

Manifold, pressure 4-unit

Manifold, 10-unit spray (5L-5R) Sprays (5)

Manifold, 10-unit spray (5L-5R) Sprays (5)

Manifold, pressure 4-unit

Manifold, 10-unit spray (5L-5R) Sprays (5)

Manifold, RH cutter side spray 7unit Sprays (7)

Manifold, RH cutter side spray 7-unit Sprays (7)

Manifold, CH bottom spray 5 units Sprays (5)

Valve, atmospheric relief Manifold, CH bottom spray 5 units Sprays (5)

Manifold, GH sprays 5-unit Sprays (3) Manifold, GH sprays 5-unit Sprays (3)

Manifold, throat sprays 6-unit Sprays (6)

Gauge, pressure 0-160 psi (2) Gauge, pressure 0-400 psi Manifold, scrubber back flush sprays Manifold, scrubber sprays Nozzle, spray (6) Pump, jet Valve, flow control 3/4 NPT Valve, ball 3/4 NPT Manifold, water Valve, flow control Switch, flow Switch, pressure Valve, ball 1” NPT Valve, bal 3/4 NPT (2) Valve, ball 1/2 NPT (3) Valve, pressure regulator (3)

Valve, pilot operated (2) Manifold, pressure (7 unit)

Strainer, diffuser

Manifold, washdown Valve, ball 1/2 NPT Valve, relief Valve, ball 1-1/4 NPT Filter, water Gauge, pressure 0-400 psi Strainer, reverse flushing

_________________________________________________________________ 5.98 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

Valve, atmospheric relief

______________________________________________________ Water Water supply circuit Mine water is supplied to the miner from a connection located on the right side of the miner (typical). The water supply to the miner is controlled through a two position, manually operated ball valve. Immediately after is a connection for an optional washdown hose for the right hand side of the miner. The mine water then passes through a strainer that is equipped with an automatic backflush feature and then through a 150 micron filter.

From the filter, the water is directed to a water distribution manifold.

The supply to the manifold is monitored by a flow switch and a pressure switch. These switches are inputs to the electrical system that are interlocks for the cutter motors to start and/or continue running. See the Electrical section of this chapter for more information on the switches.

© BUCYRUS AMERICA, INC.

From the water distribution manifold, water supplies the left hand washdown hose, the scrubber sprays, fire sprays, throat sprays, dust sprays, and manual scrubber sprays, and to another water distribution block.

Gauges measure the pressure of the mine water and the water pressure as it exits the water filter. For component locations, see Fig. 57.

The water supply circuit described above and shown in Fig. 58 is typical. The circuit for your machine may vary depending on your dust plan and unique requirements. Always refer to the schematic in the Bucyrus parts book for your machine.

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Water _______________________________________________________

© BUCYRUS AMERICA, INC.

Fig. 58: Water supply circuit

_________________________________________________________________ 5.100 Bucyrus – Model 30M4-NP Continuous Miner

______________________________________________________ Water Scrubber spray circuit The scrubber circuit (Fig. 59) uses water supplied by the water distribution manifold and is operated by remote via solenoid control or manually. This circuit includes the scrubber sprays, strainer backflush, and sump washout functions.

Reference Figures 59 and 60.

When the scrubber spray solenoid is energized, it shifts a spool, allowing hydraulic oil to flow tot the hydraulic pilot operated, normally closed water valve. The hydraulic oil shifts the spool, allowing water to pass through it to the scrubber sprays. To manually operate the scrubber sprays, open the 1/2 inch ball valve, “MANUAL SCRUBBER WATER”.

© BUCYRUS AMERICA, INC.

During normal operations, valve “A” is open. After passing through a strainer, water exits the scrubber and flows through valve “A” to be dumped into the sump.

To backflush the scrubber strainer, valves “A” and “C” (“SUMP WASHOUT VALVE”) are closed and valve “B” (“BACKFLUSH STRAINER VALVE) is opened. When valve “A” is closed water exiting the scrubber is directed through a pressure regulator, where pressure is reduced to 75 psi, and then tees in with the backflush scrubber water flowing through valve “B”. The water then flows through a second pressure regulator, where pressure is reduced to 50 psi, through a normally open needle valve, used to adjust water flow as necessary, to the backflush scrubber sprays.

To wash out the sump, valves “A” and “B” must be closed and valve “C” is open. Water flows into the scrubber sump and out via the strainer.

Water then is directed through the 75 psi pressure regulator, through a needle valve, used to adjust water flow as necessary, and to the cleaning sprays.

The scrubber spray circuit described above and shown in Fig. 59 is typical. The circuit for your machine may vary depending on your dust plan and unique requirements. Always refer to the schematic in the Bucyrus parts book for your machine.

______________________________________________________________ A6474X326 VTSV/00 5.101

Water _______________________________________________________

© BUCYRUS AMERICA, INC.

Fig. 59: Scrubber spray circuit

_________________________________________________________________ 5.102 Bucyrus – Model 30M4-NP Continuous Miner

______________________________________________________ Water Fig. 60: Water control valves “MANUAL SCRUBBER WATER”

“WASHDOWN HOSE”

“MANUAL SCRUBBER BACKFLUSH SPRAYS”

“FIRE SPRAY”

“MANUAL COOLING/ DUST WATER”

“BACKFLUSH STRAINER VALVE B”

“COOLING/ DUSTSCRUBBER MANIFOLD WATER”

“SUMP WASHOUT VALVE C”

© BUCYRUS AMERICA, INC.

“EMERGENCY STOP”

______________________________________________________________ A6474X326 VTSV/00 5.103

Water _______________________________________________________ Fire spray circuit During normal mining operations, the fire spray circuit (Fig. 61) is actuated by remote solenoid control. When the fire spray solenoid “FS” is energized, it shifts a spool, allowing hydraulic oil to flow to the hydraulic pilot operated, normally closed water valve. The hydraulic oil shifts the spool, allowing water to pass through it to the fire sprays.

When the miner is under supported roof, the fire sprays may also be actuated by manually via the fire spray valve, typically located to the left of the control case on the right hand side of the machine or by opening the “FIRE SPRAY” valve (Fig. 60) located on the left hand side of the machine.

The fire spray circuit described above and shown in Fig. 61 is typical.

The circuit for your machine may vary depending on your dust plan and unique requirements. Always refer to the schematic in the Bucyrus parts book for your machine.

© BUCYRUS AMERICA, INC.

Fig. 61: Fire spray circuit

_________________________________________________________________ 5.104 Bucyrus – Model 30M4-NP Continuous Miner

______________________________________________________ Water Dust-cooling water supply circuit The dust-cooling water circuit (Fig. 62) utilizes water supplied by the water distribution manifold and is operated by remote solenoid control.

When the dust-cooling solenoid (“DS”) is energized, it shifts a spool, allowing hydraulic oil to travel to the hydraulic pilot operated normally closed water valve. The hydraulic oil shifts the spool, allowing water to pass through it to the secondary dust-cooling water manifold. Water can also be supplied to the manifold via a manual cooling water valve (Fig. 60).

The secondary dust-cooling water manifold distributes water to the four unique dust-cooling circuits:

© BUCYRUS AMERICA, INC.

1.

2.

3.

4.

Right hand cutter motor cooling circuit Left hand cutter motor cooling circuit Left hand chassis cooling circuit Right hand chassis cooling circuit

The dust-cooling circuit described above and shown in Fig. 62 is typical. The circuit for your machine may vary depending on your dust plan and unique requirements. Always refer to the schematic in the Bucyrus parts book for your machine.

Fig. 62: Dust-cooling water supply circuit

______________________________________________________________ A6474X326 VTSV/00 5.105

Water _______________________________________________________ Right hand cutter motor cooling circuit From the secondary dust-cooling water manifold, water is supplied to the right hand cutter motor cooling circuit (Fig. 63) where it supplies cooling/spray water to the right hand cutter motor and the right hand cutter head sprays. There is a relief valve set at 175 psi between the right hand cutter motor and the dust sprays.

The right hand cutter motor cooling circuit described above and shown in Fig. 63 is typical. The circuit for your machine may vary depending on your dust plan and unique requirements. Always refer to the schematic in the Bucyrus parts book for your machine.

© BUCYRUS AMERICA, INC.

Fig. 63: Right hand cutter motor cooling circuit

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______________________________________________________ Water Left hand cutter motor cooling circuit From the secondary dust-cooling water manifold, water is supplied to the left hand cutter motor cooling circuit (Fig. 64) where it supplies cooling/spray water to the left hand cutter motor and the left hand cutter head sprays. There is a relief valve set at 175 psi between the left hand cutter motor and the dust sprays.

The left hand cutter motor cooling circuit described above and shown in Fig. 64 is typical. The circuit for your machine may vary depending on your dust plan and unique requirements. Always refer to the schematic in the Bucyrus parts book for your machine.

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Fig. 64: Left hand cutter motor cooling circuit

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Water _______________________________________________________ Left hand chassis cooling circuit From the secondary dust-cooling water manifold, water is supplied to the left hand chassis cooling circuit (Fig. 65) where it supplies cooling/ spray water to the left hand tram motor, the pump motor, the right and left hand CLA motors, the right and left hand gathering head sprays, the left hand chassis sprays, and the center cutter head sprays.

The left hand chassis circuit described above and shown in Fig. 65 is typical. The circuit for your machine may vary depending on your dust plan and unique requirements. Always refer to the schematic in the Bucyrus parts book for your machine.

© BUCYRUS AMERICA, INC.

Fig. 65: Left hand chassis cooling circuit

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______________________________________________________ Water Right hand chassis cooling circuit From the secondary dust-cooling water manifold, water is supplied to the right hand chassis cooling circuit (Fig. 66) where it supplies cooling/ spray water to the control transformer, the right hand tram motor, the transformer, the throat sprays, and the right hand chassis sprays. The right hand cooling circuit is protected by a relief valve set at 350 psi.

The right hand chassis circuit described above and shown in Fig. 66 is typical. The circuit for your machine may vary depending on your dust plan and unique requirements. Always refer to the schematic in the Bucyrus parts book for your machine.

© BUCYRUS AMERICA, INC.

Fig. 66: Right hand chassis cooling circuit

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Water _______________________________________________________

_________________________________________________________________ 5.110 Bucyrus – Model 30M4-NP Continuous Miner

___________________________________________________ Electrical Electrical system The following pages contain a brief description of the electrical components and assemblies located on the 30M4-NP continuous miner.

WARNING! This section is intended only to familiarize the user with the electrical components of the continuous miner. Electrical maintenance should only be performed by a qualified electrician with knowledge of the functions of the components involved.

WARNING! Before removing any cover from an electrical case or attempting any maintenance or troubleshooting, the main power must be disconnected and locked out at the main power center.

© BUCYRUS AMERICA, INC.

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

Schematics A schematic diagram is an illustration which shows the electrical relationship of the various components and the circuits. A schematic diagram does not show the physical location of the components. In an electrical schematic, components are shown in their de-energized position. A set of normally open contacts (N.O.) close when the coil is energized and a set of normally closed (N.C.) open when the coil is energized. Related components share the same designation. In tracing a particular circuit, it may be helpful to think of the flow of electricity as being similar to the flow of water through a hose. When a set of contacts are open, the current cannot flow across them, and when contacts are closed, the current can flow. When three (3) lines are connected in a tee, the current will flow in whatever direction that it can. Like water or hydraulic fluid, an electrical current will tend to follow the path of least resistance through a circuit. Finally, for a circuit to work, the electrical current must make a complete loop, similar to hydraulic fluid going through a circuit and returning to a tank.

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Electrical ____________________________________________________

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Fig. 56: Standard electrical symbols

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___________________________________________________ Electrical

© BUCYRUS AMERICA, INC.

Fig. 57: Electrical component locator

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Electrical ____________________________________________________

© BUCYRUS AMERICA, INC.

Fig. 58: Electrical block diagram

1. Reversing light 2. Water pressure switch 3. Water flow switch 4. IS junction box 5. Scrubber motor 6. Left #1 emergency stop 7. Left brake release pressure switch 8. Area light 9. Head light 10. Left #2 emergency stop 11. Left tram motor 12. Pump motor 13. Hydraulic oil level/temperature switch 14. Left CLA motor 15. Left cutter motor

16. Methane sensor 17. Right cutter motor 18. Right CLA motor 19. Right brake release pressure switch 20. Right tram motor 21. Antenna 22. Main breaker case 23. Victor plug and coupler 24. Emergency tram pendant 25. Transmitter pendant 26. Graphic display case 27. Trolex trip amplifier 28. Radio receiver case 29. Pump/tram pre-start alarm 30. Warning light

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___________________________________________________ Electrical Trailing cable A trailing cable with three power conductors, labeled L1, L2, L3, two (2) ground conductors (G), and a ground check conductor (GC) supplies power to the machine. A three-conductor 120mm2 or a 95mm2 cable is typically used with the 1140V nominal machines.

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

© BUCYRUS AMERICA, INC.

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

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

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

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

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

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

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

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Electrical ____________________________________________________ General The incoming 1140 V power supply is connected to the machine via the cable handler and the incoming main circuit breaker. AC power is then transferred to the main case where it is distributed via contactors to the pump, fan, cutter, and CLA motors. Power to the DC tram motors is distributed from the power supply to a tram transformer (1140/350 V), to the right and left tram drives, and then to the right and left tram motors.

The control transformer steps the incoming voltage down to 120 VAC and 12 VAC for the lighting, methane monitoring, ground check, and controls systems.

There are four machine stop buttons located on the machine, two on the left side and two on the right side, and an emergency stop button located on the transmitter and the emergency tram pendant. Pressing any one of these buttons will trip the Power Center, de-energizing the trailing cable. The customer has the option to set up the machine so that pressing any one of these buttons will remove power to any item capable of creating a movement (motors and solenoids).

_________________________________________________________________ 5.116 Bucyrus – Model 30M4-NP Continuous Miner vacuum contactors

© BUCYRUS AMERICA, INC.

The machine is operated by remote control during normal operations.

There is an emergency tram pendant available to tram the machine in the event that the control system loses signal from the remote control.

___________________________________________________ Electrical Operator’s case The operator’s case (Fig. 59) is located on the right near the rear of the machine and houses the major electrical components of the miner.

The front of the case houses the “MACHINE STOP” button, the “MINER MODE” selector switch, three earth relay ground test switches, the “MACHINE LIGHTING” selector switch, the conveyor and cutter motor hour meters, and the reset levers for the machine circuit breakers. For operation of the switches and reset levers, please see Controls and indicators in the Operation section of this chapter.

Electrical components are mounted inside the case on the top, bottom, rear, and side panels, as well as on the front and back sides of the swing panel.

Fig. 59: Control case “MINER MODE”

“350 VOLT GRND CHK”

“120 VOLT GRND CHK”

“12 VOLT GRND CHK”

“MACHINE LIGHTING”

Circuit breakers

“CONVEYOR HOUR METER”

“CUTTING HEAD HOUR METER”

© BUCYRUS AMERICA, INC.

“MACHINE STOP”

“CUTTER MOTOR CIRCUIT BREAKER”

“TRAM CIRCUIT BREAKER”

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Electrical ____________________________________________________ Control case - rear wall The rear wall of the operator’s case (Fig. 60) is accessed by opening the two face panels. The control system components, ground fault sensors, relays, and emergency tram overloads are typically located on this panel.

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

Fig. 60: Control case - rear wall

Vacuum contactor, “F”

Vacuum contactor, “A”

Vacuum contactor, “B”

© BUCYRUS AMERICA, INC.

Control transformer, “T1”

vacuum contactor, “F”

Vacuum contactor “F” is the fan motor contactor.

vacuum contactor, “A”

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

vacuum contactor, “B”

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

control transformer “T1”

“T1” is the control transformer that converts the incoming 1140V power supply to 12V and 120V.

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___________________________________________________ Electrical Control case - top wall The top wall of the control case (Fig. 61) is accessed by swinging open the top face panel and typically houses the junction terminal, “JB”.

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

© BUCYRUS AMERICA, INC.

Fig. 61: Control case - top wall

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Electrical ____________________________________________________ Control case - door panel The door panel of the control case (Fig. 62) houses control breakers, hour meters, and switches. There is also a panel to view the graphics display.

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

Fig. 62: Control case - door panel (as seen from inside control case)

“TT1”

“M C B 4”

“M C B 3”

“M C B 2”

“M C B 1”

“M C B 7”

“M C B 8”

“LS1”

“RS4

“RS3

“RS2

“RS1

Control case E-stop

© BUCYRUS AMERICA, INC.

“TT”

“M C B 6”

“M C B 5”

View panel

View panel

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© BUCYRUS AMERICA, INC.

___________________________________________________ Electrical “TT”

“TT” is the cutter hour meter and it displays the total number of running hours for the cutter motors.

“TT1”

“TT1” is the conveyor hour meter and it displays the total number of running hours for the conveyor motors.

“MCB1”

“MCB1” is a 15A breaker on the 120VAC+ side of the control power circuit.

“MCB2”

“MCB2” is a 15A breaker on the 120VAC- side of the control power circuit.

“MCB3”

“MCB3” is a 20A breaker for the left head light circuit.

“MCB4”

“MCB4” is a 20A breaker for the right head light circuit.

“MCB5”

“MCB5” is a 20A breaker for the reverse lights circuit.

“MCB6”

“MCB6” is a 15A breaker for the area lights circuit.

“MCB7”

“MCB7” is a 10A breaker on the motor contactors communication portion of the control circuit.

“MCB8”

“MCB8” is a 3A breaker on the solenoid communication portion of the control circuit.

“LS1”

“LS1” is the lighting selector switch.

“RS1”

“RS1” is the machine mode of operation rotary switch. The switch has two positions, “REMOTE” and “OFF/E-TRAM”.

“RS2”

“RS2” is a momentary switch with spring return that works in conjunction with the earth leakage ground check “EL350”. When the switch is turned to ground check, “GND CHK”, a short circuit to ground is created in the tram motor drive circuit.

“RS3”

“RS3” is a momentary switch with spring return that works in conjunction with earth leakage ground check “EL120”. When the switch is turned to ground check, “GND CHK”, a short circuit to ground is created in the 120V circuit.

“RS4”

“RS4” is a momentary switch with spring return that works in conjunction with earth leakage ground check “EL12”. When the switch is turned to ground check, “GND CHK”, a short circuit to ground is created in the 12V circuit.

control case E-stop

The control case machine stop switch (E-stop) can be sued to quickly shut down the machine. Depressing the button will shut down the pump motor, thereby shutting down all machine functions.

view panels

The view panels are used to view components located on the front side of the swing panel.

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Electrical ____________________________________________________ Control case - right panel The right panel of the control case (Fig. 63) houses circuit breakers “CB2” and “CB3”.

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

Fig. 63: Control case - right panel “CB3”

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“CB2”

“CB2”

“CB2” is a 600 A circuit breaker (instantaneous setting at 1,250 A) on the cutter motor circuit. The circuit breaker can be reset with the breaker handle located on the front of the control case.

“CB3”

“CB3” is a 400 A circuit breaker (instantaneous setting at 300 A) on the tram motor circuit.

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___________________________________________________ Electrical Control case - left panel The left panel of the control case (Fig. 64) houses three vacuum contactors, “CF”, “CR”, and “P”.

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

Fig. 64: Control case - right panel “CR”

“P”

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“CF”

“CF”

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

“CR”

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

“P”

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

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Electrical ____________________________________________________ Control case - floor panel The floor panel of the control case (Fig. 65) houses the left and right tram drives, “LD” and “RD”, resistors, and the earth leakage relay, “ELR”.

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

Fig. 65: Control case - floor panel “R7”

“ELR”

“CT8”

“LD”

“RD”

“R9” “R8” “R4” “R3” “R2” “R1”

“CT9”

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© BUCYRUS AMERICA, INC.

“T5”

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___________________________________________________ Electrical “R1” and “R2”

“R1” and “R2” are 1,100 ohm, 5 watt neutral ground resistors on the 120V circuit.

“R3” and “R4”

“R3” and “R4” are 130 ohm, 5 watt neutral ground resistors on the 12V circuit.

“R7”

“R7” is a 1,500 ohm, 25 watt neutral ground resistor on the 350V tram drive circuit.

“R8”

“R8” is a 100 ohm 25 watt resistor on the 12V lighting circuit (head and rear lights).

“R9”

“R9” is a 100 ohm 25 watt resistor on the 120V lighting circuit (head and rear lights).

“CT7”

“CT7” is a current transducer used with earth leakage relay “EL120” on the 120V circuit.

“CT8”

“CT8” is a current transducer used with earth leakage relay “EL12” on the 12V circuit.

“ELR”

“ELR” is the relay between the current transformer (1140V to 120/12V) three earth leakage relay circuits.

“LD”

“LD” is the left tram motor drive.

“RD”

“RD” is the right tram motor drive.

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Electrical ____________________________________________________ Control case - swing panel, front side The front side of the swing panel of the control case (Fig. 66) houses the main control unit (“MCU”), power supplies, relays, and the tram pendant interface (“TPI”).

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

Fig. 66: Control case - swing panel, front side “MCU”

“CPS1”

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“MPS”

“BRE”

“TPI”

“IST” “PS24”

“ISW”

Spare

“ISBT” “ISB” “EL350” “TCS” “DPS” “FSR” “L” “EL120”

“RL”

“ESR”

“PCT”

“BRM” (not visible)

“MMR”

“EL12”

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© BUCYRUS AMERICA, INC.

___________________________________________________ Electrical “TPI”

The tram pendant interface, “TPI”, is the communication interface between the tram pendant and the control system when the “MINER MODE” of operation switch is in the “E-TRAM” position.

“MCU”

The main control unit, “MCU”, is a custom programmable logic controller (PLC) used to automate monitoring and control of the machine.

“MPS”

“MPS” is the intrinsically safe (IS) power supply for the methane system.

“BRE”

“BRE” is a bridge rectifier used to convert the AC input from the emergency stop push button circuit to a DC output used to pull in the emergency stop relay, “ESR”.

“BRM”

“BRM” is a bridge rectifier used to convert the AC input from the methane system to a DC output used to pull in the methane monitoring relay, “MMR”.

“PS24”

“PS24” is the power supply for the solenoids and the fire suppression.

“PCT”

“PCT” is the power center trip relay and is used to open the power relay, ultimately opening the pilot core of the trailing cable to trip the power center. It is controlled by the PLC.

“FSR”

“FSR” is the fire suppression relay.

“TCS”

“TCS” is the trailing cable start relay. It is energized by the breaker on output and is activated by the operator by pressing “SHIFT” and “BREAKER ON” on the transmitter. It is used to restart the power center from the remote control as long as the battery backup power supplies still have power.

“DPS”

“DPS” is the power supply for the graphics display.

“MMR”

Contactor “MMR” is a relay in the methane monitoring circuit.

“ESR”

Contactor “ESR” is a contactor in the emergency stop circuit. When this contactor is open, power is removed from the machine.

“RL”

“RL” is the reverse light contactor. When this contactor is closed, the reverse lights are on.

“L”

“L” is the head light contactor. When this contactor is closed, the head lights are on.

“EL12”

“EL12” is an earth leakage monitor on the 12V circuit.

“EL120”

“EL120” is an earth leakage monitor on the 120 V circuit.

“EL350”

“EL350” is an earth leakage monitor on the 350 V circuit.

“ISB”

“ISB” is a intrinsically safe (IS) barrier that provides an approved IS circuit between the transmitter pendant and the control system.

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Electrical ____________________________________________________ “ISBT” is a intrinsically safe (IS) barrier that provides an approved IS circuit between the emergency tram pendant and the control system.

“ISW”

“ISW” is a intrinsically safe (IS) barrier that provides an approved IS circuit between the water flow and pressure sensors and the control system.

“IST”

“IST” is a intrinsically safe (IS) barrier that provides an approved IS circuit between the left and right tram brake release signal and the control system.

“MCU”

“MCU” is the main control unit for the control system. For more information on the “MCU”, see the Control system section in the Controls and indicators section of this chapter.

“CPS1”

“CPS1” is a back-up power supply that provides 12VDC and 5VDC for the MCU and radio receiver.

© BUCYRUS AMERICA, INC.

“ISBT”

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___________________________________________________ Electrical Control case - swing panel, rear side The rear side of the swing panel of the control case (Fig. 67) houses fuses, resistors, and a back-up power supply.

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

Fig. 67: Control case - swing panel, rear side

“CPS2”

“F1”

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“F2” “F3” “F4” “F5” “F7”

“F6”

“F8” “F9” “F10” “F11” “F12”

“R5” “R6”

“CT9”

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Electrical ____________________________________________________ “F1”

“F1” is a 15A fuse between the machine voltage positive input and the MCU.

“F2”

“F2” is a 15A fuse between the machine voltage negative input and the MCU.

“F3”

“F3” is a 15A fuse protecting the left head light circuit.

“F4”

“F4” is a 15A fuse protecting the right head light circuit.

“F5”

“F5” is a 10A fuse protecting the reverse light circuit.

“F6”

“F6” is a 10A fuse protecting the area light circuit.

“F7” and “F8” are 5A fuses protecting the graphics display power supply, “DPS”.

“F9”

“F9” is a 3A fuse protecting the back-up power supply, “PS24”.

“F10”

“F10” is a 10A fuse protecting the tram alarm circuit.

“F11”

“F11” is a 10A fuse protecting the start alarm circuit.

“F12”

“F12” is a 10A fuse protecting the dual tone warning horn.

“CPS2”

“R5” and “R6” “CT9”

“CPS2” is back-up power supply used in series with “CPS1” to operate the 24VDC fire suppression solenoid and/or the 24VDC trailing cable start relay when power from the power center is lost.

“R5” and “R6” are 540 ohm, 75 watt neutral ground resistors on the tram transformer.

“CT9” is the current transducer used with the tram transformer.

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© BUCYRUS AMERICA, INC.

“F7” and “F8”

___________________________________________________ Electrical Power circuit with control Power is available to the line side of motor starter circuits to the control and 110V transformers (“T1”, and “T5”) as soon as the trailing cable is connected to the machine and the main circuit breaker (“CB1”) is turned on. Power is available to the cutter motor starter when the cutter circuit breaker (“CB2”) is turned on. Power is available to the tram transformer (“PT1”) when the tram breaker (“CB3”) is turned on and the pump contactor closes.

The power schematic shown in Fig. 68 is typical for this miner. Always refer to the schematic in the Bucyrus parts book for your machine.

© BUCYRUS AMERICA, INC.

Fig. 68: Power circuit with control

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Electrical ____________________________________________________

© BUCYRUS AMERICA, INC.

Fig. 68: Power circuit with control, continued

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___________________________________________________ Electrical Methane monitor circuit The methane monitor detects gas when the continuous miner is powered up. Before any motor or function can be activated, the methane monitor checks for the presence of methane gas. If the methane gas level is below a preset level, the methane monitor relays will close, resulting in the power center trip relay opening. Power is now available to the machine. The methane monitor is powered by the methane system IS power supply “MPS”.

The methane monitor circuit shown in Fig. 69 is typical for this miner.

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

© BUCYRUS AMERICA, INC.

Fig. 69: Methane monitor circuit

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Electrical ____________________________________________________ Machine lighting circuit The machine lighting is powered by both the 120VAC and 12VAC circuits. The head lights and reverse lights are on the 120VAC circuit and the area lights are on the 12VAC circuit. The lights are controlled by a switch on the front of the control case or by the TX-945 transmitter.

The light switch, “MACHINE LIGHTING”, has four positions: “OFF”, “ON”, “HEAD LIGHTS”, and “AREA LIGHTS”. When tramming in reverse, the head lights are automatically turned off and the reverse lights are automatically turned on.

The “LIGHTS” switch on the transmitter will turn on the lights, area and head/rear lights.

The lighting circuit shown in Fig. 70 is typical for this miner. Always refer to the schematic in the Bucyrus parts book for your machine.

© BUCYRUS AMERICA, INC.

Fig. 70: Machine lighting circuit

_________________________________________________________________ 5.134 Bucyrus – Model 30M4-NP Continuous Miner

___________________________________________________ Electrical Hydraulic low oil level/high temperature circuit The hydraulic low oil level/high temperature circuit indicates when the oil level in the hydraulic oil tank is low or when the oil temperature exceeds a preset value. There are two oil level float switches and a temperature switch located within a permissible switch assembly enclosure. When the oil level reaches the first float switch, the switch will open, removing power from the circuit. The MCU will then send a low oil warning to the graphics display. When the oil level reaches the second float switch, the switch will open, removing power from the circuit.

The MCU will then shut down the machine. When the oil temperature exceeds the allowable value programmed into the MCU, the switch will open, removing power from the circuit. The MCU will then shut down the machine.

The low oil/high oil temperature circuit shown in Fig. 71 is typical for this miner. Always refer to the schematic in the Bucyrus parts book for your machine.

© BUCYRUS AMERICA, INC.

Fig. 71: Hydraulic low oil/high temperature circuit

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Electrical ____________________________________________________ Water flow and pressure circuit The water flow and water pressure inputs are interlocks for the cutter motors. If the water flow and/or the water pressure inputs is below the value programmed into the MCU, the MCU will either prevent the motors from starting or, if the motors are running, will shut down the motors.

The water flow and pressure circuit shown in Fig. 72 is typical for this miner. Always refer to the schematic in the Bucyrus parts book for your machine.

© BUCYRUS AMERICA, INC.

Fig. 72: Water flow and pressure circuit

_________________________________________________________________ 5.136 Bucyrus – Model 30M4-NP Continuous Miner

___________________________________________________ Electrical Pump motor power circuit with control The pump motor can be started from the transmitter (remote control) or from the tram pendant. The pump start function is a two hand function from either device. To start the pump from the transmitter, the “ENABLE” button must be pushed and held while the “PUMP ON” button is pushed. The pump motor must be running before any other motor can be started.

The pump motor contactor, “P”, closes when power is applied to the machine, circuit breaker “CB1” is closed, the methane monitor relay, “MMR”, is closed, and the emergency stop relay, “ESR”, is closed. The pump motor is continuously monitored and operating conditions (current and temperature) are sent to the MCU. If an input value is outside of the preset value, the MCU will shutdown the pump motor.

© BUCYRUS AMERICA, INC.

The pump motor circuits shown in Fig. 73 are typical for this miner.

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

Fig. 73: Pump motor circuit

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Electrical ____________________________________________________

© BUCYRUS AMERICA, INC.

Fig. 73: Pump motor circuit, continued

_________________________________________________________________ 5.138 Bucyrus – Model 30M4-NP Continuous Miner

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

The cutter motor is a two hand start. To start the cutter motors, press and hold the “ENABLE” button the transmitter and then press the “CUTTER START” button.

The cutter motors are continuously monitored and operating conditions (current and temperature) are sent to the MCU. If an input value is outside of the preset value, the MCU will shutdown the cutter motors.

The cutter motor circuits shown in Fig. 74 are typical for this miner.

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

© BUCYRUS AMERICA, INC.

Fig. 74: Cutter motor circuit

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

The conveyor motor is a two hand start. To start the conveyor motors, press and hold the “ENABLE” button the transmitter and then press the “CONVEYOR START” button.

The conveyor motors are continuously monitored and operating conditions (current and temperature) are sent to the MCU. If an input value is outside of the preset value, the MCU will shutdown the conveyor motors.

The conveyor motor circuits shown in Fig. 75 are typical for this miner.

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

© BUCYRUS AMERICA, INC.

Fig. 75: Conveyor motor circuit

_________________________________________________________________ 5.140 Bucyrus – Model 30M4-NP Continuous Miner

___________________________________________________ Electrical Fan motor power circuit with control The pump motor must be running before the fan motor will start.

The fan motor is a two hand start. To start the fan motor, press and hold the “ENABLE” button the transmitter and then press the “FAN START” button.

The fan motor is continuously monitored and operating conditions (current and temperature) are sent to the MCU. If an input value is outside of the preset value, the MCU will shutdown the conveyor motors.

The fan motor circuit shown in Fig. 76 is typical for this miner. Always refer to the schematic in the Bucyrus parts book for your machine.

© BUCYRUS AMERICA, INC.

Fig. 76: Fan motor circuit

_____________________________________________________________ A6474X326 VTSV/00 5.141

Electrical ____________________________________________________ Tram power circuit with control The miner can be trammed from the transmitter or from the tram pendant (see Tram pendant circuit in this section). When power is applied to the miner and the tram circuit breaker, “CB3” is closed, power is available to the tram transformer, “PT1”, after the pump is energized.

The “TRAM ENABLE” button on the transmitter must be pushed before tramming is active.

The tram circuit shown in Fig. 77 is typical for this miner. Always refer to the schematic in the Bucyrus parts book for your machine.

© BUCYRUS AMERICA, INC.

Fig. 77: Tram power circuit with control

_________________________________________________________________ 5.142 Bucyrus – Model 30M4-NP Continuous Miner

___________________________________________________ Electrical

© BUCYRUS AMERICA, INC.

Fig. 77: Tram power circuit with control, continued

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Electrical ____________________________________________________ Machine emergency stop circuit The emergency stop relay, “ESR”, is used to remove power from the primary control circuits. The relay is controlled by one of four buttons: two on the right side of the machine and two on the left side. Any one of these four buttons will trip the relay.

The schematic shown in Fig. 78 is typical. Always refer to the schematic in the Bucyrus parts book for your machine.

© BUCYRUS AMERICA, INC.

Fig. 78: Machine emergency stop circuit

_________________________________________________________________ 5.144 Bucyrus – Model 30M4-NP Continuous Miner

___________________________________________________ Electrical Tram pendant circuit In the event that there is a loss in communication between the transmitter and the control system, the machine can be operated with limited functions using the tram pendant. The tram pendant can be used to start the pump motor, raise and lower the cutter head, tram the machine.

The schematic shown in Fig. 79 is typical. Always refer to the schematic in the Bucyrus parts book for your machine.

© BUCYRUS AMERICA, INC.

Fig. 79: Tram pendant circuit

_____________________________________________________________ A6474X326 VTSV/00 5.145

Electrical ____________________________________________________ Solenoid control circuit Solenoids are used to control the hydraulic functions (cylinder movement), dust sprays, fire suppression, etc.

The schematic shown in Fig. 80 is typical. Always refer to the schematic in the Bucyrus parts book for your machine.

© BUCYRUS AMERICA, INC.

Fig. 80: Solenoid control circuit

_________________________________________________________________ 5.146 Bucyrus – Model 30M4-NP Continuous Miner

________________________________________________ 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

© BUCYRUS AMERICA, INC.

Please observe the following: ■

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.

______________________________________________________________ A6474X326 VTSV/00 5.147

Maintenance _________________________________________________ ■

Only work on the miner in an area where the roof is properly supported.

■

Block any and all elevated assemblies before working under them.

Make sure that the blocking can support the weight of the assembly without slipping or failing.

■

Relieve all hydraulic pressures and position the levers and controls in neutral or off.

■

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

■

Do not perform maintenance on a circuit while there is a load resting on the hydraulic cylinder. Booms must be securely blocked with the boom in the raised position if maintenance is to be performed.

WARNING! Never disconnect a hydraulic hose if the circuit is pressurized or if there is a load on the circuit. If a hose is disconnected while the circuit is pressurized or a load is on the circuit, the load will fall causing damage to the machine or serious injury or death to you or other workers.

WARNING! You could be seriously injured or even killed by falling loads. Observe the safe working load limits of lifting or blocking devices and keep a safe distance from suspended loads.

■

Do not perform maintenance in a congested area. This could endanger the maintenance person or others in the vicinity.

■

Whenever a potential problem is uncovered during a periodic maintenance check, it is imperative that it be corrected immediately by a qualified maintenance technician.

■

Cleanliness cannot be overemphasized as the essential ingredient of a good maintenance program. Machines should be kept as free as possible of dirt and debris which could impede performance or infiltrate systems and cause premature wear or failure.

_________________________________________________________________ 5.148 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

WARNING! Do not move any hydraulic control lever unless you are certain that everyone is completely clear of any machine movement. Accidental machine movement can cause serious injuries or even death to you or the maintenance person.

________________________________________________ Maintenance Torque values When installing bolts, refer to the torque values on the drawings in the Bucyrus America, Inc. part book for your machine. If a torque value is not listed, refer to Chapter 6 of this manual

Lubricants and fluid capacities

© BUCYRUS AMERICA, INC.

Table 2: Lubricants and fluid capacities Location

Specification

Approximate capacity

Hydraulic oil tank

Quintolubric 88-68 or Condat D 68 Spec. 100-15 Spec. 100-15 Spec. 100-15 Spec. 100-15

95 gals. (360 L)

1 gal (3.79 L) 2.5 gal (9.46 L) 3 gal (11.36 L) 0.5 gallon (1.89 L)

Spec. 100-15

5 gal (18.93 L)

Spec. 100-14

Variable

GH Assembly CLA Primary GH Assembly CLA POT Tram Drive Assembly Drum Drive Assembly, high speed (back) Drum Drive Assembly, low speed (front) Motor Lube Hoses

Notes

1

Notes: 1. All motor lube hoses are to be filled with high temperature electric motor grease (Spec. 100-14) before assembling them to the electric motor to ensure that there are no air gaps between the grease nipple and the point where the grease enters the motor.

______________________________________________________________ A6474X326 VTSV/00 5.149

Maintenance _________________________________________________

Item

Places

Lubricant

Specification

1 2 3 4 5 6

Description Every Shift Cutter head lift cylinder pin, upper Cutter head lift cylinder pin, lower Conveyor swing cylinder pin, front Conveyor swing cylinder pin, rear Cutter head pivot pin Cutter head bits

2 2 1 1 2 Inspect

Lithium based grease Lithium based grease Lithium based grease Lithium based grease Lithium based grease

Spec. 100-3 Spec. 100-3 Spec. 100-3 Spec. 100-3 Spec. 100-3

7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

Daily Conveyor take-up shaft Gathering head pivot pin Crawler idler roller Conveyor raise pivot pin Stabilizer shoe cylinder pin, upper Stabilizer shoe cylinder pin, lower Conveyor raise cylinder pin, upper Conveyor raise cylinder pin, lower Conveyor swing pivot pins Gathering head cylinder pin, upper Gathering head cylinder pin, lower CLA head pot assembly (Check) CLA head transfer case (Check) Tram gear case (Check) Input cutter head gear case (Check) Main cutter head gear case (Check) Hydraulic oil level (Check)

2 2 2 2 2 2 2 2 8 2 2 2 2 2 2 2 1

Lithium based grease Lithium based grease Lithium based grease Lithium based grease Lithium based grease Lithium based grease Lithium based grease Lithium based grease Lithium based grease Lithium based grease Lithium based grease High demulsibility EP gear oil High demulsibility EP gear oil High demulsibility EP gear oil High demulsibility EP gear oil High demulsibility EP gear oil Quintolubric 88-68 or Condat D 68 Lithium based grease

Spec. 100-3 Spec. 100-3 Spec. 100-3 Spec. 100-3 Spec. 100-3 Spec. 100-3 Spec. 100-3 Spec. 100-3 Spec. 100-3 Spec. 100-3 Spec. 100-3 Spec. 100-15 Spec. 100-15 Spec. 100-15 Spec. 100-15 Spec. 100-15

24 25 26 27 28 29 30 31 32 33 34 35 36 37

Stab shoe pivot, frame Weekly Filter, pressure (Change) Filter, return (Change) Filter, pilot, bypassing (Change) Filter, pilot, non-bypassing (Change) Filter, water (Change) Crawler chain Conveyor chain Fasteners (nuts, bolts, screws) Electrical cables, conduits, and glands Hydraulic hoses and connections Lighting Reflectors and warning tags Machine stop switch (Inspect)

2 1 1 1 1 1 Inspect Inspect Inspect Inspect Inspect Inspect Inspect 4

Spec. 100-3 See Parts Book See Parts Book See Parts Book See Parts Book See Parts Book

_________________________________________________________________ 5.150 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

Table 3: Lubrication and maintenance schedule

________________________________________________ Maintenance Table 3 (continued): Lubrication and maintenance Item

Places

Lubricant

Specification

2 2 2 2 Inspect 2 2 2 2 2 2 1

High demulsibility EP gear oil High demulsibility EP gear oil High demulsibility EP gear oil High demulsibility EP gear oil

Spec. 100-15 Spec. 100-15 Spec. 100-15 Spec. 100-15

Sample Sample Sample Sample Sample Sample Sample

See Note 1 See Note 1 See Note 1 See Note 1 See Note 1 See Note 1 See Note 1

4

High temperature lithium complex grease High temperature lithium complex grease High temperature lithium complex grease High temperature lithium complex grease

Spec. 100-14

2

High demulsibility EP gear oil

Spec. 100-15

1

Quintolubric 888-68 or Condat D 68

50 51

Gathering head motor

4

52

Pump motor

2

53

Scrubber motor

2

54 55 56

Every six months Tram gear case oil (Change) Crawler idler roller oil (Change) Hydraulic oil (Change)

57 58 59

Breathers Strainer, reverse flushing Filter, manual oil fill (Change)

38 39 40 41 42 43 44 45 46 47 48 49

© BUCYRUS AMERICA, INC.

Description Monthly CLA head pot assembly oil (Change) CLA head transfer case oil (Change) Input cutter head gear case oil (Change) Main cutter head gear case oil (Change) CLAs Input cutter head gear case oil Main cutter head gear case oil CLA head pot assembly oil CLA head transfer case oil Tram gear case oil Crawler idler roller oil Hydraulic oil (tank) Every three months Cutter motor

All Inspect 1

Spec. 100-14 Spec. 100-14 Spec. 100-14

See Parts Book

Note 1: When the oil sample and oil change interval are identical, a sample of the old oil is to be taken and sent for analysis prior to changing the oil (see the Oil sampling procedure in this chapter). Always inspect breathers when taking hydraulic oil samples.

______________________________________________________________ A6474X326 VTSV/00 5.151

Maintenance _________________________________________________ Fig. 92: Lubrication and maintenance chart 7

4

31

3

59

23, 49, 56

21, 40, 43

22, 41, 44 _________________________________________________________________ 5.152 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

29, 58

________________________________________________ Maintenance Fig. 93: Lubrication and maintenance chart, continued

21, 40, 43

50 51 18, 38, 45 19, 39, 46 16 9, 48, 55 17 30 2, 5, 8, 10

© BUCYRUS AMERICA, INC.

25. 26, 27, 28

20, 47, 54

12

29, 58

15

______________________________________________________________ A6474X326 VTSV/00 5.153

Maintenance _________________________________________________ Fig. 92: Lubrication and maintenance chart, continued

15

12

20, 47, 54

30 52

17

9, 48, 55 19, 39, 46

16 51 18, 38, 45

50

21, 40, 43

_________________________________________________________________ 5.154 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

11, 14, 24, 53

________________________________________________ Maintenance Specific lubrication and maintenance procedures Every shift cutter head lift cylinder pins (upper and lower)

Lubricate the upper and lower cutter head cylinder pins (right and left).

The upper pins are lubricated through the grease fittings located on each pin (Fig. 93). The lower cylinder pins are lubricated through a lubrication block mounted on each side of the machine (Fig. 93). Pump approximately 50 cubic cm (3 cubic inches) into each fitting.

© BUCYRUS AMERICA, INC.

Fig. 93: Cutter head cylinder pins (typical both sides)

Cutter head lift cylinder pin, upper (typical both sides)

Lower cutting head cylinder pin (One for each side)

______________________________________________________________ A6474X326 VTSV/00 5.155

Maintenance _________________________________________________ conveyor swing cylinder pin (front and rear)

Lubricate the front and rear conveyor swing cylinder pins through the grease fittings located on each end of the cylinder (Fig. 94). Pump approximately 50 cubic cm (3 cubic inches) into each fitting.

Fig. 94: Conveyor swing cylinder pin lubrication

cutter head pivot pin (left and right)

Front conveyor swing cylinder pin

Lubricate left and right cutter head pivot pins through the grease fittings located on the left and right front lubrication blocks (Fig. 95). Pump approximately 3 cu. in. (50 cu. cm) of grease into each fitting.

Fig. 95: Cutter head pivot pins (typical both sides)

Cutting head pivot pin (typical both sides)

_________________________________________________________________ 5.156 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

Rear conveyor swing cylinder pin

________________________________________________ Maintenance cutter head bits

Inspect the cutter head bits to ensure that they will rotate in their holders and for damaged or missing bits (Fig. 96). Replace bits immediately if any are missing or damaged.

© BUCYRUS AMERICA, INC.

Fig. 96: Cutter head bits (typical shown)

Inspect cutter head bits

______________________________________________________________ A6474X326 VTSV/00 5.157

Maintenance _________________________________________________ Daily conveyor take-up shaft

Lubricate the conveyor take-up shaft through the two (2) grease fittings located on the shaft (Fig. 97). Pump approximately 3 cu. in. (50 cu. cm.) into each fitting.

Grease fitting

Grease fitting

gathering head pivot pin (right and left)

Lubricate the left and right gathering head pivot pins through the grease fittings located on the left and right front lubrication blocks (Fig. 98).

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

conveyor raise pivot (right and left)

Lubricate the conveyor raise pivot through the grease fitting located on the right and left front lubrications blocks (Fig. 98). Pump approximately 3 cu. in (50 cu. cm) of grease into each fitting.

Fig. 98: Gathering head and conveyor raise pivot pins (typical both sides)

Gathering head pivot lube (typical both sides)

Conveyor pivot lube (typical both sides)

_________________________________________________________________ 5.158 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

Fig. 97: Conveyor take-up shaft lubrication

________________________________________________ Maintenance crawler idler roller (right and left)

Lubricate the left and right crawler idler rollers (Fig. 98) through the grease fittings located on the outside face of the crawler idler roller.

Fig. 98: Crawler idler roller

stabilizer shoe cylinder pin, lower (right and left)

Lubricate the lower stabilizer shoe cylinder pins (right and left) through the grease fittings located on the cylinder clevis (Fig. 99). Pump approximately 3 cu. in (50 cu. cm) of grease into each fitting.

© BUCYRUS AMERICA, INC.

Fig. 99: Lower stabilizer shoe cylinder pins (right and left) Stabilizer shoe cylinder pin grease fitting

Stabilizer shoe cylinder pin grease fitting

______________________________________________________________ A6474X326 VTSV/00 5.159

Maintenance _________________________________________________ stabilizer shoe cylinder pin, upper (right and left)

Lubricate the upper and lower stabilizer shoe cylinder pins (right and left) through the four grease fittings located on the lubrication block in the hydraulic compartment on the left side of the machine (Fig. 99).

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

conveyor raise cylinder pin, lower (left and right)

Lubricate the lower conveyor raise cylinder pins (right and left) through the grease fittings located on the left side of the conveyor (Fig. 99).

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

stabilizer shoe pivot pin

Lubricate the stabilizer shoe pivot pin through the grease fittings located on the lubrication panel (Fig. 99). Pump approximately 3 cu. in (50 cu. cm) of grease into each fitting.

© BUCYRUS AMERICA, INC.

Fig. 99: Upper stab shoe, lower conveyor raise cylinder, and stab shoe pivot pin lubrication

Left and right lower conveyor raise cylinder pin

Stab shoe pivot pin

Left and right upper stab shoe cylinder pin

_________________________________________________________________ 5.160 Bucyrus – Model 30M4-NP Continuous Miner

________________________________________________ Maintenance conveyor swing pivot pins

Lubricate the conveyor swing pivot pins through the four (4) grease fittings located each side of the conveyor (Fig. 100). Pump approximately 3 cu. in (50 cu. cm) of grease into each fitting.

© BUCYRUS AMERICA, INC.

Fig. 100: Conveyor swing pivot pin

Conveyor swing pivot pins lubrication fittings (4) (typical both sides)

gathering head raise cylinder pins

Lubricate the upper gathering head raise cylinder pins (Fig. 101) through the grease fittings located on each end of the cylinder. Pump approximately 3 cu. in (50 cu. cm) of grease into each fitting.

Fig. 101: Gathering pan raise cylinder pins (typical both sides)

Upper gathering head cylinder pin lubrication (typical both sides)

Lower gathering head cylinder pin lubrication (typical both side)

______________________________________________________________ A6474X326 VTSV/00 5.161

Maintenance _________________________________________________ CLA head pot assembly (right and left)

Level the miner and place the gathering head on grade before checking or adding lubricant. Check the oil level in the pot assembly (Fig. 102).

If oil is needed, add oil through the fill hole until oil comes out the breather.

CLA head transfer case (right and left)

Level the miner and place the gathering head on grade before checking or adding lubricant. Check the oil level in the hydraulic transfer case (Fig. 102). If oil is needed, add oil through the fill hole until oil comes out the breather.

Fig. 102: CLA head pot assembly and transfer case lubrication

Oil fill, transfer case

tram gear case (right and left)

Oil check, pot assembly

© BUCYRUS AMERICA, INC.

Oil fill, pot assembly

Oil check, transfer case

With the miner in a level position, check the oil level in both tram gear cases by looking at the sight glass located on the side of each gear case (Fig. 103). Oil should be visible in each sight glass. If oil level is low, add oil through either the fill pipe (accessed from the top of the machine) or the fill plug hole (accessed from the side of the machine).

Fig. 103: Tram gear case oil level (typical both sides)

Oil fill plug (typical both sides) Breather Oil level sight glass (typical both sides)

_________________________________________________________________ 5.162 Bucyrus – Model 30M4-NP Continuous Miner

________________________________________________ Maintenance input cutter gear case

With the gathering head lowered to ground level and the cutter head boom level with ground, check the oil level in both of the input cutter gear cases by removing the check plug located on each side of the cutter head assembly (Fig. 104). 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. 104: Input cutter gear case (s) oil level

© BUCYRUS AMERICA, INC.

Sight glasses (two per side)

Oil fill plug (typical both sides)

Oil level/check plug (typical both sides)

main cutter gear case

With the cutter head boom level with ground, check the oil level in both of the main cutter head gear cases by removing the check plug located on the front of each gear case (Fig. 105). 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. 105: Main cutter head gear case (s) oil level

Oil fill plug (One for each side)

Oil level/check plug (One for each side)

______________________________________________________________ A6474X326 VTSV/00 5.163

Maintenance _________________________________________________ hydraulic oil level

Check the hydraulic tank oil level (Fig. 106). 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. 106: Hydraulic oil tank level

© BUCYRUS AMERICA, INC.

Oil level dipstick

_________________________________________________________________ 5.164 Bucyrus – Model 30M4-NP Continuous Miner

________________________________________________ Maintenance Weekly The return, main pressure, and non-bypassing pilot pressure filters are located behind a cover on the right hand side of the machine (Fig. 107). return filter

The filter on the left is the return filter. Change the return filter element weekly. If the element is extremely dirty, a more frequent change interval may be required.

main pressure filter

The filter located in the middle is the main pressure filter. Change the main pressure filter element weekly. If the element is extremely dirty, a more frequent change interval may be required.

pilot pressure filter, non-bypassing

The filter on the right is the non-bypassing pilot pressure filter. Change the pilot pressure filter element weekly. If the element is extremely dirty, a more frequent change interval may be required.

© BUCYRUS AMERICA, INC.

Fig. 107: Filter locations

Return filter

Main pressure filter

Pilot pressure filter, non-bypassing

______________________________________________________________ A6474X326 VTSV/00 5.165

Maintenance _________________________________________________ pilot pressure filter, bypassing

The bypassing pilot pressure filter is located on the left hand side of the machine (Fig. 108). Change the pilot pressure filter element weekly. If the element is extremely dirty, a more frequent change interval may be

Pilot pressure filter, bypassing

_________________________________________________________________ 5.166 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

Fig. 108: Pilot pressure element, bypassing

________________________________________________ Maintenance water filter

The water filter is located near the back bumper on the right hand side of the machine (Fig. 110). Change the water filter element weekly. If the element is extremely dirty, a more frequent change interval may be required.

© BUCYRUS AMERICA, INC.

Fig. 110: Water filter location

Water filter

______________________________________________________________ A6474X326 VTSV/00 5.167

Maintenance _________________________________________________ crawler track tension

Check the crawler tracks for proper tension. If adjustment is necessary, see the Crawler track adjustment procedure in this chapter.

To check the track for proper tension:  Raise the complete crawler assembly off of the ground and securely block under the machine. The machine must be securely supported off the ground.

WARNING! Observe the safe working load limits of all blocking devices. You could be seriously injured or killed by falling loads.  Chain sage should be 64 to 89 mm (2-1/2 to 3-1/2 inches (89 mm) at the center of the crawler (Fig. 108).

Fig. 108: Crawler track tension measurement

conveyor chain tension

64 to 90 mm gap (2-1/2 to 3-1/2 inches)

Top of tram track

Check the conveyor chain tension with the machine running. The conveyor chain should rise about 51 mm (2 inches) or less above the gathering head foot shaft sprocket as the chain emerges from under the conveyor pan (Fig. 109). If adjustment is necessary, see the Conveyor chain tension adjustment procedure in this chapter.

Fig. 109: Conveyor chain tension measurement

Chain measurement area

_________________________________________________________________ 5.168 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

Bottom of tractor wear shoe

________________________________________________ Maintenance fasteners

© BUCYRUS AMERICA, INC.

electrical cables, conduits, and glands hoses and fittings

The miner is subjected to continual shock loading and vibration and close attention to all mounting bolts and screws is required. Loose fasteners will cause premature wear and failure of bearings, couplings, etc. Inspect the fasteners for the following and tighten as required : ■

Cutter head gear case

■

Cutter head motors

■

Center drums

■

End drums

■

Tram cases

■

Tram motors

■

Gathering head CLAs

■

Gathering head pots

■

Gathering head motors

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

Visually inspect and hydraulic and water hoses and fittings for signs of wear, damage, or leakage. This inspection should be performed with the machine running. Observe the following precautions/procedures while checking for leaks: ■ ■ ■

Relieve pressure before disconnecting hoses.

Check for leaks with a piece of cardboard. Do not use hands.

Do not exceed the working pressure of hydraulic hoses.

WARNING! Use extreme caution when inspecting for leaks with the machine running. Unexpected machine movement, or contact with moving parts, could result in injury.

Escaping fluids under pressure can penetrate skin and cause serious injury. Do not attempt to locate hydraulic leaks be feeling hoses and fittings with bare hands. Pin hole leaks can penetrate the skin. lighting

Turn on the lights and visually inspect for bulbs that need to be replaced.

reflectors and warning tags

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

machine stop switches

Check the machine stop switches located on each side of the machine for proper operation. Start the machine and strike the switch; the machine pump motor will shutdown, in turn shutting down all other motors.

Repeat for each of the four switch.

______________________________________________________________ A6474X326 VTSV/00 5.169

Maintenance _________________________________________________ Monthly CLA head pot assembly

Change the oil in both CLA head pot assemblies (Fig. 111).  Level the miner, raise the gathering head pan, and secure in place.  Clean dirt and debris from around the drain plug located under the gear case.  Remove the drain plug and allow oil to completely drain from the gear case.  Clean and reinstall drain plug.  Clean dirt and debris from around the check plug and remove the plug.

 Slowly add oil through the fill plug until oil begins to flow from the check plug hole. Allow sufficient time for the oil to ravel through the gear case when filling.  Clean and reinstall the check and fill plugs.

CLA head transfer case

Change the oil in both CLA head transfer cases (Fig. 111).  Level the miner, raise the gathering head pan, and secure in place.  Clean dirt and debris from around the drain plug located under the gear case.  Remove the drain plug and allow oil to completely drain from the gear case.  Clean and reinstall drain plug.  Slowly add oil through the fill plug until oil is visible in the sight glass. Allow sufficient time for the oil to ravel through the gear case when filling.  Clean and reinstall the fill plugs.

NOTICE! If the gear case is scheduled for oil drain and refill, obtain the oil sample prior to the oil change.

IMPORTANT! Always collect oil samples using a siphon pump. Do not remove the drain plug and collect oil by allowing it to run out into the bottle.

_________________________________________________________________ 5.170 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

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

________________________________________________ Maintenance Fig. 111: CLA pot assembly and input transfer case

© BUCYRUS AMERICA, INC.

Oil check, pot assembly

Oil fill, transfer case

Oil fill, pot assembly

Oil check, transfer case

______________________________________________________________ A6474X326 VTSV/00 5.171

Maintenance _________________________________________________ input cutter head gear case

Change the oil in both input cutter head gear cases (Fig. 112).  Position the cutter head horizontally (flat back in a vertical position).

Clean dirt and debris from around the drain plug located under the gear case.  Remove the drain plug and allow oil to completely drain from the gear case.  Clean and reinstall the drain plug.  Clean dirt and debris from around the check plug and remove the plug.  Clean dirt and debris from around the fill plug and remove the plug.  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.

Fig. 112: Input cutter head gear case Oil fill plug (One for each side) Flat back

Sight glasses (Two for each side)

Oil level/check plug (One for each side)

NOTICE! If the gear case is scheduled for oil drain and refill, obtain the oil sample prior to the oil change.

IMPORTANT! Always collect oil samples using a siphon pump. Do not remove the drain plug and collect oil by allowing it to run out into the bottle.

_________________________________________________________________ 5.172 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

 Clean and reinstall the check and fill plugs.

________________________________________________ Maintenance main cutter head gear case

Change the oil in both main cutter head gear cases (Fig. 113).  Lower the cutter head completely to the ground. Clean dirt and debris from around the drain plug, located under the gear case.  Remove the drain plug and allow oil to completely drain from the gear case.  Clean and reinstall the drain plug.  Clean dirt and debris from around the check plug and remove the plug.  Clean dirt and debris from around the fill plug and remove the plug.  Slowly add oil through the fill plug until oil begins to flow from the check plug hole. Allow sufficient time fro the oil to travel throughout the gear case when filling.

© BUCYRUS AMERICA, INC.

 Clean and reinstall the check and fill plugs.

Fig. 113: Main cutter head gear case

Oil fill plug (One for each side)

Oil level/check plug (One for each side)

Oil drain plug (One for each side)

______________________________________________________________ A6474X326 VTSV/00 5.173

Maintenance _________________________________________________ CLAs

Inspect the CLAs (Fig. 114) for damage. If a CLA needs replaced, see CLA removal and installation procedure in this chapter.

Fig. 113: CLAs (typical)

CLA

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

One sample bottle and collection hose is required for each gear case to be sampled. Label each container with the identifying name of the gear case (crawler gear case, left or cutter head gear case, right front, etc.).

Collection of oil samples NOTICE! If the gear case is scheduled for oil drain and refill, obtain the oil sample prior to the oil change.

Each oil sample should be taken while the oil is at normal operating temperature. If the machine has not been operating just prior to sampling, run the machine until oil temperature reaches approximate normal operating temperature. Shutdown the machine and allow 2 - 3 minutes for the oil to drain back and stabilize it’s level.

IMPORTANT! Always collect oil samples using a siphon pump. Do not remove the drain plug and collect oil by allowing it to run out into the bottle.

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© BUCYRUS AMERICA, INC.

Oil sampling plan

________________________________________________ Maintenance IMPORTANT! Always use the collection hose provided with each bottle. Always discard hose immediately following collection of the oil and do not use it for the next sample. To do so will contaminate the next sample with oil from the previous sample.

After taking sample, check and refill gear case back to proper fill level.

Following collection of all oil samples, record the specific brand and product name of the lubricant that has been installed in each gear case.

© BUCYRUS AMERICA, INC.

Recommended gear cases to be sampled: ■

Input cutter head gear case (left and right)

■

Main cutter head gear case (left and right)

■

Input gathering head gear case (left and right)

■

Main gathering head gear case (left and right)

■

Main hydraulic oil tank

■

Crawler idler roller

Fig. 115: Oil sampling procedure 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

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Maintenance _________________________________________________ Every three months IMPORTANT! For motor bearings that require high temperature lithium complex grease (Spec. 100-15), Bucyrus provides a special “button” style lubrication fitting (Fig. 116) to prevent the accidental use of multipurpose lithium complex grease at these locations. cutter motor bearings

Lubricate the left and right cutter head motor bearings with high temperature lithium complex grease through the two grease fittings located on each side of the cutter head (Fig. 116) using the following procedure:  Open the cover (Fig. 116) to access the motor.  Inspect the grease fittings on the exit side of the front and rear motor bearing.

Lubricate both motor bearings until new grease appears out of the relief ports on the exit side of the bearing.  Operate the motor for five (5) minutes and then inspect for grease leaks in the bearing area.

If the exit side motor bearing ports are equipped with plugs, then:  Remove the plug and lubricate both motor bearings until new grease appears out of the relief ports on the exit side of the bearing.  Operate the motor for five (5) minutes and then inspect for grease leaks in the bearing area.  Replace the plugs in the ports.

NOTICE! Incorrect grease or over greasing of the electric motor may cause serious damage to the motor. Follow the greasing procedure outlined above.

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© BUCYRUS AMERICA, INC.

If the exit side motor bearing ports are equipped with spring load relief fittings, then

________________________________________________ Maintenance Fig. 116: Cutter motor bearing lubrication (typical each side)

© BUCYRUS AMERICA, INC.

Cutting head motor grease fittings (two per side)

Button type grease fitting

Spring loaded grease relief fitting

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Maintenance _________________________________________________ gathering head motor bearings

Lubricate the left and right gathering head motor bearings with high temperature lithium complex grease through the two grease fittings located on each motor (Fig. 117).

To lubricate the motors:  Open the cover (Fig. 117) to access the motor.  Inspect the grease fittings on the exit side of the front and rear motor bearing.

If the exit side motor bearing ports are equipped with spring load relief fittings (Fig. 117), then Lubricate both motor bearings using the button type grease fitting until new grease appears out of the relief ports on the exit side of the bearing.

If the exit side motor bearing ports are equipped with plugs, then:  Remove the plug and lubricate both motor bearings using the button type grease fitting until new grease appears out of the relief ports on the exit side of the bearing.  Operate the motor for five (5) minutes and then inspect for grease leaks in the bearing area.  Replace the plugs in the ports.

NOTICE! Incorrect grease or over greasing of the electric motor may cause serious damage to the motor. Follow the greasing procedure outlined above.

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© BUCYRUS AMERICA, INC.

 Operate the motor for five (5) minutes and then inspect for grease leaks in the bearing area.

________________________________________________ Maintenance

© BUCYRUS AMERICA, INC.

Fig. 117: Gathering head motor bearing lubrication (typical each side)

Gathering head motor grease fitting (one per side)

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

Button type grease fitting

Spring loaded grease relief fitting

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Maintenance _________________________________________________ pump motor bearings

Lubricate the pump motor (Fig. 118) with high temperature lithium complex grease (Spec. 100-14) through the two (2) grease fittings located the left side of the machine using the following procedure:  Open the cover (Fig. 118) to access the motor.  Lubricate both bearings using the grease fittings on the side of the miner until new grease appears out of the relief ports on the exit side of the bearing.  Operate the motor for five (5) minutes and then inspect for grease leaks in the bearing area.  Replace the motor access cover.

NOTICE! Incorrect grease or over greasing of the electric motor may cause serious damage to the motor. Follow the greasing procedure outlined above. © BUCYRUS AMERICA, INC.

Fig. 118: Pump motor bearings

Pump motor grease fitting (2)

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________________________________________________ Maintenance scrubber motor bearings

Lubricate the fan motor bearings (Fig. 119) with high temperature lithium complex grease (Spec. 100-14) through the fitting located on the lubrication block located on the rear left side of the machine: IMPORTANT! For motor bearings that require high temperature lithium complex grease (Spec. 100-15), Bucyrus provides a special “button” style lubrication fitting to prevent the accidental use of multi-purpose lithium complex grease at these locations.   Remove the cover to access the motor.  Lubricate both motor bearings using the button type fittings (Fig. 118) until new grease appears out of the relief port on the exit side of the bearing.  Operate the motor for five minutes.

© BUCYRUS AMERICA, INC.

 Inspect for any grease leakage in the area around the bearing.  Replace the motor access cover.

Fig. 119: Scrubber motor

Scrubber motor grease fitting

Scrubber motor grease fitting

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Maintenance _________________________________________________ Every six months tram gear case

Change the oil in both tram gear cases (Fig. 120).  Remove the drain plug and allow oil to completely drain from the gear case.  Clean and reinstall the drain plug.  Replace the breather, located in the fill tube.  Remove the fill plug located on top of the gear case or on the tram brake gear case.  Add oil through the fill plug hole until oil is visible in the sight glass.

When filling, allow sufficient time for the oil to travel throughout the gear case.

Fig. 120: Tram gear case Oil fill plug

Breather

Oil level sight

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© BUCYRUS AMERICA, INC.

 Clean and reinstall the fill plug.

________________________________________________ Maintenance crawler idler roller (s)

Change oil in both crawler idler rollers. (Fig. 121).  Rotate idler roller until the two (2) pipe plugs are positioned at the 3 o-clock and 9 o-clock position.  Remove drain plug and allow oil to completely drain from the crawler idler roller.  Clean and reinstall drain plug.  Remove both fill plugs.  Add oil through either of the fill plug holes until oil begins to flow from the other. Allow sufficient time for the oil to travel throughout crawler idler roller when filling.

Fig. 121: Crawler idler roller oil change

© BUCYRUS AMERICA, INC.

Oil fill/check plug (One for each side)

Oil level/check plug (One for each side)

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Maintenance _________________________________________________ hydraulic oil, suction strainer, and breather

Change the oil in the hydraulic oil tank (Fig. 122).  Remove drain plug and allow oil to completely drain from the tank.  Clean and reinstall drain plug.  Remove and replace the breather.  Refill the tank manually with oil (Quintolubric 88-68 or Condat D68) 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.

Fig. 122: Hydraulic oil tank Oil level dipstick © BUCYRUS AMERICA, INC.

Breather

gear case breathers

Change the breathers on the main and input cutter gear cases, the CLA head pot and transfer gear cases, and the tram gear cases.

strainer back flushing stranier

Clean and replace as required the water strainer and the back flushing strainer.

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_______________________________________ Adjustment procedures

© BUCYRUS AMERICA, INC.

Setting hydraulic pressures ■

Always refer to the hydraulic schematic in the Bucyrus America, Inc. parts book supplied with your miner.

■

Most relief valves are set to factory specifications and should require no further adjustment. If a problem occurs which requires the relief valves to be adjusted, make certain the correct procedures are followed and all work is performed by a qualified person.

■

Generally speaking, when adjusting relief valves, turning the adjusting screw in (clockwise) will increase the pressure setting. The instructions in this manual are based on this general principle.

■

If the valve pressure setting is unknown, always adjust the valve fully counterclockwise prior to initiating any action that will create flow and prove the potential for pressure. This will allow the pressure setting to be achieved in a safe, controlled manner.

WARNING! Use extreme caution when performing test procedures and making adjustments. Unless noted in the procedures, all controls are to be in the neutral position.

The miner is equipped with nine (9) hydraulic pressure gauges to aid in setting relief pressures. Three of the gauges have a redundant gauge: one located in the pit and one located on the hydraulic shelf. The gauges measure the following pressures: ■

cutter head pressure (part of the cutter head circuit)

■

main pressure (all functions of the MCV) - 2 gauges

■

pilot pressure

■

brake cooling pressure

■

conveyor chain take-up pressure

■

anti-chatter/maintenance (shear down) pressure

■

gathering head float/relief pressure

■

cylinder load pressure

There will be occasions when relief valves, or other pressure control valves, must be set or adjusted. Setting relief valve pressure is necessary when a relief valve is replaced with a new unit or when an existing relief valve needs to be adjusted, for example, during the course of troubleshooting a hydraulic system fault. To properly adjust a relief valve, the circuit must be “dead-headed”. This section describes the proper procedure for setting the relief valves.

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Adjustment procedures ________________________________________ IMPORTANT! Always use the proper tools when adjusting valve cartridges.

IMPORTANT! Do not start any motors - CLA, cutter head, pump, or traction motors - until all pressures are set. Start the pump motor as directed.

Load holding valve adjustment The load holding valve is factory preset and should not be field adjusted.

Always refer to your parts manual when ordering load holding valves for the cutter or conveyor cylinders.

The adjustment procedure should start with the pilot pressure circuit.

This system is a “closed center” circuit (except for the brake cooling portion) and will build pressure as soon as the pump is started. The primary pressure circuits are “open center” circuits and very little pressure is present until a function is activated. The main relief valve on the main control valve (MCV) and high speed cutter head raise control valve, as well as the pilot pressure relief and brake cooling circuit pressure reducing valve, should all be adjusted to their lowest setting prior to initial start up and adjustment. Reference circuit descriptions, abbreviations, and terms in the Hydraulic section of this chapter.

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WARNING! Never rely on the load holding valve as a means of supporting the cutter or conveyor boom while making repairs. Severe injury or death could result.

_______________________________________ Adjustment procedures Pilot pressure circuit relief/reducing valve adjustments The following procedure is for start up of new and rebuilt machines.

IMPORTANT! Reference the Hydraulic section in this chapter for individual circuit information. Always refer to the hydraulic schematic in your Bucyrus America, Inc. parts manual for your miner.

WARNING! Two people are required to adjust pressure settings. One person will make the adjustments while the second person must remain at the machine stop at all times during the adjustment procedure. Failure to do so may result in serious injury or death.

© BUCYRUS AMERICA, INC.

 1. Pilot pressure  a. Loosen the nut on the pilot pressure relief valve cartridge and turn the screw fully out (counterclockwise) using an Allen wrench to ensure a low pressure start up condition and to prevent over pressuring the gauge on this circuit.  b. Remove the hex socket head plug on the conveyor chain take up relief/reducing valve section of the multipurpose valve. Using an Allen wrench, turn the screw fully out (counterclockwise) to ensure that the pressure in this circuit is at its minimum setting.  c.

Loosen the nut on the brake cooling pressure relief/ reducing valve cartridge and, using an Allen wrench, turn the screw full out (counterclockwise) to ensure a low pressure start up condition on this circuit.

 d. Close both needle valves on the brake cooling circuit.  e. Start the pump motor (see Start up procedure in this chapter).  f.

Adjust the pilot pressure relief valve by turning the screw clockwise until the system pilot pressure reaches the setting specified on the hydraulic schematic.

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Adjustment procedures ________________________________________

  2. Brake cooling pressure  a. Ensure Pilot pressure adjustment steps 1c and 1d have been completed.  b. Adjust the screw on the brake cooling pressure relief/ reducing valve until the pressure reaches the setting specified on the hydraulic schematic. this valve is used to prevent over pressurization of the brake cooling cavity which results in leakage at the shaft seal of the brake.  c.

Open both brake cooling valves approximately one (1) turn.

 d. If more cooling is required, open the needle valves accordingly to increase the cooling flow rate. To decrease the cooling rate, close the needle valves.  e. Tighten lock nut after adjusting.

 a. Ensure Pilot pressure adjustment step 1b has been completed.  b. Adjust the screw on the conveyor chain-take up pressure reducing/relieving valve, located in the multipurpose valve, until the pressure reaches the setting specified on the hydraulic schematic.

Fig. 123: Multi-purpose valve - conveyor chain take-up adjustment

Conveyor chain take-up pressure reducing valve

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© Bucyrus America, Inc.

 3. Conveyor chain take-up pressure (Fig. 123)

_______________________________________ Adjustment procedures Directional control valve pressure adjustments (main control valve and cutter head) Each valve section has two (2) working port reliefs except for the gathering head section. When the handle is raised, oil is directed to the upper work port and relief; this is “A” port. When the handle is lowered, oil is directed to the lower work port and relief; this is ‘B” port.

WARNING! Always allow cylinder functions to bottom out (stop moving) before adjusting any pressure. Pressure adjustments will only be accurate when the cylinder is in this condition.

© BUCYRUS AMERICA, INC.

Main control valve (MCV) adjustment IMPORTANT! The main inlet relief is set higher than the port reliefs and will only relieve if a spike occurs in the system or if the port relief does not function properly. This provides protection of the main pump section, A2.

CAUTION! Do not adjust the main inlet relief over 207 bar (3,000 psi). Destruction of the valve bank and the main pump could result.

CAUTION! Always be alert for any unintended machine movement.

IMPORTANT! Reference the Hydraulic section in this chapter for individual circuit information. Always refer to the hydraulic schematic in your Bucyrus America, Inc. parts manual for your miner.

WARNING! Two people are required to adjust pressure settings. One person will make the adjustments while the second person must remain at the machine stop at all times during the adjustment procedure. Failure to do so may result in serious injury or death.

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Adjustment procedures ________________________________________

■

The procedure will raise the machine off the ground. Be careful to keep body parts clear from under the machine while it is raised off the ground.

■

During the adjustment procedure, pump output pressure and flow will be relieved past either the main relief or the stabilizer extend port relief which will cause rapid heating of the hydraulic oil. Preparation should be made to perform the adjustment procedure efficiently and in a relatively short period off time. It may be necessary to wait several minutes between adjustment periods.

■

It is critical that the stabilizer extend port relief valve be adjusted back to its proper setting after the main relief is adjusted. This procedure is described in detail below.

MCV Main inlet relief adjustment  Loosen the nut on the adjusting screw on the near port relief (stab shoe down) of the stabilizer working section and turn the adjusting screw in all the way.  Loosen the nut on the main inlet relief cartridge. Turn the main inlet relief adjusting screw two turns clockwise.  Start the pump (see Start up procedure in this chapter) and activate the stabilizer shoe down function. This will raise the back portion of the machine off the ground.

WARNING! Keep body parts clear of machine while in raised position or serious injury could result.  With the stabilizer shoe down function bottomed out, turn the main relief cartridge adjusting screw in (clockwise) until a pressure of 207 bar (3,000 psi) is obtained.  With the stabilizer shoe function in the neutral position, hold the main relief cartridge screw in place and tighten the nut to lock the screw in place. Check the pressure setting to verify that the screw was not moved while tightening the nut.  Adjust the stabilizer shoe down port relief (see Port relief adjustment procedure in this chapter).

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© Bucyrus America, Inc.

To properly adjust any relief valve, the hydraulic system must be “dead headed”. Dead heading MCV functions is achieved by actuating a cylinder function and allowing it to travel to its full stroke position (either extended or retracted). To set the main system relief, it is recommended that the stabilizer shoe cylinder be extended until it is dead headed. Since the stabilizer section of the main control valve is equipped with a port relief in the extend circuit, the port relief must be temporarily adjusted to a pressure setting higher than the main relief.

This procedure is described in detail below. Caution must be exercised when performing this procedure with particular attention being paid to the following:

_______________________________________ Adjustment procedures Note: The pressure settings given in this manual are typical. Always refer to the schematic and/or parts book for your machine.

Port relief valve adjustment - Main control valve Port relief valves are functional when operating the circuit in which they are installed. As the particular function is activated and the pressure reaches the adjusted setting, the port relief will relieve excessive pressure to the tank cavity within the valve bank, preventing damage to the circuit.

WARNING! Always allow function to bottom out and stop moving before adjusting any pressure.

© BUCYRUS AMERICA, INC.

If the correct pressure reading is not obtained as noted in Items 1 through 4 below, the port relief for that function must be adjusted.

The adjustment procedure for each port relief is the same and is:  Remove the protective cap on the port relief and loosen the nut on the adjusting screw.  Turn the port relief screw in (clockwise) to increase pressure and out (counter-clockwise) to decrease pressure.  Once the correct pressure reading is obtained, return the function to the neutral position, hold the screw in place, and tighten the lock nut. Check the pressure reading to ensure that the screw did not turn while the lock nut was being tightened.  All pressure settings in this procedure refer to the load sense gauge.

WARNING! Keep body parts clear of machine while in raised position or serious injury could result.

Pressure settings 1. Conveyor raise/lower port relief  Activate the conveyor raise circuit to fully raise the conveyor.

The load sense pressure gauge should read 145 bar (2,100 psi).  Activate the conveyor lower circuit to fully lower the conveyor.

The load sense pressure gauge should read 27 bar (400 psi).

Note: Be sure that the ball valve is closed on the tank oil fill part of this circuit.

Note: The conveyor raise section is also equipped with a pressure limiter adjustment. See Pressure limiter adjustment procedure in this section.

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Adjustment procedures ________________________________________ 2. Conveyor swing port relief  Activate the conveyor swing left circuit to fully swing the conveyor to the left. The load sense pressure gauge should read 172 bar (2,500 psi).  Activate the conveyor swing right circuit to fully swing the conveyor to the right. The load sense pressure gauge should read 172 bar (2,500 psi).

Note: The conveyor swing section is also equipped with a pressure limiter adjustment. See Pressure limiter adjustment procedure in this section.

3. Stabilizer shoe port relief

 Activate the stabilizer shoe lower circuit allow to fully lower the stabilizer shoe. The load sense pressure gauge should read 193 bar (2,800 psi).

4. Gathering head port relief  Activate the gathering head raise circuit to fully raise the gathering head. The load sense pressure gauge should read 117 bar (1,700 psi).  If 117 bar (1,700 psi) is not obtainable, check that the relief in the gathering head float valve that is stamped “CR” is set to 124 bar (1,800 psi) (see Gathering head raise/hold/float-lower circuit in the Hydraulic section of this chapter).

5. Cutter head directional control valve pressure adjustment  Activate the cutter head raise circuit to fully raise the cutter head. The load sense pressure gauge should read 207 bar (3,000 psi).  Activate the cutter head lower circuit to fully lower the cutter head and raise the front of the machine off the ground. The load sense pressure gauge should read 207 bar (3,000 psi).

6. High speed cutter head control valve  Loosen the nut on the adjusting screw on the lower port relief (cutter head down) of the high speed cutter head raise section.   Remove the protective cap from the inlet relief cartridge. turn the main inlet relief adjusting screw two (2) turns clockwise.  Start the pump (see Start up procedure in this chapter) and activate the cutter head down function using the manual control lever on the high speed cutter control valve. _________________________________________________________________

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Bucyrus – Model 30M4-NP Continuous Miner

© Bucyrus America, Inc.

 Activate the stabilizer shoe raise circuit to fully raise the stabilizer shoe. The load sense pressure gauge should read 97 bar (1,400 psi).

_______________________________________ Adjustment procedures WARNING! Keep body parts clear of machine while in raised position or serious injury could result.

  With the cutter head fully lowered, turn the main pressure relief cartridge in (clockwise) until a pressure of 207 bar (3,000 psi) is obtained.  With the high speed cutter head raise function in the neutral position, hold the main relief cartridge screw in place and tighten the nut to lock the screw in place.  Check the pressure setting to verify that the screw was not moved while tightening the nut.  Set the port reliefs on the high speed cutter head raise control valve (see Cutter head port relief adjustment procedure in this section).

© BUCYRUS AMERICA, INC.

Pressure limiter adjustments 1. Conveyor raise/lower pressure limiter  Activate the conveyor raise circuit to fully raise the conveyor.

The load sense pressure gauge should read 145 bar (2,100 psi) as specified in the relief adjustment section.  Adjust the pressure limiter until the pressure reading on the load sense gauge is 124 bar (1,800 psi).

Note: If the initial pressure reading of the conveyor raise function is less than 145 bar (2,100 psi), the pressure limiter may already be set at a lower value. Increase the setting of the pressure limiter until it is possible to change the pressure reading by adjusting the port relief. DO NOT adjust the relief or pressure limiter to a value above 172 bar (2,500 psi). Then set the pressure setting of the relief as specified in the Port relief valve adjustment procedure in this section.

2. Conveyor swing pressure limiter  Activate the conveyor swing circuit to fully swing the conveyor to the left. The load sense pressure gauge should read 172 bar (2,500 psi) as specified in the relief adjustment section.  Adjust the pressure limiter until the pressure reading on the load sense gauge is 124 bar (1,800 psi).

Note: If the initial pressure reading of the conveyor swing function is less than 172 bar (2,500 psi), the pressure limiter may already be set at a lower value. Increase the setting of the pressure limiter until it is possible to change the pressure reading by adjusting the port relief. Then set the pressure setting of the relief as specified in the Port relief valve adjustment procedure in this section.

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Adjustment procedures ________________________________________ Multipurpose Valve Adjustments The multipurpose (Fig. 124) has three distinct sections controlling the following functions: ■

Anti-chatter/maintenance (shear down) pressure

■

Gathering head float/relief pressure

■

Conveyor chain take up pressure

The adjustment procedures for these functions are as follows: IMPORTANT! Reference the Hydraulic section in this chapter for individual circuit information. Always refer to the hydraulic schematic in your Bucyrus America, Inc. parts manual for your miner.

Anti-chatter/maintenance (shear down) pressure

 Loosen the nut on the counterbalance valve on the anti-chatter/ maintenance section of the multipurpose valve and turn the screw using an Allen wrench. To increase the resistance (back pressure), turn the screw clockwise. To decrease the resistance, adjust the screw counterclockwise.  Raise the cutter head to its fully raised position. While lowering the cutter head, the “CH DOWN” pressure gauge displays the pressure setting of the counterbalance valve. This back pressure should be kept high enough to prevent the cutter head from chattering (bouncing) during the lower cycle but low enough to allow free movement of the cutter head. This setting is typically around 83 bar (1200 psi).

Fig. 124: Multi-purpose valve

Gathering head adjustment “CR” (CR)

(VR)

Anti-chatter valve adjustment

Gathering head adjustment “VR”

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© Bucyrus America, Inc.

 To adjust the resistance to a free falling cutter head:

_______________________________________ Adjustment procedures Gathering head float/relief pressure (Fig. 124)  Remove the hex socket head plugs on the counterbalance valve (VR) and relief valve (CR) located in the gathering head float/relief section of the multipurpose valve. To increase the pressure on these valves, use an Allen wrench to turn the screw clockwise. To decrease the pressure on these valves, turn the screw counterclockwise. Start off with both of these valves at a low pressure setting.  To adjust the gathering head float relief valve (VR):

© BUCYRUS AMERICA, INC.

 Eenergize the gathering head raise solenoid (or move the valve handle to the gathering head raise position).  Increase the pressure setting on the gathering head relief valve until the gathering head responds in a crisp manner and is fully extended. The gathering head must be able to maintain its raised position when the telescopic cylinder is fully extended and the gathering head section of the MCV is in the hold (neutral) position.  The gathering head float function is adjusted with the gathering head cylinder in its fully extended position. From this position: 

Energize the gathering head float solenoid (or move the handle to the gathering head float position). To decrease the speed at which the gathering head floats to the ground, increase the pressure setting on the gathering head counterbalance valve (CR). To increase the speed at which the gathering head floats to the ground, decrease the pressure setting on the gathering head counterbalance valve (CR). This back pressure also prevents the pan from digging into the ground during tramming/operation. Adjusting this valve requires a compromise between float speed and the tendency of the pan to dig into the ground.

Conveyor chain take up pressure See Pilot Pressure Adjustment Procedure in this section. To bleed off any pressure in this circuit, open the needle valve to connect the cylinder extend port to tank.

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Adjustment procedures ________________________________________ Tram track adjustment  1. Lower the conveyor tail section until it is level with the floor.  2. Raise the gathering head and cutter head and block both assemblies following standard blocking procedures.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all blocking devices.  3. Lower the gathering head and cutter head onto the blocking so that the front end of the miner lifts off the floor.  4. Extend the stabilizer completely so that the rear end of the miner lifts off the floor.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load of all blocking devices.  6. Raise the stabilizer, gathering head, and cutter head assemblies so that the weight of the miner rests on the blocking.  7. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine lockout/tagout regulations.

WARNING! Follow all Federal and mine lockout/tagout regulations and procedures. Failure to do so could result in machine damage or serious injury or death to personnel.  8. Double check the tractor frame support blocking now that the weight of the tractor frame is completely upon it.  9. Evaluate the tram track for proper tension (Fig. 122). The tram track is at the proper tension when it hangs approximately 64 to 89 mm (2-1/2 to 3-1/2 inches) from the bottom wear shoes when the tractor frame is blocked off the floor. Using this evaluation, determine whether step 13, 14, or 15 provides the appropriate sub-procedure to correct improper track tension.

Fig. 122: Tram track adjustment Bottom of tractor wear shoe

64 to 90 mm gap (2-1/2 to 3-1/2 inches)

Top of tram track

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© Bucyrus America, Inc.

 5. Securely block under the machine. The machine must be securely supported off the ground with the tram track free to turn.

_______________________________________ Adjustment procedures

  10. Locate the front idler take-up jack grease fitting and attach the grease gun to the fitting (Fig. 123).

© BUCYRUS AMERICA, INC.

 11. If the tram track tension is too tight, readjust the idler position using the following steps: ■

Pump grease into the take-up jack to extend the cylinder and remove pusher plate pressure on the idler shims.

■

Remove one or more idler adjustment shims from the idler slide channel.

■

Open the pressure release valve for the front idler take-up jack and allow the jack to contract (Fig. 123). The pusher plate will slide backwards until it is stopped by the remaining idler shims.

■

Pump grease into the idler take-up jack to extend the cylinder, move the idler assembly forward and tighten the tram track until it is at the correct tension. The tram track is at the proper tension when it hangs 64 to 89 mm (2-1/2 to 31/2 inches) from the bottom wear shoes when the tractor frame is blocked off the floor.

 12. If the tram track is too loose, readjust the idler position using the following steps: ■

Pump grease into the idler take-up jack to extend the cylinder, move the idler assembly forward and tighten the tram track until it is at the correct location. The tram track is at the proper tension when it hangs 64 to 89 mm (2-1/2 to 31/2 inches) from the bottom wear shoes when the tractor frame is blocked off the floor.

■

Insert shims (Fig. 123) into the idler slide channel until the space between the tractor frame and the pusher plate is filled.

■

Open the pressure release valve for the front idler take-up jack and allow the cylinder to contract. The idler adjustment shims will keep the idler stationary and the track tensioned.

■

Evaluate the resulting track tension and repeat these steps until the track reaches proper tension.

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Adjustment procedures ________________________________________

 CAUTION! Shims must be inserted completely into the idler slide channel. A shim that is not correctly seated on the idler slide channel’s inside surface provides uneven support that can cause idler slant. A slanted idler can cause uneven wear and stress on the tram track and can cause improper operation of or damage to the tram system.

IMPORTANT! Check that the shims are correctly seated on the idler slide channel’s inside surface by looking at the channel’s inside surface from the opposite side of the miner through the space between the gathering head and the idler assembly.

Fig. 123: Tram track adjustment Crawler chain take-up lubrication

Pressure relief valve

© Bucyrus America, Inc.

Take-up cylinder

Shims

Idler assembly

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_______________________________________ Adjustment procedures

  13. If the tram track tension is still too loose when the entire 5” shim set is inserted into the idler slide channel, re-adjust the idler position after removing a tram track link using the following steps:  Pump grease into the take-up jack to extend the cylinder and remove the pusher plate pressure on the idler shims.  Remove all of the idler adjustment shims from the idler slide channel.  Open the pressure release valve for the front idler take-up jack and allow the cylinder to contract.  The tram track tension should now be reduced and separation of the tram track will be easier.  Locate a tram track link near the tram idler.

© BUCYRUS AMERICA, INC.

 Remove the two capscrews and nuts (Fig. 124) that secure the tram track link to the track.  Remove the tram track pins to disconnect the link from the track. Remove the disconnected link.  Store the tram track link, one of the tram track pins and two capscrews and nuts in a safe place.  Connect the two ends of the tram track and secure the two end links together with the remaining tram track pin.  Secure the tram track pin between the two links with the remaining two capscrews and nuts.  Pump grease into the idler take-up jack to extend the cylinder, move the idler assembly forward and tighten the tram track until it is at the correct tension. The tram track is at the proper tension when it hangs approximately 64 to 89 mm (2-1/2 to 3-1/2 inches) from the bottom wear shoes when the tractor frame is blocked off the floor.  Insert shims into the idler slide channel until the space between the tractor frame and the pusher plate is filled.  Open the pressure release valve for the front idler take-up jack and allow the cylinder to contract. The idler adjustment shims will keep the idler stationary and the track tensioned.  The idler adjustment shims will keep the idler stationary and the track tensioned.  Evaluate the resulting track tension and repeat until the track reaches proper tension.

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Adjustment procedures ________________________________________ Fig. 123: Tram track adjustment

Track retention pin

Capscrew and nut

 14. When the tram track has been adjusted to the proper tension, remove the grease gun from the idler take-up jack grease fitting.  15. Open pressure release to take pressure off of take-up cylinder.  16. Connect the trailing cable to energize the miner.  17. Raise the tractor frame off the blocking by lowering the stabilizer and gathering head and cutter head assemblies.  18. Carefully remove the support blocking from under the tractor frame.  19. Lower the tractor frame onto the floor by raising the stabilizer and gathering head and cutter head assemblies.  20. Carefully remove the blocking from underneath the raised stabilizer, gathering head, and cutter head assemblies.

_________________________________________________________________ 5.200 Bucyrus – Model 30M4-NP Continuous Miner

© Bucyrus America, Inc.

Pad

_______________________________________ Adjustment procedures Tail shim adjustment As the conveyor wears the tail section may sag relative to the conveyor front section. The conveyor has been designed to allow correction of the sag by adding shims.  1. Lower the cutter head and gathering head assemblies until they touch the floor.  2. Position the conveyor tail section directly behind the miner and raise it to its highest position.  3. Insert blocking under the tail section and lower the tail onto the blocking. The conveyor should be at an angle with the rear end of the tail section slightly higher than the front.

© BUCYRUS AMERICA, INC.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all blocking devices.  4. Insert blocking between the top of the tractor frame and the bottom of the conveyor, leaving about 51 mm (2 inches) of space between the blocking and the conveyor bottom.  5. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine lockout/tagout regulations.

WARNING! Follow all Federal and mine lockout/tagout regulations and procedures. Failure to do so could result in machine damage or serious injury or death to personnel. 

6. Loosen the socket head capscrews that secure the shims between the shim retainer and the conveyor lower pivot plate (Fig. 125).

Fig. 125: Shim removal Socket head capscrews

Lower pivot plate

Shim retainer

Shims

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Adjustment procedures ________________________________________

  7. Connect the trailing cable to energize the miner.

WARNING! The following steps releases the shims, which will fall free. Watch out for falling shims when loosening the capscrews.  8.

Slowly lower the conveyor slightly so that the front section rests on the frame support blocking. The slotted shims will now fall free.

 9.

Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine lockout/tagout regulations.

WARNING! Follow all Federal and mine lockout/tagout regulations and procedures. Failure to do so could result in machine damage or serious injury or death to personnel.  10. Replace the removed shims (Fig. 125) and add the number of shims required to level the conveyor front and tail sections.

Fig. 125: Tail shim adjustment

Socket head capscrews

Shim retainer

Shims

Lower pivot plate

 12. Connect the trailing cable to energize the miner.  13. Raise the conveyor tail from the blocking.  14. Remove both sets of blocking and lower the conveyor tail until it is level with the floor.  15. Check the gap and alignment at the juncture of the conveyor front and tail sections for alignment. If the sections are not horizontally aligned, then add or subtract shims as required.

_________________________________________________________________ 5.202 Bucyrus – Model 30M4-NP Continuous Miner

© Bucyrus America, Inc.

 11. Tighten the socket head capscrews.

_______________________________________ Adjustment procedures Fig. 126: Tail shim adjustment Correct gap and alignment Conveyor tail section

Conveyor front section

Add shims Conveyor tail section

Conveyor front section

Remove shims

© BUCYRUS AMERICA, INC.

Conveyor tail section

Conveyor front section

 16. Re-insert the blocking between the top of the tractor frame and the bottom of the conveyor following mine standard blocking procedures.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all blocking devices.  17. Securely retighten the socket head capscrews.

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Adjustment procedures ________________________________________ Conveyor chain tension adjustment The conveyor chain is tensioned with a hydraulic take-up cylinder. If the chain tension is not being maintained, then: 1. The conveyor chain take-up valve may need to be adjusted. See the Conveyor chain take-up valve adjustment procedure (Pilot/ auxiliary pump circuit relief valve adjustments) in this section. If the valve adjustment is correct, then

© Bucyrus America, Inc.

2. The cylinder may be fully extended and, therefore, unable to take up any more chain slack. Remove a link from the chain or replace chain as necessary.

_________________________________________________________________ 5.204 Bucyrus – Model 30M4-NP Continuous Miner

____________________________________ Replacement of wear parts Instructions on the replacement of wear parts It is essential that wear parts be replaced before reaching the lowest wear limit. To ensure that this happens, wear parts must be inspected at regular intervals.

CAUTION! Disassembly and assembly procedures listed in this section are specialized and, as such, should only be performed by qualified personnel.

© BUCYRUS AMERICA, INC.

Cutter head (boom) assembly The cutter head assembly (Fig. 128) is powered by two electric motors mounted on each side of the cutting head support frame. Each motor drives through a torque limiting clutch to an input gear case, which in turn drives a common shaft, allowing the two drive motors to share the cutting load. Each input gear case is removable as a separate unit from the main cutting head gear case. The cutting head is attached to the main frame at a heavy-duty pivot. Two hydraulic cylinders raise and lower the cutting head.

The cutter head assembly can be removed as an assembly or as individual components.

Fig. 128: Cutter head assembly

Boom

Input cutter gear case (typical both sides)

Boom pivot pin (typical both sides)

Shear cylinder (typical both sides)

Torque limiting clutch (typical both sides)

Cutter head motor (typical both sides)

Center drum

End drum (typical both sides)

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Replacement of wear parts _____________________________________ Cutter head assembly removal and installation cutter head assembly removal

To remove the cutter head assembly (Fig. 129):  Attach an appropriate lifting device to the boom assembly. Take up the slack in the lifting device so that the weight is supported as the assembly is unpinned from the miner.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all lifting and blocking devices and keep a safe distance from suspended loads.  Lower the gathering head and the cutter head to the floor and position the conveyor tail section level with the floor.

WARNING! Failure to follow all applicable regulations regarding lockout/ tagout procedures may result in machine damage or serious injury or death of personnel.  Disconnect and tag the power cables from the motors. Be sure to tape the power cables as power will be restored to the machine.  Disconnect, tag, and cap the lubrication and hydraulic lines going to the cutting head.

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 under load, the load will fall. Machine damage or serious injury or death to personnel may result.  Remove the two (2) boom pivot pins.  Remove the two (2) socket head cap screws from the retaining plate on the right and left pivot pins and remove the retaining plate.  On either side, force the main pivot pin inward from the outboard side, using the two (2) tapped jack screw holes, if necessary.  Connect electrical power to the machine.  Extend the shear cylinders to push the boom pivots out of their tractor frame clevises.

_________________________________________________________________ 5.206 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

 Disconnect and lock out the electrical power to the miner. Follow all applicable regulations regarding lockout/tagout procedures.

____________________________________ Replacement of wear parts  Block the boom and shear cylinders to keep them stationary during pin removal.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all lifting and blocking devices and keep a safe distance from suspended loads.  Disconnect and lock out the electrical power to the miner. Follow all applicable regulations regarding lockout/tagout procedures.

WARNING! Failure to follow all applicable regulations regarding lockout/ tagout procedures may result in machine damage or serious injury or death of personnel.  Remove the shear cylinder boom clevis pins.

© BUCYRUS AMERICA, INC.

 Remove the two (2) socket head cap screws and lock washers that secure the cylinder pin keeper plates on each side of the machine.  Insert a slide hammer into the threaded hole in the end of the pin and remove the pin from each side of the machine.  Connect electrical power to the machine.  Retract the shear cylinders to pull their bearings free from the boom clevises.  Raise the rear of the boom assembly until it is above the top edge of the gathering head backboard.  Slowly tram the machine backwards until the cutter boom pivot points clear the front of the gathering head.

Fig. 129: Cutter head assembly Shear cylinder clevis pin (2)

Cutter boom

Cutter boom pivot (2) (not shown)

Shear cylinder (2)

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Replacement of wear parts _____________________________________ cutter head assembly installation

To install the cutter head assembly (Fig. 129):  Slowly tram the machine forward towards the raised end of the boom until the pivot pins clear the gathering head backboard.  Lower the boom pivot points until the shear cylinders can reach their clevises. Block the boom to keep it in a secure position.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all lifting and blocking devices and keep a safe distance from suspended loads.  Extend the shear cylinders until the cylinder end bearings can be inserted into the cutter boom clevises.

WARNING! Failure to follow all applicable regulations regarding lockout/ tagout procedures may result in machine damage or serious injury or death of personnel.  Install the shear cylinder boom clevis pin on each side of the machine.  Position the right shear cylinder end bearing in the boom clevis.

WARNING! Do not use your fingers to check the alignment of the rod bearing in the clevis. Shifting of the parts could result in serious injury.   Insert the cylinder end pin through the aligned clevis bushing and cylinder end bearing.   Insert the keeper plate and secure to the boom clevis with the two (2) socket head cap screws lock washers.  Connect electrical power to the machine.  Once the shear cylinders are secured to the cutter boom remove the boom blocking to allow boom movement.  Retract the shear cylinders to pull the cutter boom pivot points into position in the tractor frame boom pivot clevises.

IMPORTANT! In addition to the shear cylinders, the stabilizer and gathering head can be used to adjust the cutter boom’s position to allow easier installation of the cutter boom pivot pins.

_________________________________________________________________ 5.208 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

 Disconnect and lock out the electrical power to the miner. Follow all applicable regulations regarding lockout/tagout procedures.

____________________________________ Replacement of wear parts  Install both cutter boom pivot pins.  Insert the main pivot pin from the inside toward the outboard side of the clevis.  Insert the retainer plate and secure with the two (2) socket head cap screws.  Disconnect and lock out the electrical power to the miner. Follow all applicable regulations regarding lockout/tagout procedures.

WARNING! Failure to follow all applicable regulations regarding lockout/ tagout procedures may result in machine damage or serious injury or death of personnel.  Connect the power cables and cooling cables to the cutter motors (see Cutter motor installation procedure in this chapter).

© BUCYRUS AMERICA, INC.

 Connect all hydraulic and lubrication hoses.  Connect electrical power to the machine.

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Replacement of wear parts _____________________________________ Shear cylinder assembly removal and installation shear cylinder removal

To remove a shear cylinder (Fig. 131):  Lower the gathering head until it touches the floor. Lower the conveyor tail section until it is even with the floor.  Raise the cutter head assembly and install the cutter boom safety supports (Fig. 130).  Support the shear cylinder so that when it is unpinned from the machine, it does not move.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all lifting and blocking devices.

WARNING! Failure to follow all applicable regulations regarding lockout/ tagout procedures may result in machine damage or serious injury or death of personnel.  Remove the shear cylinder frame mounting pin:    Locate the shear cylinder retainer plate and pin inside the front cover in the crawler frame.   Remove the two (2) hex head bolts and lock washers that secure the cylinder pin keeper plate.  Disconnect and cap the grease line going to the pin.  Remove the grease fitting adapter from the end of the pin.  Insert a slide hammer into the threaded hole in the end of the pin and pull the pin.  Connect electrical power to the machine.  Retract the shear cylinder to pull the bearing free from the boom clevis.  Disconnect and lock out the electrical power to the miner. Follow all applicable regulations regarding lockout/tagout procedures.

WARNING! Failure to follow all applicable regulations regarding lockout/ tagout procedures may result in machine damage or serious injury or death of personnel.  Cycle the shear cylinder control lever several times to release hydraulic pressure from the shear cylinder.

_________________________________________________________________ 5.210 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

 Disconnect and lock out the electrical power to the miner. Follow all applicable regulations regarding lockout/tagout procedures.

____________________________________ Replacement of wear parts WARNING! The following steps will disconnect the shear cylinder from the frame. The shear cylinder is extremely heavy. Make sure that it’s weight is supported and that the cylinder will not swing free or move. Failure to follow this warning may result in machine damage or in severe injury or death to personnel.   Open the front cover on the side of the cylinder by removing the two (2) socket head cap screws.  Disconnect and cap the hydraulic line to the shear cylinder.

WARNING! Never disconnect a hydraulic hose if the circuit is pressurized or if there is a load on the circuit. If a hose is disconnected while the circuit is pressurized or under load, the load will fall. Machine damage or serious injury or death to personnel may result.

© BUCYRUS AMERICA, INC.

 Remove the shear cylinder boom clevis pin.  Remove the two (2) socket head cap screws and lock washers that secure the cylinder pin keeper plate.  Remove the grease fitting adapter from the end of the pin.  Insert a slide hammer into the threaded hole in the end of the pin and pull the pin.

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Replacement of wear parts _____________________________________

Cutter head safety support (typical both sides)

Cutter head safety support (typical both sides)

_________________________________________________________________ 5.212 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

Fig. 130: Cutter head safety supports

____________________________________ Replacement of wear parts

© BUCYRUS AMERICA, INC.

Fig. 131: Shear cylinder removal and installation

Shear cylinder boom clevis pin Shear cylinder frame mounting pin

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Replacement of wear parts _____________________________________ shear cylinder installation

To install a shear cylinder (Fig. 131):  Attach an appropriate lifting device to the shear cylinder and position the cylinder so that the cylinder clevis is aligned in the mounting clevis on the cutter head.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all lifting and blocking devices.  Install the boom clevis pin. 

  Install the pin from the outside, toward the inside, of the machine with the threaded hole end of the pin toward the outside of the machine.

IMPORTANT! The pin should be inserted so that it’s retaining channel remains outside the bushing.

  Install the grease fitting into the end of the pin.  Attach the hydraulic hoses to the cylinder.  Connect the trailing cable to energize the machine.  Slowly extend the shear cylinder so that the rod clevis can be inserted into the frame mounting clevis.  Disconnect and lock out the electrical power to the miner. Follow all applicable regulations regarding lockout/tagout procedures.

WARNING! Failure to follow all applicable regulations regarding lockout/ tagout procedures may result in machine damage or serious injury or death of personnel.  Install the frame clevis pin. 

  Install the pin from the outside, toward the inside, of the machine so that the threaded hole end is toward the outside of the machine.

IMPORTANT! The pin should be inserted so that it’s retaining channel remains outside the bushing.   Insert the pin keeper plate and secure with two (2) hex head bolts and lock washers.   Install the grease fitting into the end of the pin.  Attach the grease line to the grease fitting in the pin.  Close and secure the front cover.

_________________________________________________________________ 5.214 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

  Insert the pin keeper plate and secure with two (2) socket head cap screws and lock washers.

____________________________________ Replacement of wear parts Center cutter drum removal and installation center cutter drum removal

To remove the center cutter drum (Fig. 132):  Lower the gathering head until it touches the floor. Lower the conveyor assembly until it is level with the floor.  Slowly rotate the cutter head until on of the center drum seams appears directly in front and one appears directly in the rear of the cutter head.  Lower the cutter head assembly until it is resting on the floor.  Disconnect and lock out the electrical power to the miner. Follow all applicable regulations regarding lockout/tagout procedures.

© BUCYRUS AMERICA, INC.

WARNING! Failure to follow all applicable regulations regarding lockout/ tagout procedures may result in machine damage or serious injury or death of personnel.  Remove the twenty-four (24) hex head bolts from that secure the two halves of the center drum to each other. Make sure to collect the bolts, the forty-eight (48) flat washers, and the twenty-four nuts for use in reassembly.  Attach a lifting device to the top half of the center drum and lift the it off of the assembly. It may be necessary to use a pry bar or other force to break the seal between the top and bottom halves of the center drum before the top half can be lifted off.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all lifting and blocking devices and stay clear of suspended loads.  Remove the four (4) alignment keys from the bottom half of the center drum and store for use in reassembly.  Connect the trailing cable to energize the machine.  Slowly raise the cutter head assembly until it is clear of the bottom half of the center drum.  Slowly tram the miner backwards away from the bottom half of the center drum. 



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Replacement of wear parts _____________________________________ Fig. 132: Center drum removal and installation

Hex head bolts (24)

Center drum, upper half

Alignment keys (4)

Center drum, lower half

_________________________________________________________________ 5.216 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

Center drum seam

____________________________________ Replacement of wear parts center cutter drum installation

To install the center cutter drum (Fig. 132):  Place the four (4) alignment keys into the keyway slots around the outer edges of the bottom half of the center drum.  Slowly rotate the cutter head until the center drum drive keys are positioned directly on top and bottom of the cutter head assembly.  Slowly lower the cutter head assembly onto the bottom half of the center drum.  Disconnect and lock out the electrical power to the miner. Follow all applicable regulations regarding lockout/tagout procedures.

WARNING! Failure to follow all applicable regulations regarding lockout/ tagout procedures may result in machine damage or serious injury or death of personnel.

© BUCYRUS AMERICA, INC.

 Attach a lifting device to the upper half of the center drum.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all lifting and blocking devices and stay clear of suspended loads. 

 Lower the upper half of the center drum onto the cutter head assembly, making sure that the keyways align with the keys on the bottom half.  Check that the upper half of the center drum is fully seated on the bottom half. Using a rod, check the bolt holes for alignment. Adjust the position of the upper half of the center drum as necessary to align the bolt holes. 

 Install the twenty-four (24) hex head bolts that secure the two halves of the center drum to each other, placing a flat washer under the head of the bolt and between the bolt and the nut. Install the bolt heads in the direction of rotation, if lacing permits.  Torque the bolts appropriately using the pattern shown in Fig. 133.

Fig. 133: Center drum bolt torque pattern

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Replacement of wear parts _____________________________________ End drum removal and installation end drum removal

To remove an end drum (Fig. 134):  Place the miner so that the cutting head is easily accessible and there is side clearance to pull the end drum off of the cutting head.  Disconnect and lock out the electrical power to the miner. Follow all applicable regulations regarding lockout/tagout procedures.

WARNING! Failure to follow all applicable regulations regarding lockout/ tagout procedures may result in machine damage or serious injury or death of personnel.

 Using the four puller holes in the end cap and four of the eight socket head screw just removed, remove the end cap.

CAUTION! If the assembly is seized, it may be necessary to pry on the edges.

Care must be taken not to damage the o-ring or its seal land.  Attach a lifting device to the end drum and apply tension so that the weight of the drum is supported by the lifting device.

WARNING! You can be seriously injured or killed by falling loads. Observe the safe working load limits of lifting or blocking devices and keep a safe distance from suspended loads.  Loosen the eighteen (18) socket head cap screws that secure the wedge block assembly and the drum to the cutting head hub.  Match mark both the end drum and the cutting head hub so that the cutting bit arrangement is not disturbed upon reassembly.  Grind the weld off and remove each key retainer plate from the end drum.  Slowly pull the end drum off of the main assembly, maneuvering it away from the miner.

_________________________________________________________________ 5.218 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

 There may be an optional cap on the end of the drum. If the end cap is present, remove the eight (8) socket head cap screws that secure it to the drum. Apply heat as necessary to liquify Loctite used when the cap screws were installed.

____________________________________ Replacement of wear parts

© BUCYRUS AMERICA, INC.

Fig. 134: End drum removal and installation

Socket head cap screw (8) Key plate retainer (2) Puller hole (4)

End cap (optional)

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Replacement of wear parts _____________________________________ end drum installation

To install an end drum (Fig. 134)  Disconnect and lock out the electrical power to the miner. Follow all applicable regulations regarding lockout/tagout procedures.

WARNING! Failure to follow all applicable regulations regarding lockout/ tagout procedures may result in machine damage or serious injury or death of personnel.  Attach a lifting device to the end drum.

 Install the two (2) keys and perform an all-around weld to secure.  Install the eighteen (18) socket head cap screws to secure the wedge block assembly and the drum to the cutting head hub and torque appropriately.  Coat the threads of the eight socket head cap screws with Loctite 242 (blue) and install the eight socket head cap screws to secure the end cap. Torque appropriately.

_________________________________________________________________ 5.220 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

WARNING! You can be seriously injured or killed by falling loads. Observe the safe working load limits of lifting or blocking devices and keep a safe distance from suspended loads.   Using the match marks made when the end drum was removed, align the end drum and the cutting head hub.

____________________________________ Replacement of wear parts Cutter drum drive motor removal and installation cutter drum drive motor removal

To remove the cutter drum drive motor (Fig. 135):  Lower the gathering head until the front of the pan rests on the floor.  Lower the cutter head to a comfortable working height. Block it in this position under the support frame.

WARNING! You can be seriously injured or killed by falling loads. Observe the safe working load limits of all lifting and blocking devices.

© BUCYRUS AMERICA, INC.

 Disconnect and lock out the electrical power to the miner. Follow all applicable regulations regarding lockout/tagout procedures.

WARNING! Failure to follow all applicable regulations regarding lockout/ tagout procedures may result in machine damage or serious injury or death of personnel.  Remove the hex head capscrews that secure the top motor cover and remove the cover to expose the motor.  Remove the hex head capscrews that secure the side motor cover and remove the cover to expose the side of the motor and the motor’s junction box.

Fig. 135: Cutter drum drive removal and installation

Side cover

Top cover

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Replacement of wear parts _____________________________________

  Remove the hex head capscrews that secure the junction box cover and then remove the cover Fig. 136)  Locate the three (3) lug power connections.

IMPORTANT! Before detaching these three (3) lugs, tag the wires to make reconnection easier.  Tag the lugs for correct reconnection and then remove the hex head capscrews that secure the three power cable lugs to the three motor lugs.  Remove the socket head capscrews that secure the global plug to the junction box (Fig. 136).

WARNING! Power should not be reconnected to the miner while the motor power cable is disconnected. Damage to the miner or personal injury or death could result.  To prevent damage to the motor power cable lugs and gland assembly, cover the power cable and secure it to the miner in a safe location.   Disconnect, tag, and cap the two (2) cooling hoses from the motor cooling fittings (Fig. 136).  Remove the two cooling fittings from the motor and store for reuse during installation.  Plug the motor cooling ports to prevent contamination.  Disconnect, tag, and cap the motor bearing grease lines.  Attach an appropriate lifting device to the motor and take up the slack so that the weight of the motor is resting on the lifting device.

WARNING! Always observe the safe working load limits of all lifting devices.

You could be seriously injured or killed by falling loads.  Remove the hex head bolts that secure the cutter motor clutch cover and then remove the clutch cover.  Remove the seal cap and internal retaining ring which restrains the motor input shaft. Remove the motor input shaft from the inside of the motor going into the input gear case.  Remove the motor mounting bolts and the rear support bracket.  Carefully lift motor out of the frame.

_________________________________________________________________ 5.222 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

 Slide the global plug out of the junction box. At this point, the power cable should be completely disconnected from the motor.

____________________________________ Replacement of wear parts

© BUCYRUS AMERICA, INC.

Fig. 136: Cutter drum drive motor removal and installation

Clutch cover

Junction box cover

Mounting bolts

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Replacement of wear parts _____________________________________ cutter drum drive motor installation

To install the cutter drum drive motor (Fig. 136): WARNING! Law requires that mining equipment electrical components must be inspected by a certified electrician before the equipment can be operated.

WARNING! This procedure involves attaching an electrical power cable to a motor. The trailing cable must be disconnected and locked and tagged out to safely perform this operation. Follow all Mine, State, and Federal lockout/tagout procedures. Failure to do so may result in serious injury or death.

WARNING! Observe the safe working load limits of all lifting and blocking devices. You can be seriously injured or killed by falling loads.  Insert the mounting bolts to secure the motor to the boom. Torque appropriately.  Attach the rear mounting support bracket.  Install the two motor cooling fittings into the cooling ports on the motor.  Attach the cooling hoses to the fittings.  Remove the four (4) hex head capscrews that secure the junction box cover and then remove the junction box cover.  Insert the three lugs of the power cable (with gland and stuffing box already installed) into the motor’s junction box.  Tighten the two socket head capscrews to secure the gland to the junction box.  Inside the junction box, locate the motor’s lug connections.  Match the motor lugs with the corresponding power cable lugs.  Attach the first motor lug to its corresponding power cable lug by inserting a hex head capscrew through the motor lug, the power cable lug, a flat washer, and a lock washer. Secure the capscrew with a hex nut. Repeat for the other two lugs.  When all three connections have been secured, wrap each of the three connections with a layer of rubber tape, then a layer of black tape, and then a layer of glass tape.

_________________________________________________________________ 5.224 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

 Block up the cutter head drum drive motor in position against the rear of the boom so that the motor’s mounting holes align with the boom’s motor mounting holes.

____________________________________ Replacement of wear parts  Replace the junction box o-ring and cover and secure with the four hex head capscrews.

IMPORTANT! A certified electrician must inspect all work and check for permissibility.  Attach the grease lines to the grease fittings on the motor.  Insert the motor input shaft and then insert the retaining ring and seal cap.  Replace the clutch cover and secure with hex head capscrews.  Replace the top cover and secure with hex head capscrews.

© BUCYRUS AMERICA, INC.

 Replace the side cover and secure with hex head capscrews.

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Replacement of wear parts _____________________________________ cutter drum drive gear case removal

The cutter head gear case may be removed with cutter drum installed but it is easier with it removed.

To remove the cutter drum drive gear case (Fig. 137):  Disconnect and lockout the trailing cable. Follow all applicable regulatory lockout/tagout procedures.

WARNING! Failure to follow all regulatory lockout/tagout procedures may result in machine damage or serious injury or death of personnel.  Remove the cutter head center drum (see Center cutter drum removal procedure in this chapter).  Remove the cutter head end drums (see End drum removal procedure in this chapter).

 Securely block the cutter head gear case so that it will not fall when it is unbolted from the frame.

WARNING! Observe the safe working load limits of all lifting and blocking devices. You can be seriously injured or killed by falling loads.

IMPORTANT! During the removal of the cap screws that secure the gear case to the frame, it may be necessary to adjust the blocking under the gear case. Ensure that the gear case is securely blocked at all times and that it does not shift as it is unbolted.  Remove the cover off of the clutch.  Remove the snap ring from the motor shaft and then pull the motor shaft out.   Carefully loosen and remove the forty (40) capscrews that secure the cutter head gear case to the cutter head support frame.  Connect the trailing cable to energize the miner.

WARNING! Stand clear of the miner and the gear case while tramming the miner. You could be seriously injured or killed by falling loads.

Do not attempt to start the cutter head motors. You could be seriously injured or killed.

CAUTION! Use care when tramming the miner away from the gear case.

While each cutter motor is supported by a bracket at the rear of the motor, excessive bumping could cause the motor to fall.  Slowly tram the miner away from the gear case. _________________________________________________________________ 5.226 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

 Ensure that the cutter head assembly is adequately blocked.

____________________________________ Replacement of wear parts Fig. 137: Cutter drum drive gear case removal and installation

© BUCYRUS AMERICA, INC.

Mounting capscrew (40)

Cutter drum drive gear case

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Replacement of wear parts _____________________________________ cutter drum drive gear case installation

To install the cutter drum drive gear case (Fig. 137):  Ensure that the gear case is securely blocked so that the miner can be trammed into position behind it.

WARNING! Observe the safe working load limits of all lifting and blocking devices. You can be seriously injured or killed by falling loads.  Slowly tram the miner into position behind the gear box.  Disconnect and lock out the electrical power to the miner. Follow all applicable regulations regarding lockout/tagout procedures.

 Using a metal rod, check for alignment between the mounting holes on the miner and the mounting holes in the gear case.  Install the forty capscrews that secure the gear case to the miner.

Torque appropriately.  Insert the motor shaft and secure with the snap ring.  Replace the clutch cover.  Install the end drums (see End drum installation procedure in this chapter).  Install the center drum (see Center drum installation procedure in this chapter).

_________________________________________________________________ 5.228 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

WARNING! Failure to follow all applicable regulations regarding lockout/ tagout procedures may result in machine damage or serious injury or death of personnel.

____________________________________ Replacement of wear parts Gathering head assembly The gathering head assembly (Fig. 138) consists of the gathering pan, the continuous loading arms (CLAs), lift cylinders, and two drive motors connected to an input gear case through a torque shaft.

The gathering head can be removed as an assembly or as individual components.

© BUCYRUS AMERICA, INC.

Fig. 138: Gathering head assembly

Foot shaft

Motor (behind cover)

Gathering pan

CLA

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Replacement of wear parts _____________________________________ Gathering head assembly removal and installation gathering head assembly removal

To remove the gathering head assembly (Fig. 139):  Place the machine in a position where both sides in front of the crawlers are accessible.  Lower the gathering head until the pan rest on the mine floor.  Raise the cutter head and block it securely.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all lifting and blocking devices and keep a safe distance from suspended loads.

WARNING! Failure to follow all Mine, State, and Federal lockout/tagout procedures may result in machine damage or serious injury or death of personnel.  Remove the motor access cover on the side of the gathering head frame by removing the capscrews that secure it to the frame.  Wash motor compartment thoroughly for easier removal of motor.  Disconnect and tag the power cables to the gathering head motors.

Be sure to tape the power cables as power will be restored to the machine.  Disconnect, tag, and cap the cooling hoses going to the gathering head motors.  Disconnect the conveyor chain (see Conveyor chain removal procedure in this chapter). The chain does not have to be completely removed from the miner. After disconnecting the chain from the foot shaft, the top strand must be pulled back clear of the gathering head conveyor section. The bottom of the chain can be left where it is.  Securely block the gathering head frame. The gathering head frame must be blocked at the rear of the frame, as close to the pivot as possible, to prevent falling when the pivot pins are removed.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all lifting and blocking devices and keep a safe distance from suspended loads.  Support the gathering head raise cylinders.

_________________________________________________________________ 5.230 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

 Disconnect and lock out the electrical power to the miner. Follow all applicable mine, State, and Federal regulations regarding lockout/tagout procedures.

____________________________________ Replacement of wear parts NOTICE! The gathering head cylinders do not have to be removed from the frame. Rotate them away from the gathering head and securely fasten them to the main frame.   Remove the upper cylinder pins.  Remove the pivot pin retainer.  Force the gathering head hinge pin out from the outboard side going in. If the pin does not come out, check to see that support under the rear of the gathering head is adequate but is not forcing.  Reconnect the trailing cable to energize the miner.

© BUCYRUS AMERICA, INC.

WARNING! Do not attempt to start the cutter head or gathering head motors.

IMPORTANT! Make sure that the lower section of the conveyor chain is free of the foot shaft so that when the miner is trammed away from the gathering head, the chain will pull free of the return deck.  Slowly tram the miner away from the gathering head until the gathering head is clear and the conveyor chain is free.  Lower the cutting head to the floor.  Disconnect and lock out the electrical power to the miner. Follow all applicable mine, State, and Federal regulations regarding lockout/tagout procedures.

WARNING! Failure to follow all regulatory lockout/tagout procedures may result in machine damage or serious injury or death of personnel.

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Replacement of wear parts _____________________________________ Fig. 139: Gather head assembly removal and installation

© BUCYRUS AMERICA, INC.

Hinge pin

Motor access cover

_________________________________________________________________ 5.232 Bucyrus – Model 30M4-NP Continuous Miner

____________________________________ Replacement of wear parts gathering head assembly installation

To install the gathering head assembly (Fig. 139):  Reconnect the trailing cable to energize the miner.

NOTICE! When the gathering head was removed, the lower length of the conveyor chain was pulled free of the gathering head. This end of the conveyor chain must be brought forward when the miner is trammed to the gathering head.  Tram the miner to the gathering head frame. Using a puller cable or wire, feed the lower end of the conveyor chain through the gathering head return deck and up to the foot shaft.

© BUCYRUS AMERICA, INC.

 Position the miner to align the pivots in the main frame with those on the gathering head.

DANGER! All personnel must stay clear of the miner while it is tramming and being aligned with the gathering head assembly. Standing under the cutter head or in the path of the miner while it is tramming may result in severe injury or death.  Once the miner is aligned with the gathering head assembly, block the cutting head in its raised position.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all lifting and blocking devices and keep a safe distance from suspended loads.  Disconnect and lock out the electrical power to the miner. Follow all applicable regulations regarding lockout/tagout procedures.

WARNING! Failure to follow all applicable regulations regarding lockout/ tagout procedures may result in machine damage or serious injury or death of personnel.  Coat the pivot pins and their bushings with grease to aid in installation.  Install both the right and left hand pivot pins. Be sure that the pivot bores in the gathering head and the main frame are aligned and that you do not damage the end of the pivot bushing during installation.  Position each pivot pin so that it is flush with the main frame bushing.  Insert the pivot pin retainer and secure with capscrews. Tighten the capscrews to the appropriate torque.

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Replacement of wear parts _____________________________________  Align the gathering head frame clevises with the gathering head cylinder end clevises. Install the upper cylinder pins through the clevises and secure.  Lubricate the cylinder and pivot pins.  Install the conveyor chain (see Conveyor chain installation procedure in this chapter).  Connect all cooling lines to the motors.  Connect the electrical leads to the motor.  Secure the motor access cover to the gathering head frame with the capscrews.

© BUCYRUS AMERICA, INC.

 Check the oil levels in the gathering head pot cases and the gathering head input gear cases.

_________________________________________________________________ 5.234 Bucyrus – Model 30M4-NP Continuous Miner

____________________________________ Replacement of wear parts Gathering head motor removal and installation gathering head motor removal

To remove a gathering head motor (Fig. 140):  Lower the gathering head until the pan rests on the mine floor.  Raise the cutter head and block it securely.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all lifting and blocking devices and keep a safe distance from suspended loads.  Disconnect and lock out the electrical power to the miner. Follow all applicable regulations regarding lockout/tagout procedures.

© BUCYRUS AMERICA, INC.

WARNING! Failure to follow all applicable regulations regarding lockout/ tagout procedures may result in machine damage or serious injury or death of personnel.  Remove the motor access cover on the side of the gathering head frame.  Wash motor compartment thoroughly for easier removal of motor.  Disconnect and tag the power cables to the gathering head motors.  Disconnect, tag, and cap the cooling hoses going to the gathering head motors.  Remove the bearing cap cover from the exposed end of the motor.  Remove the snap ring and plug from the end of the motor, exposing the torque shaft.  Remove the torque shaft.  Securely block the motor to prevent it from falling when the mounting bolts are removed.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all lifting and blocking devices and keep a safe distance from suspended loads.  Remove the motor mounting bolts and carefully back the motor out of the frame.

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Replacement of wear parts _____________________________________ Fig. 140: Gathering head motor removal and installation

© BUCYRUS AMERICA, INC.

Top access cover

Motor access cover

_________________________________________________________________ 5.236 Bucyrus – Model 30M4-NP Continuous Miner

____________________________________ Replacement of wear parts gathering head motor installation

To install a gathering head motor (Fig. 140): Ensure mating surfaces of the frame and motor are clean and free of contaminants.    Carefully position the motor in the frame.  Insert the motor mounting bolts and torque appropriately.  Insert the torque shaft into the motor.  Replace the plug and snap ring over the end of the torque shaft.  Replace the bearing cap cover.  Reconnect the cooling hoses to the motor.

© BUCYRUS AMERICA, INC.

 Reconnect the power cable to the motor.  Replace the motor access cover on the side of the gathering head frame.

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Replacement of wear parts _____________________________________ Gathering head gear case and pot removal and installation gathering head gear case and pot removal

To remove a gathering head gear case and pot (Fig. 141):  Disconnect the conveyor chain (See Conveyor chain removal procedure in this chapter).  Disconnect and lock out the electrical power to the miner. Follow all applicable regulations regarding lockout/tagout procedures.

WARNING! Failure to follow all applicable regulations regarding lockout/ tagout procedures may result in machine damage or serious injury or death of personnel.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all lifting and blocking devices and keep a safe distance from suspended loads.  Disconnect any oil fill lines connected to the pot.  Attach a lifting device to the top surface of the pot and input gear case.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all lifting and blocking devices and keep a safe distance from suspended loads.  Remove the CLA (see CLA removal procedure in this chapter).   Loosen the pot case attachment from the frame by removing the hex head capscrews from the four corners of the pot. Removing these screws will also remove the four wedge blocks which secure the pot in position.  Lift the pot and input case from the gathering head frame.  To separate the input gear case from the pot: 

Remove the capscrews that secure the input gear case to the pot and back the input gear case away from the pilot bore in the pot case.

_________________________________________________________________ 5.238 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

 Remove the gathering head motor (see Gathering head motor removal procedure in this chapter).   Securely block the input gear case in position to prevent the gear case from falling when the capscrews that secure it are removed.

____________________________________ Replacement of wear parts Fig. 141: Gathering head gear case and pot removal and installation

© BUCYRUS AMERICA, INC.

Top access cover

Motor access cover

CLA retainer plate

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Replacement of wear parts _____________________________________ gathering head gear case and pot installation

To install a gathering head gear case and pot (Fig. 141):  Align the input gear case with the pot case (if separated) and secure with capscrews.  Attach a lifting device to the gear case assembly.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all lifting and blocking devices and keep a safe distance from suspended loads.  Ensure that mating surfaces are clean and then position the gear case assembly in the gathering head frame.  Position the four wedge blocks which secure the pot in position and secure to the frame by installing hex head capscrews through the four (4) corners of the pot.

 Install the gathering head motor (see Gathering head motor installation procedure in this chapter).  Install CLA (see CLA installation procedure in this chapter).

_________________________________________________________________ 5.240 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

 Connect the oil fill lines to the pot.

____________________________________ Replacement of wear parts Foot shaft removal and installation foot shaft removal

To remove the foot shaft (Fig. 142):  Lower the gathering head assembly until it touches the floor.  Position the conveyor tail section directly behind the miner so that it is level with the floor.  Raise the cutter head assembly to its highest position and block.

WARNING! Observe the safe work load limits of all blocking devices. You can be seriously injured or killed by falling loads.

© BUCYRUS AMERICA, INC.

 Open the needle valve on the left hand side of the machine to release the oil from the conveyor take-up cylinders. This will relax the tension on the conveyor chain.  Disconnect and lock out the electrical power to the miner. Follow all applicable regulations regarding lockout/tagout procedures.

WARNING! Failure to follow all applicable regulations regarding lockout/ tagout procedures may result in machine damage or serious injury or death of personnel.

CAUTION! To avoid injury while relieving tension off of the conveyor chain, wear proper personal protective equipment, to include, at a minimum, safety glasses and gloves.  Using a pry bar, lift the chain off the conveyor deck several times to relieve tension in the chain.  Remove the two retaining pins from the closest connecting pin to the foot shaft and then remove the connecting pin.  Pull the conveyor chain away from the foot shaft sprocket (fold it back).  Remove the four (4) socket head capscrews that secure the two foot shaft covers to the gathering head assembly and remove the covers.  Remove the four socket head capscrews from each clamp ring on the foot shaft assembly and remove the clamp rings.  Slide both adapter shafts from the ends of the foot shat toward the sprocket in the center. This will free the foot shaft from the gear case.  Remove the foot shaft from the gathering head.

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Replacement of wear parts _____________________________________ Fig. 142: Foot shaft assembly removal and installation

Sprocket Clamp ring

© BUCYRUS AMERICA, INC.

Adapter shaft

_________________________________________________________________ 5.242 Bucyrus – Model 30M4-NP Continuous Miner

____________________________________ Replacement of wear parts foot shaft installation

To install the foot shaft (Fig. 142):  Slide an adapter shaft onto each end of the foot shaft.  Slide the foot shaft into position between the two gathering head gear case bevel pinions.

IMPORTANT! Position the foot shaft so that it’s sprocket will engage the conveyor chain links when the chain is reconnected.  Align the foot shaft splines with the bevel pinion splines.  Slide the right adapter shaft over the foot shaft spline onto the bevel pinion splines until it touches the gear case seal carrier. Repeat for the left side.

© BUCYRUS AMERICA, INC.

 Place a collar onto each end of the foot shaft so that the adapter shaft is secured against the bevel gear case seal carriers.  Insert and tighten the capscrews through both halves of the collars to secure the collars to the foot shaft.  Replace the foot shaft covers and secure with the four (4) 3/4-10 socket head capscrews.  Reattach the two ends of the conveyor chain by replacing the connecting pin.  Close the needle valve to the conveyor take-up cylinders.  Reconnect the trailing cable to energize the miner.  Start the pump so that the conveyor chain take-up cylinders are pressurized.  Turn on the gathering head motors to run the conveyor chain.  Elevate the conveyor full up and down and swing the discharge conveyor full left and right. Check that the conveyor chain is running smoothly.  Shutdown the machine and check the conveyor chain tension. If adjustment is necessary, see the Conveyor chain adjustment procedure in this chapter.

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Replacement of wear parts _____________________________________ CLA removal and installation CLA removal

To remove a continuous loading arm (CLA) (Fig. 143):  Lower the gathering head assembly until it touches the floor.  Raise the cutter head assembly to its highest position and block.

WARNING! Observe the safe work load limits of all blocking devices. You can be seriously injured or killed by falling loads.  Disconnect and lock out the electrical power to the miner. Follow all applicable regulations regarding lockout/tagout procedures.

 Remove the eight (8) 1”-8 socket head capscrews from the CLA retainer plate and remove the retainer plate. There are two puller holes, protected by cup-point set screws, in the retainer plate to assist with it’s removal.  Remove the three capscrews located where the arms meet the CLA hub. There are three puller holes, protected by cup-point set screws, in the arm to assist with it’s removal.  Remove the three dowel pins, which position the CLA to the pot disc and keep for reassembly.  The CLA is now free and can be removed.

_________________________________________________________________ 5.244 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

WARNING! Failure to follow all applicable regulations regarding lockout/ tagout procedures may result in machine damage or serious injury or death of personnel.

____________________________________ Replacement of wear parts Fig. 143: CLA removal and installation

© BUCYRUS AMERICA, INC.

Puller hole (3)

CLA arm to hub capscrews (3)

Puller hole (2)

CLA retainer plate capscrews (8)

CLA tip

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Replacement of wear parts _____________________________________ CLA installation

To install a continuous loading arm (CLA) (Fig. 143):  Install the three dowel pins into the pot disc.   Position the CLA on the gathering head ensuring that CLAs are aligned as shown in Fig. 143.  Insert the three capscrews into the arms and tighten.  Insert the retainer cap into the center of the arm.  Apply Loctite 262 to the eight (8) 1”-8 socket head capscrews and install the capscrews into the retainer plate. Torque incrementally and evenly in a crossing pattern to 734 lb-ft as follows:

 Reconnect the trailing cable.

CLA tip replacement

CLA tip replacement To replace a CLA tip (Fig. 143):  Lower the gathering head assembly until it touches the floor.  Raise the cutter head assembly to its highest position and block.

WARNING! Observe the safe work load limits of all blocking devices. You can be seriously injured or killed by falling loads.  Disconnect and lock out the electrical power to the miner. Follow all applicable regulations regarding lockout/tagout procedures.

WARNING! Failure to follow all applicable regulations regarding lockout/ tagout procedures may result in machine damage or serious injury or death of personnel.  Remove the two (2) hex head capscrews that secure the tip to the arm and remove the tip.  Slide a new tip onto the arm and secure with two (2) hex head capscrews.  Reconnect the trailing cable.

_________________________________________________________________ 5.246 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

Step 1: Snug Step 2: 245 ft-lb Step 3: 500 ft-lb Step 4: 734 ft-lb

____________________________________ Replacement of wear parts Gathering head cylinder removal and installation gathering head cylinder removal

To remove a gathering head cylinder (Fig. 144):  Raise the gathering head off the ground by fully extending the gathering head cylinder and securely block.  Raise the cutter head and securely block.

WARNING! Observe the safe working load limits of all lifting and blocking devices. You can be seriously injured or killed by falling loads.  Disconnect and lock out the electrical power to the miner. Follow all applicable regulations regarding lockout/tagout procedures.

© BUCYRUS AMERICA, INC.

WARNING! Failure to follow all applicable regulations regarding lockout/ tagout procedures may result in machine damage or serious injury or death of personnel.  Attach a lifting device to the gathering head cylinder so that when the cylinder is unpinned, the lifting device will support the cylinder.   Remove the two (2) capscrews that secure the pin retainer plate to the frame and the remove the retainer plate.  Remove the lower (rod end) pin from the frame mounting clevis.  Connect the trailing cable to energize the miner.

WARNING! Stand clear of the blocked cutter head and gathering head assemblies whenever the miner is energized.  Slowly contract the cylinder until the rod eye is free of the gathering head clevis.  Disconnect and lock out the electrical power to the miner. Follow all applicable regulations regarding lockout/tagout procedures.

WARNING! Failure to follow all applicable regulations regarding lockout/ tagout procedures may result in machine damage or serious injury or death of personnel.  Check the cutter head and the gathering head are still securely blocked.  Move the gathering head lift cylinder valve handle to extend and retract the cylinder in order to release any hydraulic pressure from the cylinder.

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Replacement of wear parts _____________________________________  Disconnect and plug the hydraulic hose from the cylinder.

WARNING! Never disconnect a hydraulic hose if the circuit is pressurized or if there is a load on the circuit. If a hose is disconnected while the circuit is pressurized or under load, the load will fall. Machine damage or serious injury or death to personnel may result.  Remove the spiral pin from the upper (tube end) cylinder pin and then remove the pin.

© BUCYRUS AMERICA, INC.

 The cylinder is now free and can be lifted off of the machine.

_________________________________________________________________ 5.248 Bucyrus – Model 30M4-NP Continuous Miner

____________________________________ Replacement of wear parts

© BUCYRUS AMERICA, INC.

Fig. 144: Gathering head cylinder removal and installation

Frame mounting pin

Gathering head cylinder

Cylinder tube pin

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Replacement of wear parts _____________________________________ Gathering head cylinder installation

gathering head cylinder installation

To install the gathering head cylinder (Fig. 144):

 Check that the gathering head and cutter head assemblies are securely blocked.  Insert the cylinder end clevis of the gathering head cylinder into the gathering head clevis.

WARNING! This procedure involves the alignment of cylinder clevises with mounting clevises in order to install retaining pins. Do not check for alignment with your fingers. Shifting of the aligned pieces could cause serious injury.  Insert the retaining pin through the cylinder and gathering head mounting clevises.

 Attach the hydraulic hose to the cylinder.  Connect the trailing cable to energize the miner.

WARNING! Stand clear of the blocked cutter head and gathering head assemblies whenever the miner is energized.  Slowly extend the cylinder so that the rod end clevis can be inserted into the frame mounting clevis.

WARNING! Stand clear of the blocked cutter head and gathering head assemblies whenever the miner is energized.  Disconnect and lock out the electrical power to the miner. Follow all applicable regulations regarding lockout/tagout procedures.

WARNING! Failure to follow all applicable regulations regarding lockout/ tagout procedures may result in machine damage or serious injury or death of personnel.  Insert the retaining pin through the rod and frame mounting clevis.  Insert the pin retaining plate over the end of the pin and secure to the clevis with two (2) capscrews.

_________________________________________________________________ 5.250 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

 Insert the spiral lock pin through the retaining pin.

____________________________________ Replacement of wear parts Crawler assembly Each (left or right) crawler assembly (Fig. 145) consists of a tram drive motor, a tram drive gear case, a crawler chain, a chain take-up roller, and a grease adjusted, shim lock take-up system. These components are mounted in a crawler frame, which is an integral part of the main frame.

© BUCYRUS AMERICA, INC.

Fig. 145: Crawler assembly

Gear case Motor

Crawler track (chain)

Roller

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Replacement of wear parts _____________________________________ Tram motor removal and installation tram motor removal

To remove a tram motor (Fig. 146):  Position the miner so that there is adequate work space on the side from which the motor is being removed.  Block the miner so that the tram track is clear of the floor and is free to turn. Be sure that the miner is level when blocked.

WARNING! Observe the safe working load limits of all blocking devices. You can be seriously injured or killed by falling loads.

WARNING! Failure to follow all applicable regulations regarding lockout/ tagout procedures may result in machine damage or serious injury or death of personnel.  Remove two (2) bolts that secure the top cover to the tram rub rail and slide the cover off the rub rail.   Remove the two (2) rub rail pins that secure the tram rub rail to the two rub rail sections adjacent to it and then remove the tram rub rail to expose the tram gear case.  Remove the capscrews that secure the end cap on the motor.  Remove the snap ring inside the motor shaft.  Remove the shaft plug and o-ring, exposing the quill shaft.  Carefully remove the quill shaft and store in a safe place.  Remove the four (4) bolts that secure the motor to the tram case.

Store the two (2) locks for use in motor installation.  Replace the end cap on the motor and secure with the four capscrews.  Disconnect, tag, and cap the cooling hoses from the cooling fittings located on the motor.  Remove the bolts that secure the inspection cover to the motor and remove the cover.  Disconnect the power cable lugs from the motor.  Locate the three taped power connections inside the motor and strip the tape covering each lug connection.  Tag each connection and remove the capscrew, washer, and nut that secures each of the power cable lugs. _________________________________________________________________ 5.252 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

 Disconnect and lock out the electrical power to the miner. Follow all applicable regulations regarding lockout/tagout procedures.

____________________________________ Replacement of wear parts  Replace the inspection cover on the motor and secure with bolts.  Cover the connection opening in the side of the motor to prevent motor contamination while the power cables are disconnected.

WARNING! Do not reconnect the trailing cable to the miner while the power cable is disconnected from the motor. Serious injury or death may occur.

© BUCYRUS AMERICA, INC.

 Carefully remove the motor from the tram case, be careful not to damage the motor during removal.

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Replacement of wear parts _____________________________________ Fig. 146: Tram motor removal and installation Inspection cover

Top cover Tram rub rail

Motor

Lock (2)

Bolt (4)

Connection opening

_________________________________________________________________ 5.254 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

Pin (2)

____________________________________ Replacement of wear parts tram motor installation

To install the tram motor (Fig. 146):  Clean the motor and the motor cavity in the tram case thoroughly.  Install a new o-ring (lubricated) on the motor mounting flange (rear bell).  Oil the bore of the input planetary (in the motor cavity) to ease installation.  Carefully position the motor in the tram case, being careful not to damage the motor or the o-ring on the rear bell.

© BUCYRUS AMERICA, INC.

 Continue to position the motor into the bore of the input planetary and the flange ears on the motor are flush with the tram case. If the ears are not flush within 0.5 mm ( 0.020 inches), the motor is not seated properly.  Install the motor quill shaft, rotating it until the splines on the end inside the motor mesh with the internal splines of the pinion ear in the input planetary assembly.  Install the shaft plug and o-ring and the snap ring on the end of the shaft.  Install the motor end cap and secure with capscrews. Tighten to the correct torque.  Install the two (2) locks and two (2) socket head capscrews to secure the motor to the tram case. Tighten to the correct torque.  Install the two (2) socket head capscrews to secure the motor to the tram case. Tighten to the correct torque.  Refill the tram gear case with high demulsibility, extreme pressure gear oil (Spec. 100-15) to the correct level. Check the oil level using the sight gauge on the outer face of the gear case.  Remove the bolts that secure the inspection cover to the motor and remove the cover.   Reconnect the power cable to the motor.  Locate the motor lug connections inside the motor.  Secure each of the power connections with a capscrew, flat, washer, lock washer, and nut.  When the each of the three connections have been secured, wrap each connections with a layer of rubber tape, a layer of electrical (black) tape, and a layer of glass tape.  Reconnect the cooling lines to the motor.  Reconnect power to the miner and check tram for correct operation.

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Replacement of wear parts _____________________________________ WARNING! Stay clear of the blocked miner while the machine is energized.

Failure to follow this warning may result in sever injury or death.    Disconnect and lock out the electrical power to the miner. Follow all applicable regulations regarding lockout/tagout procedures.

WARNING! Failure to follow all applicable regulations regarding lockout/ tagout procedures may result in machine damage or serious injury or death of personnel.   Replace the tram rub rail and secure with the two (2) pins.

© BUCYRUS AMERICA, INC.

 Replace the top cover on the tram rub rail and secure.

_________________________________________________________________ 5.256 Bucyrus – Model 30M4-NP Continuous Miner

Replacement of wear parts _____________________________________ Tram gear case removal and installation tram drive gear case removal

To remove a tram drive gear case (Fig. 147):  Position the miner so that there is adequate work space on the side from which the motor is being removed.  Block the miner so that the tram track is clear of the floor and free to turn. Make sure the miner is level.

WARNING! Observe the safe working load limits of all blocking devices. You can be seriously injured or killed by falling loads.

WARNING! Failure to follow all applicable regulations regarding lockout/ tagout procedures may result in machine damage or serious injury or death of personnel.  Remove the two (2) rub rail pins that secure the tram rub rail to the two rub rail sections adjacent to it and then remove the tram rub rail to expose the tram gear case.  Separate the crawler chain (see Crawler chain removal procedure in this chapter) at a place near the tram gear case and move the chain clear of the drive sprocket. For ease of reconnection, attach a small steel cable to upper crawler pad so that is accessible for pulling the crawler back into place during installation.  Disconnect, tag, and cap all cooling and lubrication lines from the gear case.  The main gear case and final planetary gear case may be drained, if desired, but it is not necessary.  Disconnect and tag the power cable lugs from the motor.

WARNING! Do not reconnect the trailing cable to the miner while the power cable is disconnected from the motor. Serious injury or death may occur.  Remove the tram brake (see the Tram brake removal procedure in this chapter).   Clean out the jacking holes on each side of the gear case.  Remove the socket head capscrews and wedge blocks.

_________________________________________________________________ 5.257 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

 Disconnect and lock out the electrical power to the miner. Follow all applicable regulations regarding lockout/tagout procedures.

____________________________________ Replacement of wear parts  Remove the nine (9) screws from the mounting plate (four (4) on the rear/sprocket side and five (5) on the forward/motor side).  Insert a screw into the two jacking holes and, using these holes, slowly jack the main case free of the frame.  Position a loading device, such as a scoop, at the bottom edge of the main case. Connect a couple of chains between the loading device and the back of the mounting plate.

WARNING! Observe the working load limits of chains. Overstressing the chains could cause the chain to break, resulting in serious injuries.  Slowly maneuver the gear case and motor assembly clear of the machine and onto the loading device.

© BUCYRUS AMERICA, INC.

 Cover the tram case compartment in the crawler assembly to keep out dirt and debris.

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Replacement of wear parts _____________________________________ Fig. 147: Tram case removal and installation

Pin (2)

Tram rub rail

_________________________________________________________________ 5.259 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

Tram case

____________________________________ Replacement of wear parts tram drive gear case installation

To install the tram gear case (Fig. 147);  Ensure that the crawler frame mounting area is cleared of dirt and debris. Pay special attention to the keyways and the bore in the inner face of the main frame. Apply a light coating of Molykote G-N past to aid re-installation.  Ensure that the mounting faces on both the tram drive gear case and the crawler frame are clean.  Coat the mounting keys on the gear case and the bearing carrier on the inboard end of the main gear case with Molykote G-N paste.

The bearing carrier serves as a plug to fit into the bore in the main frame.

© BUCYRUS AMERICA, INC.

 Slowly maneuver the gear case into position next to the machine, aligning the keys on the gear case with the keyways/slots on the frame.

IMPORTANT! If the miner and the gear case assembly are not both level and aligned correctly, installing the gear case assembly into the machine will be very difficult.  Slowly push the gear case assembly into the crawler frame, allowing the keys on the gear case to engage the keyways in the main frame. Be sure that cap screw mounting holes line up.  Install the nine (9) socket head capscrews and washers and torque appropriately.  Install the wedge blocks and secure with capscrews. Tighten to the correct torque.  Reconnect all cooling and lubrication lines to the gear case.  Reconnect the electrical leads to the motor.  Check the oil level in the gear case and add high demulsibility, extreme pressure gear oil (Spec. 100-15) as required.  Reconnect the crawler chain (see Crawler chain installation procedure in this chapter).

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Replacement of wear parts _____________________________________  Connect the trailing cable to energize the miner.  Operate the tramming function on the side where the tram gear case assembly was installed. Check for correct operation.  Disconnect and lock out the electrical power to the miner. Follow all applicable regulations regarding lockout/tagout procedures.

WARNING! Failure to follow all applicable regulations regarding lockout/ tagout procedures may result in machine damage or serious injury or death of personnel.

© BUCYRUS AMERICA, INC.

 Replace the tram rub rail, securing it with the two (2) pins.

_________________________________________________________________ 5.261 Bucyrus – Model 30M4-NP Continuous Miner

____________________________________ Replacement of wear parts Crawler chain removal and installation (with grease take-up) crawler chain removal and installation

To remove the crawler chain (Fig. 148):  Position the miner so that there is sufficient clearance to work and enough space to pull the chain off.  Block the machine so that the crawler assembly is off of the mine floor. Do not place blocking under the crawler track.  Raise the gathering head assembly to its highest position and securely block it.

WARNING! Observe the safe working load limits of all blocking devices. You can be seriously injured or killed by falling loads.

© BUCYRUS AMERICA, INC.

 Lower the cutter head assembly so that it rests on the gathering head.  Lower the conveyor.  Disconnect and lock out the electrical power to the miner. Follow all applicable regulations regarding lockout/tagout procedures.

WARNING! Failure to follow all applicable regulations regarding lockout/ tagout procedures may result in machine damage or serious injury or death of personnel.  Attach a grease gun to the crawler grease take-up fitting and pump grease into the take-up cylinder to extend the cylinder and remove pusher plate pressure on the idler shims.  Remove the hex head cap screw securing the shims to the take-up housing and remove all shims and store them in a safe place.  Bleed off pressure in the grease take-up cylinder by opening the needle valve in the grease line. Be sure that the cylinder collapses to relieve tension in the crawler chain.

WARNING! The end of the chain, just forward of the separation point, should be blocked. Personnel should stay clear of the chain during separation to avoid injury when the chain is disconnected.  Locate a tram track link near the track opening at the bottom of the tram case. Remove the two (2) capscrews and nuts, one on each side of the crawler pad, and drive the two crawler pins out of the crawler pad.

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Replacement of wear parts _____________________________________  Break the chain at the bottom of the drive sprocket.   Unblock the loose length of chain and lower it to the mine floor.

Attach a pull chain or cable to the end of the crawler chain.  Attach new crawler to bottom portion of old crawler.  Attach top of old crawler to a pull vehicle.  Tram crawler in reverse as pull vehicle holds just enough tension to “tram” on new crawler.

© BUCYRUS AMERICA, INC.

 Disconnect the old chain and pin the new chain together.

_________________________________________________________________ 5.263 Bucyrus – Model 30M4-NP Continuous Miner

____________________________________ Replacement of wear parts

© BUCYRUS AMERICA, INC.

Fig. 148: Crawler chain removal and installation

Pin, bolt, and nut

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Replacement of wear parts _____________________________________ crawler chain installation

To install the crawler chain (Fig. 148):  Ensure that the miner is correctly cribbed.  Lay the crawler chain on the mine floor under the crawler frame and extending forward in front of the mine. The grousers should be facing down.

IMPORTANT! Be sure that the grousers are in the correct direction before installing the chain into the machine. Check the parts book for your machine to verify the correct direction.  Attach a pull cable to the rear of the crawler chain.

 Slowly pull the crawler chain into position on the drive sprocket so that the sprocket teeth engage the pockets in the first crawler pad.

Continue pulling the chain slowly as it engages the rest of the exposed sprocket teeth and moves forward on the upper crawler chain return deck. Pull the end of the chain clear of the take-up roller until it drapes over the roller.  Block the bottom of the chain near the front.  Coat the connecting pins with EP#2 multi-purpose grease.  Remove the pull cable and mate the two ends of the chain using the two connecting pins.  Apply Loctite 271 to the bolts then secure the pins with the flat head socket capscrews and nuts.  Ensure that the needle valve on the grease take-up cylinder has been closed.  Pump grease into the take-up cylinder grease fitting until the proper chain sag is achieved (Fig. 149).

Fig. 149: Crawler chain sag measurement

Bottom of tractor wear shoe

64 to 90 mm gap (2-1/2 to 3-1/2 inches)

Top of tram track

_________________________________________________________________ 5.265 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

 Feed the loose end of the pull cable around the drive sprocket and into the upper crawler chain return deck. Continue feeding the pull cable forward until it is at the front of the crawler frame and past the take-up roller. Run the cable forward where it can be attached to a vehicle or other pulling device.

____________________________________ Replacement of wear parts Crawler take-up roller removal and installation crawler take-up roller removal

To remove the crawler take-up roller (Fig. 150):  Position the miner so that there is sufficient clearance to work.  Block the machine so that the crawler assembly is off of the mine floor. Block under the crawler chain, just behind the crawler takeup roller.  Raise the gathering head assembly to its highest position and securely block it.

WARNING! Observe the safe working load limits of all blocking devices. You can be seriously injured or killed by falling loads.

© BUCYRUS AMERICA, INC.

 Lower the cutter head assembly so that it rests on the gathering head.  Lower the conveyor.  Disconnect and lock out the electrical power to the miner. Follow all applicable regulations regarding lockout/tagout procedures.  Attach a grease gun to the crawler grease take-up fitting and pump grease into the take-up cylinder to extend the cylinder and remove pusher plate pressure on the idler shims.  Remove the hex head cap screw securing the shims to the take-up housing and remove all shims and store them in a safe place.  Bleed off pressure in the grease take-up cylinder by opening the needle valve in the grease line. Be sure that the cylinder collapses to relieve tension in the crawler chain.

WARNING! Failure to follow all applicable regulations regarding lockout/ tagout procedures may result in machine damage or serious injury or death of personnel.  Separate the crawler chain near the bottom of idler and use a hoist to raise top of crawler off of idler.  Place a lifting device around both sides of the take-up roller and slide the roller forward until it clears the frame.

WARNING! Observe the safe working load limits of all blocking devices. You can be seriously injured or killed by falling loads.

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Replacement of wear parts _____________________________________

© BUCYRUS AMERICA, INC.

Fig. 150: Crawler track take-up idler removal and installation

Crawler takeup roller

_________________________________________________________________ 5.267 Bucyrus – Model 30M4-NP Continuous Miner

____________________________________ Replacement of wear parts crawler take-up roller installation

To install the crawler chain take-up idler roller (Fig. 150):  Apply a thin coating of grease to the top and bottom take-up slide areas of the crawler frame.  Verify the proper oil fill on the inside of the take-up roller housing.

Place the assembly on its side with the roller shaft vertical. Remove both pipe plugs visible on the side of the roller. Pour gear oil into one hole until it runs out the other hole.  Position the crawler take-up assembly in front of the slide area of the crawler frame.  Slide the assembly into the main frame, then rearward until it stops against the piston of the take-up cylinder.  Ensure that the piston end of the take-up cylinder fits properly into the take-up plug in the roller assembly.

© BUCYRUS AMERICA, INC.

 Reconnect the crawler chain.  Unblock the chain and check for proper tension (Fig. 149). If necessary, adjust the shims until the required sag is achieved.  Connect the trailing cable to energize the miner.  Remove all blocking.  Check the crawler assembly for correct operation.

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Replacement of wear parts _____________________________________ Tram brake removal and installation tram brake removal

To remove the tram brake:  Disconnect and lock out the electrical power to the miner. Follow all applicable regulations regarding lockout/tagout procedures.

WARNING! Failure to follow all applicable regulations regarding lockout/ tagout procedures may result in machine damage or serious injury or death of personnel.  Remove all necessary covers to access brake (Fig. 151).

Fig. 151: Cover removal Tram brake access cover

© BUCYRUS AMERICA, INC.

Tram brake access cover

 Thoroughly clean the area around the tram brake to keep debris from getting into the tram gear case once the tram brake has been removed.  Remove, tag, and cap all hydraulic lines to the tram brake.  Remove and tag all electrical lines to the tram brake.  Remove the six (6) hex head bolts and lock washers and two (2) socket head cap screws and lock washers which secure the tram brake gear case to the tram gear case (Fig. 152). Save these bolts and washers for installation.

_________________________________________________________________ 5.269 Bucyrus – Model 30M4-NP Continuous Miner

____________________________________ Replacement of wear parts Fig. 152: Tram brake gear case removal Socket head cap screw

Socket head cap screw

Hex head bolt (6)

Tram brake

Tram gear case

© BUCYRUS AMERICA, INC.

Tram brake gear case

 Attach a lifting device to the tram brake and tram brake gear case and hoist the assembly off of the machine.

WARNING! You can be seriously injured or killed by falling loads. Always observe the safe working load limits of all lifting devices.  Locate the gasket which goes between the tram brake gear case and the tram gear case for possible reuse during installation.  Remove the four (4) hex head bolts which secure the tram brake to the tram brake gear case (Fig. 153) and put aside for use during installation.  Locate the gasket which goes between the tram brake and the tram brake gear case for possible reuse during installation.

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Replacement of wear parts _____________________________________ Fig. 153: Tram brake removal Tram gear case

Hex head bolt (4)

_________________________________________________________________ 5.271 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

Tram brake

____________________________________ Replacement of wear parts tram brake installation

To install the tram brake:  Inspect the gasket which goes between the tram brake and the tram brake gear case for any nicks or damage. If gasket is damaged, replace.  Install the gasket onto the tram brake.  Install the tram brake onto the tram brake gear case in the orientation shown in Fig. 154 using the four (4) hex head bolts from removal.

Fig. 154: Tram brake to tram brake gear case installation Tram brake gear case

© BUCYRUS AMERICA, INC.

Tram brake (note orientation)

Hex head bolt (4)

Tram brake installation orientation  Inspect the gasket which goes between the tram brake gear case and the tram gear case for any nicks or damage, If gasket is damaged, replace.   Install the gasket onto the tram brake gear case.  Verify that power is still disconnected and locked out.  Ensure that the area on top of the tram gear case where the tram brake gear case attaches is clear of debris, taking special care to ensure that no debris enter the tram gear case.  Attach a lifting apparatus to the tram brake and tram brake gear case assembly and hoist onto the machine.

WARNING! You can be seriously injured or killed by falling loads. Always observe the safe working load limits of all lifting devices.  Lower the tram brake and tram brake gear case onto the tram gear case. Be sure to align the dowel pins on the tram brake gear case with the holes on the tram gear case.

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Replacement of wear parts _____________________________________  Install the two (2) socket head capscrews and lock washer (Fig. 155) to secure the tram brake gear case to the tram gear case.

Torque to the appropriate value.   Install the six (6) hex head bolts and lock washers (Fig. 155) which secure the tram brake gear case to the tram gear case. Torque to the appropriate value.

Fig. 155: Tram brake gear case to tram gear case installation

Hex head bolt (6)

Socket head cap screw Socket head cap screw

Tram gear case

 Reconnect all electrical and hydraulic lines to the tram brake.  Install all covers removed during tram brake removal.  Reconnect power to the machine and ensure that the tram brake is working correctly.

_________________________________________________________________ 5.273 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

Tram brake gear case

____________________________________ Replacement of wear parts Conveyor assembly The conveyor assembly (Fig. 156) can be raised and lowered with hydraulic cylinders. The assembly is attached to the main frame at a pair of raised pivots. The discharge section of the conveyor has a double clevis swing pivot and can swing 45° to the left or right.

© BUCYRUS AMERICA, INC.

Fig. 156: Conveyor assembly

Conveyor pivot

Conveyor attachment pivots

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Replacement of wear parts _____________________________________ Conveyor chain removal and installation conveyor chain removal and installation

To remove the conveyor chain (Fig. 157):  Position the miner so that the top of the conveyor and both ends of the machine can be reached. Allow sufficient room at the back of the miner to pull the conveyor chain off.  Raise the cutter head and block it following all Mine and Federal regulations WARNING! Observe the safe working load limits of all blocking devices. You can be seriously injured or killed by falling loads.  Position the discharge conveyor in line with the intermediate conveyor and lower it to it’s lowest point.

WARNING! Failure to follow all applicable regulations regarding lockout/ tagout procedures may result in machine damage or serious injury or death of personnel.  Open the needle valve to release tension on the conveyor chain take-up cylinders, thereby relaxing tension on the conveyor chain.

CAUTION! To avoid injury while relieving tension off of the conveyor chain, wear proper personal protective equipment, to include, at a minimum, safety glasses and gloves.  Using a pry bar, lift the chain off the conveyor deck several times to relieve tension in the chain.

_________________________________________________________________ 5.275 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

 Disconnect and lock out the electrical power to the miner. Follow all applicable regulations regarding lockout/tagout procedures.

____________________________________ Replacement of wear parts Fig. 157: Conveyor chain removal and installation

Connecting pin

© BUCYRUS AMERICA, INC.

Retaining pin

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Replacement of wear parts _____________________________________ conveyor chain installation

To install the conveyor chain (Fig. 157):  Ensure that the cutting head is adequately blocked.

WARNING! Observe the safe working load limits of all blocking devices. You can be seriously injured or killed by falling loads.  Lay the new chain, uncoiled and upside down, behind the conveyor with the nearest end near the tail roller.

NOTICE! The conveyor chain does not have a right or wrong running directions, only a correct up and down side. The flat side of the flight chains must run on the deck.

 Pull the conveyor chain under the tail roller and through the return deck, stopping when the chain reaches the foot shaft.  Pull the conveyor chain up over the foot shaft sprocket and lay it in the gathering pan.  Disconnect the pulling cable from the front end of the chain and run it along the top conveyor deck to the back of the miner.  Connect the pulling cable to the other end of the conveyor chain on the mine floor. Pull it over the tail roller, through the conveyor deck, and up to the other end of the chain on the gathering pan.  Connect the chain using a connecting pin and two retaining pins. bend the retaining pins opposite the direction of conveyor chain travel.  Close the bleed valve in the conveyor chain take-up circuit so that the circuit can be pressurized when power is reapplied.

WARNING! Make sure all personnel are clear of the miner before performing the following checks. Do not stand behind the conveyor when the chain is running.  Connect the trailing cable to energize the miner.  Start the pump motor.  Swing the discharge conveyor full right and left to ensure that the chain is clear.  Turn on the gathering head motors to run the conveyor. Elevate the conveyor full up and down and swing the discharge conveyor full left and right and check that the chain is running smoothly.

_________________________________________________________________ 5.277 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

 Connect the pulling cable (attached to the old chain still in the machine) to the nearest end of the new conveyor chain.

____________________________________ Replacement of wear parts

  Observe the chain as it comes off the foot shaft and ensure that there is no excessive slack and that the chain does not contact the CLA arms.

© BUCYRUS AMERICA, INC.

 If the chain slack is excessive, adjust the chain tension (see Chain tension adjustment procedure in this chapter).

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Replacement of wear parts _____________________________________ Conveyor assembly removal and installation conveyor assembly removal

To remove the conveyor assembly (Fig. 158):  Raise the conveyor to an elevated position so at to provide access to the upper conveyor raise cylinder pins.  Block the elevated conveyor following all Mine and Federal regulations.

WARNING! Observe the safe working load limits of all blocking devices. You can be seriously injured or killed by falling loads.

WARNING! Failure to follow all applicable regulations regarding lockout/ tagout procedures may result in machine damage or serious injury or death of personnel.  Attach lifting devices to both the intermediate and discharge conveyor sections. Take up slack in the lifting device without raising the conveyor.

WARNING! Observe the safe working load limits of all lifting devices. You may be seriously injured or killed by falling loads.  Disconnect the conveyor chain (see Conveyor chain removal procedure in this chapter) and remove it from the machine.  Support the rod end of each conveyor raise cylinder.  Remove the pins from each upper cylinder pin and remove the cylinder pins.  Appropriately secure the conveyor assembly laterally to prevent it from swinging when the hydraulic lines to the swing cylinders are removed.  Remove and cap the hydraulic lines going to the swing cylinder.

WARNING! Never disconnect a hydraulic hose if the circuit is pressurized. If a hose is disconnected while the circuit is pressurized, machine damage or severe injury may result.

_________________________________________________________________ 5.279 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

 Disconnect and lock out the electrical power to the miner. Follow all applicable regulations regarding lockout/tagout procedures.

____________________________________ Replacement of wear parts

  Disconnect, tag, and cap the lubrication lines going to the right and left pivot pins.  Release any pressure that might exist between the lateral sway guides and the guide discs by backing out the set screw on each side.  Remove and cap the cooling lines near the front pivot of the conveyor.  Remove the capscrews from the conveyor pivot pin retainer and remove the retainer.  Push the conveyor pivot pins toward the center until they are free.

© BUCYRUS AMERICA, INC.

NOTICE! If the pivot pin is tight, be sure the lifting device is not binding the pivot. If the pivot is not in a bind, use the puller hole to aid in pin removal.  With the lifting device, slowly maneuver the conveyor assembly away from the machine.

Fig. 158: Conveyor assembly removal and installation

Conveyor raise cylinder

Main frame pivot

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Replacement of wear parts _____________________________________ conveyor assembly installation

To install the conveyor assembly (Fig. 158):  Attach a lifting device to the conveyor assembly and slowly maneuver it onto the machine.

WARNING! Observe the safe working load limits of all lifting devices. You can be seriously injured or killed by falling loads.  With the conveyor pivot in position, grease the conveyor pivot pins to ease installation and then drive the pins into the pivot bores.  Install the pivot pin retainer and secure with hex head cap screws.  Reconnect the grease lines to each pivot pin.

WARNING! Observe the safe working load limits of all lifting and blocking devices. You can be seriously injured or killed by falling loads.  Connect the cooling lines near the front pivot of the conveyor.   Connect the hydraulic lines to the swing cylinders.  Attach the conveyor raise cylinders to the clevises on the underside of the conveyor by installing the conveyor raise cylinder pins.  Reconnect the conveyor chain (see Conveyor chain installation procedure in this chapter).  Apply nominal pressure of the guide discs to the lateral sway guides.  Clear all tools and debris from the area and remove the lifting and blocking devices.

WARNING! Be sure all conveyor components are correctly installed and that the conveyor chain is properly engaged by the foot shaft before starting the miner.  Connect the trailing cable to energize the miner.  Start the pump motor.  Start the gathering head motors to run the conveyor chain.  Elevate the conveyor full up and down and swing the discharge conveyor full left and right and check that the conveyor chain is running smoothly.

_________________________________________________________________ 5.281 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

 Using the lifting device, pivot the conveyor into an elevated position and securely block the conveyor.

____________________________________ Replacement of wear parts Discharge conveyor removal and installation discharge conveyor removal

To remove the conveyor discharge (Fig. 159):  Position the machine so that the top and bottom of the conveyor can be reached and there is enough room at the back for removal of the conveyor chain and the discharge conveyor.  Raise the conveyor far enough to provide adequate work space under the swing pivot. Securely block the intermediate conveyor section ensuring that the swing pivot remains accessible.

© BUCYRUS AMERICA, INC.

WARNING! Observe the safe working load limits of all blocking devices. You can be seriously injured or killed by falling loads.  Align the discharge conveyor straight with the centerline of the intermediate conveyor.   Disconnect and lock out the electrical power to the miner. Follow all applicable regulations regarding lockout/tagout procedures.

WARNING! Failure to follow all applicable regulatory lockout/tagout procedures may result in machine damage or serious injury or death of personnel.  Relieve the pressure in the conveyor chain take-up circuit (see Conveyor chain removal procedure in this chapter).   Attach lifting devices to the discharge conveyor take up slack in the lifting device without raising the conveyor.

WARNING! Observe the safe working load limits of all lifting devices. You may be seriously injured or killed by falling loads.  Disconnect the conveyor chain at a connecting pin close to the end of the discharge conveyor (see Conveyor chain removal procedure in this chapter).  Disconnect, tag, and cap the hydraulic lines from the conveyor swing cylinders. Cap the ports in the cylinders.

WARNING! Never disconnect a hydraulic hose if the circuit is pressurized. If a hose is disconnected while the circuit is pressurized, machine damage or severe injury may result.  Remove the forward swing cylinder pin at the intermediate conveyor section.  Remove the bolts and stop nuts that attach flexible sideboards to each side of the intermediate conveyor.

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Replacement of wear parts _____________________________________

  Slide each sideboard from its guide on the discharge conveyor and remove it. If the sideboards are not free to slide, remove the hex head capscrews and spring lock washers from each flexible sideboard guide assembly and remove them from the top of the discharge conveyor on each side.  Remove the capscrews from the top pivot pin and remove the pin.

Two puller holes, protected by set screws and located on the top and bottom of each pivot pin, are provided to aid in removing the pivot pin. A pivot retainer will remain in the top pivot bore. If not already released, this retainer can be tapped loose and removed from the area between the top and bottom conveyor decks.  Repeat this procedure for the bottom pivot pin and pivot retainer. If the bottom pin is not free to come out, check the tension on the lifting device to make sure the pin is not in a bind.

© BUCYRUS AMERICA, INC.

 Slowly and carefully maneuver the discharge conveyor away from the intermediate conveyor section.

_________________________________________________________________ 5.283 Bucyrus – Model 30M4-NP Continuous Miner

____________________________________ Replacement of wear parts Fig. 159: Discharge conveyor removal and installation

Flexible guide

Pivot pin

© BUCYRUS AMERICA, INC.

Bolt (3 each side)

Bolt (4 each side)

Washer (3 each side)

Sideboard

Nut (3 each side)

Conveyor swing cylinder pin

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Replacement of wear parts _____________________________________ discharge conveyor installation

To install the discharge conveyor (Fig. 159):  Ensure that the trailing cable is still disconnected and properly locked/tagged out. Follow all applicable regulations regarding lockout/tagout procedures.

WARNING! Failure to follow all applicable regulations regarding lockout/ tagout procedures may result in machine damage or serious injury or death of personnel.  Ensure that the intermediate conveyor is still securely blocked.  Attach a lifting device to the discharge conveyor and slowly lift and maneuver it into the intermediate conveyor section.

 Check the top and bottom pivot pins and bushings for wear or damage and replace as necessary. Lubricate all pins and bushings with grease prior to installation.  Install the top pivot pin and pivot retainer. Secure the retainer with capscrews. Note that the pivot pin has an anti-rotation dowel which must be positioned in the slot in the top conveyor deck.  Install the bottom pivot pin and pivot retainer. Secure the retainer with capscrews. Note that the pivot pin has an anti-rotation dowel which must be positioned in the slot in the bottom conveyor deck.  If necessary, use adjustment shims to align the decks of the intermediate and discharge conveyors. Misalignment can occur due to wear or damage of the discharge conveyor.  Using the lifting device, swing the discharge conveyor fully to the left and right to make sure that it does not bind.  Grease the four pivot surface lubrication points (two on each side) until grease is visible on the mating sections of the conveyor. This will lubricate the pivot pins and bushings as well as the large plates which slide on each other.  Using the lifting device, position the conveyor to align the swing cylinder clevises with both swing cylinder eyes. Lubricate the cylinder pins with grease and insert them through the clevises and eyes.

Secure each pin with a cotter pin.  Connect the hydraulic lines to the cylinders.  With the discharge conveyor straight, reconnect the conveyor chain (see Conveyor chain installation procedure in this chapter).

_________________________________________________________________ 5.285 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

WARNING! Observe the safe working load limits of all lifting and blocking devices. You can be seriously injured or killed by falling loads.

____________________________________ Replacement of wear parts

  Install a flexible sideboard on each side of the conveyor. Secure with carriage bolts and heavy elastic stop nuts.  Connect the trailing cable to energize the miner.  Raise the conveyor and remove the blocking.

© BUCYRUS AMERICA, INC.

 Operate the conveyor raise, lower, swing left, and swing right functions and check for smooth operation.

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Replacement of wear parts _____________________________________ Tail roller removal and installation tail roller removal

To remove the tail roller (Fig. 160):  1. Position the machine so that the tail roller can be comfortable reached and there is enough room available for its removal.  2. Align the discharge conveyor straight with the centerline of the intermediate conveyor.  3. Lower the conveyor to a comfortable working height and then securely block.

WARNING! Observe the safe working load limits of all blocking devices. You can be seriously injured or killed by falling loads.

WARNING! Failure to follow all applicable regulations regarding lockout/ tagout procedures may result in machine damage or serious injury or death of personnel.  5. Relieve the pressure in the conveyor chain take-up circuit (see Conveyor chain removal procedure in this chapter).   6. Use a pry bar to lift the chain off the conveyor deck several times to relieve tension in the chain.  7. Disconnect the conveyor chain at a connecting pin close to the tail roller (see Conveyor chain removal procedure in this chapter) and clear the chain from the roller.  8. Attach a lift device to the tail roller and take up the slack so that the weight of the tail roller is supported by the lifting device.  9. Remove the cover over each side of the tail roller by removing the capscrews from each cover.  10. Remove the cotter pin from the end of the take-up cylinder.  11. Remove the attachment block by removing the two (2) socket head bolts that secure it.  12. Slide the take-up cylinder back and out of the tail roller assembly.  13. Repeat steps 9 through 12 for the other side.  14. Drive out the roll pin on each end of the tail roller to free the inserts.

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© BUCYRUS AMERICA, INC.

 4. Disconnect and lock out the electrical power to the miner. Follow all applicable regulations regarding lockout/tagout procedures.

____________________________________ Replacement of wear parts  15. Slide the insert of each end of the tail roller.  16. The tail roller should now be free of the conveyor.

Fig. 160: Conveyor tail roller removal and installation

© BUCYRUS AMERICA, INC.

Tail roller

Cover Socket head capscrew (2)

Capscrew (4)

Take-up cylinder

Insert

Attachment block

Roll pin

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Replacement of wear parts _____________________________________ tail roller installation

To install the tail roller (Fig. 160):  Position the tail roller in in the conveyor.  Slide the insert into each end of the tail roller.  Insert a roll pin into each end of the tail roller to secure the insert to the roller.  Slide the take-up cylinders back into position with the end of the cylinder sliding through the hole in the tail roller insert.  Insert a cotter pin into the end of each take-up cylinder rod  Secure the attachment block to the end of each cylinder with socket head capscrews (two (2) on each side).

 Make sure the valve is closed in the conveyor chain take-up circuit.  Reconnect the conveyor chain (see Conveyor chain installation procedure in this chapter).  Connect the trailing cable to energize the miner.  Operate the conveyor and check for correct chain tension.

_________________________________________________________________ 5.289 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

 Install the side cover over each side of the tail roller and secure with four (4) capscrews.

_____________________________________________ Troubleshooting Troubleshooting procedures The following section lists possible problems encountered when servicing the Continuous Miner and can aid in locating and correcting these problems.

This section covers basic components, with each listed in a troublecause-remedy format.

WARNING! Some procedures must be carried out with the cover of the electrical controller removed and some procedures require the controller to be energized during the tests. It is extremely important that you take all necessary precautions to prevent accidental electrical shock while working within the controller. An certified electrician must supervise and inspect all work performed.

© BUCYRUS AMERICA, INC.

For maintenance procedures and tests that DO NOT require the controller to be energized, precautions include: ■

Before removing the controller covers, remove power from the system by disconnecting the trailing cable. Follow all applicable regulations regarding the lockout/tagout of electrical power.

■

Use insulated gloves and tools where possible.

■

All connections must be tight and care must be taken to prevent bolts, nuts, washers and other small metal fasteners from being dropped or lost inside the controller. These lost fasteners could cause electrical shorts inside the controller.

For procedures that DO require that the controller be energized while the cover is off: ■

At no time should you reach inside the controller while it is energized. If it becomes necessary to make adjustments or to replace parts inside the controller, the “POWER OFF” button must be pushed and the “PILOT DISC” must be in the off position.

■

Use insulated gloves and tools where possible.

■

All connections must be tight and care must be taken to prevent bolts, nuts, washers and other small metal fasteners from being dropped or lost inside the controller. These lost fasteners could cause electrical shorts inside the controller.

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Troubleshooting ______________________________________________ WARNING! Never disconnect a hydraulic hose if the circuit is pressurized or there is a load on the circuit. If a hose is disconnected while the cylinder is supporting a load, the load will fall.

Typical hydraulic problems

■

contaminated oil or poor oil quality

■

low or insufficient oil in the system

■

using the wrong type of oil or wrong viscosity grade

■

air in the hydraulic system

■

internal or external leakage of the hydraulic system

■

improper mechanical adjustments, such as reliefs

■

mechanical or structural damage leading to component failure

■

components by-passing (internal leaking or inability to hold pressure) which leads to erosion of bushings, valve spools, and other costly, critical components

The greatest aid to troubleshooting a hydraulic system is the confidence that comes with knowing the intended operation of the system, along with a fundamental understanding of basic hydraulic principles. Every component in the system has an intended purpose. The construction and operating characteristics of each of these components should be clearly understood before attempting to troubleshoot the machine. For example, understanding that a solenoid controlled directional valve can be manually actuated will save considerable time in isolating a defective solenoid. Please familiarize yourself with the operational descriptions of the hydraulic circuits given in the Hydraulics section of this chapter.

It is also important to know the capabilities of the system. Each component in the system has a maximum rated speed, flow, torque, or pressure. If the system is loaded beyond the specifications, the possibility of failure is greatly increased. The correct operating pressures of a system must be known and must always be checked and set with a pressure gauge. Refer to the hydraulic schematic in the Bucyrus America, Inc. parts manual supplied with your machine for the correct operating parameters. When in doubt, always assume that the correct pressure is the lowest pressure that will allow adequate performance of the system function(s) while remaining below the maximum rating of the machine’s components.

_________________________________________________________________ 5.291 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

The most common causes for improper function are:

_____________________________________________ Troubleshooting

© BUCYRUS AMERICA, INC.

The ability to recognize trouble indicators in a specific system is usually acquired with experience. the gaining of this experience can be greatly enhanced by developing a logical sequence for determining the cause of a hydraulic problem and implementing the proper remedy. Refer to the general troubleshooting charts in this section that illustrate the logical sequence for shutdown, troubleshooting, and restarting the machine. The charts cover: ■

general safety procedure for shutting down the machine

■

troubleshooting excessive noise

■

troubleshooting excessive heat

■

troubleshooting incorrect flow

■

troubleshooting incorrect pressure

■

troubleshooting faulty movement/operation

■

general restart checklist and procedure

This general information is intended to enhance the understanding of basic hydraulic principles which will lead to the development of a logical troubleshooting procedure. Specific troubleshooting checklists for each hydraulic circuit are given directly after the very important “Contaminants in hydraulic systems” section.

Contaminants in hydraulic systems The primary cause of hydraulic component failure is SYSTEM CONTAMINATION! Cleanliness must be a high priority when servicing the hydraulic system. Even very small particles can damage system components by scoring valves, clogging orifices, and wearing seals prematurely. It is not the intent of this operation manual to outline a contamination control program but some of the most effective steps that have been identified in successful programs are given below: 1. Ensure that bulk oils are at acceptable cleanliness levels.

Areas where Bucyrus America, Inc. customers have made improvements in the past include: –

implementing ISO Cleanliness Code standards for bulk hydraulic oils

–

evaluating bulk oil shipments for cleanliness by conducting particle counts and maintain records

–

minimizing drum usage by utilizing tote tanks and five gallon pails

–

utilizing plastic versus steel storage tanks, if possible

–

installing desiccant breathers on all bulk tanks

–

using sealed plastic containers for adding oil to small sumps

–

locating bulk tanks near equipment and pump directly to reservoirs

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Troubleshooting ______________________________________________ –

utilizing filter carts to maintain oil cleanliness standards

–

properly training personnel on the importance of clean oil and best practices for storage and handling

–

monitoring the program closely and looking for continuous improvement

–

always clean the area around the component that is to be removed and inspected

–

store components in a plastic bag after inspection and prior to replacement on machine

–

cap off all open hoses/fittings

–

never touch a filter with bare hands when installing it back onto the machine

–

pay close attention to the filler/breather cap and replace it when damaged or in the recommended time frame

Contact your Bucyrus America, Inc. representative for more information on implementing an effective program to ensure that your oil and maintenance practices are not contributing to your equipment failure.

Specific hydraulic circuit troubleshooting Multi-function failure If more than one function fails to operate on the machine, check the output of the pumps. Since this is an “open center” circuit, the normal pressure (with all directional control valves in the center position) should be less than 100 psi. This pressure reading illustrates the necessary pressure to circulate the oil through the system. If the pressure reading under these conditions is significantly greater than 100 psi, it is likely that one of the control valves is trying to direct oil to one (or more) of the circuits on the machine.

The next step in troubleshooting a multi-function failure is to check the pilot pressure on the main control valve manifold. This pressure should be between 400 - 500 psi. If the pilot pressure is significantly below 350 psi, start with the General Troubleshooting Flow Chart IV - Incorrect Pressure. Another step to resolve multi-function failure is to have an electrician check for power to the solenoid circuits.

Check for correct pump rotation if electrical work has been performed (such as trailing cable replacement).

_________________________________________________________________ 5.293 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

2. Eliminate contamination source through “clean” maintenance practices. This is best achieved by understanding the primary sources of contamination during maintenance and troubleshooting which are given below:

_____________________________________________ Troubleshooting Individual hydraulic circuit failures Perform the following checks on the individual circuits in conjunction with the general troubleshooting: Cutter head raise Check pilot supply pressure at remote control valves.  Check pilot pressure at the Raise pilot cylinder on the cutter head directional control valve when the remote control valve is in the Raise position.  Check the directional control valve for proper operation.  Check to see that piping has not been crossed, especially if the problem occurs after maintenance or repair work.  Check that the "in-line" counterbalance holding valve is piloted and shifting to direct retract port cylinder oil flow back to tank.

© BUCYRUS AMERICA, INC.

 Check to see that there is no mechanical bind.  Check cylinders for bypassing.  Check for pilot pressure on the cutter head cylinder’s holding valves. Also check that the valves are shifting to send oil back to the tank. (Note: cylinder removal will be required to safely achieve this) Cutter head lower Check pilot supply pressure at remote control valves.  Check pilot pressure at the Lower pilot cylinder on the cutter head directional control valve when the remote control valve is in the Lower position.  Check the direction control valve for proper operation.  Check to see that piping has not been crossed, especially if the problem occurs after maintenance or repair work.  Check to see that there is no mechanical bind or hydraulic block.  Check flow control valve cartridge.  Check cylinders for bypassing.  Check for pilot pressure on the cutter head cylinder's holding valves. Also check that the valves are shifting to send (extend port) oil back to the tank. Note: cylinder removal will be required to safely achieve this.

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Troubleshooting ______________________________________________ Gathering head raise  Check the directional control valve for proper operation.  Check to see that piping has not been crossed, especially if the problem occurs after maintenance or repair work.  Check to see that there is no mechanical bind.  Check cylinders for bypassing.  Check needle valve on pilot circuit to verify that it is not open or leaking off.  Check in-line counterbalance valve for proper operation or blockage.

Gathering head float  Check the control valve for proper operation.

 Check to see that there is no mechanical bind.  Check cylinders for bypassing (they will leak out the top).  Check needle valve on pilot circuit to verify that it is not open or leaking off.  Check counterbalance valve for proper operation (see the schematic in the Bucyrus America, Inc. parts book supplied with your machine for the proper setting).

_________________________________________________________________ 5.295 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

 Check to see that piping has not been crossed, especially if the problem occurs after maintenance or repair work.

_____________________________________________ Troubleshooting Conveyor Raise  Check the directional control valve for proper operation.  Check to see that piping has not been crossed, especially if the problem occurs after maintenance or repair work.  Be sure that the built-in atmospheric-vented reliefs on the cylinders are not dumping oil.  Check to see that there is no mechanical bind.  Verify that cylinders are not bypassing.

Conveyor Lower  Check the directional control valve for proper operation.  Check to see that piping has not been crossed, especially if the problem occurs after maintenance or repair work.

© BUCYRUS AMERICA, INC.

 Verify that pilot pressure is being applied to open the piloted builtin checks.  Verify that cylinders are not bypassing.

Conveyor Swing  Check the directional control valve for proper operation.  Check for any mechanical bind or any obstruction blocking movement, either to the cylinder itself, the main pivot area, or to some point along or under the discharge conveyor itself. Also check to ensure that the pivot bushings have not frozen up from lack of lubrication.  Verify that the cylinder is not bypassing.

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Troubleshooting ______________________________________________ Stabilizer Raise  Check the directional control valve for proper operation.  Check to see that piping has not been crossed, especially if the problem occurs after maintenance or repair work.  Check the lubrication network for bound bushings.  Check for any mechanical bind or any obstruction blocking movement.  Check cylinder for bypassing.

Stabilizer Lower  Check the control valve for proper operation.  Check to see that piping has not been crossed, especially if the problem occurs after maintenance or repair work.  Check for any mechanical bind or any obstruction blocking movement.  Check cylinder for bypassing.

General safety procedure for shutting down machine When shutting down the machine for maintenance:  lower or mechanically secure (block) all suspended loads  exhaust any pressure locked in the system  drain down all accumulators  isolate the electrical control system  isolate the electrical power supply Follow all procedures listed in the Shutdown procedure in this chapter.

_________________________________________________________________ 5.297 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

 Check the lubrication network for bound bushings.

_____________________________________________ Troubleshooting Table 4: Flow chart I for troubleshooting excessive noise

Pump Noisy Cause

Motor Noisy Remedy

Cause

Relief/Counterbalance Valve Noisy Remedy

Cause

Remedy

Cavitation

A

Coupling misaligned

C

Setting too low or too close to another valve setting

D

Air in fluid

B

Motor or coupling worn or damaged

E

Worn poppet and seat

E

Coupling misaligned

C

Pump worn or damaged

E

Remedies

© BUCYRUS AMERICA, INC.

A. Any or all of the following:        

replace dirty filters wash strainers in solvent compatible with system fluid clean clogged inlet line clean reservoir breather vent change system fluid change to proper pump drive motor speed check fluid temperature check fluid level

B. Any or all of the following:  tighten leaky inlet connections  fill reservoir to proper levels: with few exceptions, all return lines should be below fluid level in the reservoir  bleed air from system  replace pump shaft seal; also replace shaft if worn at seal journal  replace pump C. All of the following:  align unit, ensure that mounting hardware is correct and tight  check condition of seals, bearings, and coupling D.  install and/or adjust pressure gauge E.  overhaul or replace defective parts

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Troubleshooting ______________________________________________ Table 5: Flow chart II for troubleshooting excessive heat Motor Heated Cause

Relief Valve Heated

Cause

Remedy

Remedy

Cause

Remedy

Fluid heated

See Fluid Heated

See Fluid Heated

System pressure too high

D

Cavitation

A

Relief or unloading valve set too high

D

Valve setting incorrect

D

Unloading valve set too high

D

Air in fluid

B

Excessive load

C

Worn or damaged valve

E

Fluid dirty or low supply

F

Relief or unloading valve set too high

D

Worn or damaged motor

E

Incorrect fluid viscosity

F

Excessive load

C

Faulty fluid cooling system

G

Worn or damaged pump

E

Worn pump, valve motor, cylinder, or other component

E

Fluid heated

Remedy See Fluid Heated

Cause

Fluid Heated

Fluid heated

Remedies A. Any or all of the following:      

replace dirty filters clean clogged inlet line clean reservoir breather vent change system fluid change to proper pump drive motor speed overhaul or replace supercharge pump

F.  change filters  check system fluid viscosity; change if necessary  fill reservoir to proper level G.  clean cooler and/or strainer  replace cooler control valve  repair or replace cooler

B. Any or all of the following:  tighten leaky inlet connections  fill reservoir to proper levels: with few exceptions, all return lines should be below fluid level in the reservoir  bleed air from system  replace pump shaft seal; also replace shaft if worn at seal journal C. All of the following:  align unit  check condition of seals, bearings, and coupling  locate and correct mechanical binding  check for workload in excess of circuit design D.  install and/or adjust pressure gauge; keep at least 125 psi difference between valve settings E.  overhaul or replace defective parts

_________________________________________________________________ 5.299 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

Pump Heated

_____________________________________________ Troubleshooting Table 6: Flow chart III for troubleshooting incorrect flow No Flow

© BUCYRUS AMERICA, INC.

Cause

Low Flow Remedy

Cause

Excessive Flow Remedy

Cause

Remedy

Pump not receiving fluid

A

Flow control set too low

D

Flow control set too high

D

Pump drive motor not operating

E

Relief or unloading valve set too low

D

RPM of pump drive motor incorrect

H

Pump to drive coupling sheared

C

Flow by-passing thru partially open valve

E of F

Improper size pump used for replacement

H

Pump drive motor turning in wrong direction

G

External leak in system

B

Directional control set in wrong position

F

RPM of pump drive motor incorrect

H

Entire flow passing over relief valve

D

Worn pump, valve, motor, cylinder, or other component

E

Damaged pump

C

Pilot filter clogged

A

Improperly assembled pump

E

Pilot filter clogged

A

Remedies A. Any or all of the following:     

replace dirty filters clean clogged inlet line clean reservoir breather vent fill reservoir to proper level overhaul or replace supercharge pump

F. Any or all of the following   check position of manually operated controls  check electrical circuit on solenoid operated controls  repair or replace pilot pressure pump G.  reverse rotation

B. Any or all of the following: H.  replace with correct unit  tighten leaky inlet connections  bleed air from system C. All of the following:  check for damaged pump or pump drive  replace and align coupling D.  adjust setting on valve E.  overhaul or replace part

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Troubleshooting ______________________________________________ Table 7: Flow chart IV for troubleshooting incorrect pressure No Pressure

Low Pressure

Erratic Pressure

Cause

Remedy

Cause

Remedy

No flow

See Table 5

Pressure relief path exists

See Table 5

Pressure reducing valve set too low

Cause

Excessive Pressure

Remedy

Cause

Remedy

Air in fluid

B

Pressure reducing, relief, or unloading valve misadjusted

D

D

Worn relief valve

E

Pressure recuing, relief, or unloading valve worn or damaged

E

Pressure reducing valve damaged

E

Contamination in fluid

A

Damaged pump, motor, or cylinder

E

Accumulator defective or has lost charge

C

Worn pump, motor, or cylinder

E

A.  replace dirty filters and system fluid B.  tighten leaky connections  fill reservoir to proper level and bleed air from system C.  gas valve for leakage  charge to correct pressure  overhaul if defective D.  adjust valve E.  overhaul or replace part

_________________________________________________________________ 5.301 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

Remedies

_____________________________________________ Troubleshooting Table 8: Flow chart V for troubleshooting faulty operation No Movement Cause

© BUCYRUS AMERICA, INC.

No flow or pressure

Slow Movement

Remedy

Cause

See Table Low flow 5

Erratic Movement

Excessive Speed or Movement

Remedy

Cause

Cause

See Table 5

Erratic pressure

See Table Excessive flow 6

See Table 5

Air in fluid

See Table Feedback 3 transducer malfunctioning

E

Remedy

Remedy

Limit or sequence device (mechanical, electrical, or hydraulic) inoperative or misadjusted

E

Fluid viscosity too high

A

Mechanical bind

B

Insufficient control pressure for valves

See Table 6

No lubrication of machine ways or linkage

G

Misadjusted or malfunctioning valve amplifier

C

No command signal to valve or amplifier

F

No lubrication of machine ways or linkage

G

Erratic command signal

F

Overriding work load

H

Inoperative or misadjusted valve amplifier

C

Misadjusted or malfunctioning valve amplifier

C

Misadjusted or malfunctioning valve amplifier

C

Inoperative solenoid or proportional valve

E

Sticking valve

D

Malfunctioning feedback transducer

E

Worn or damaged cylinder or motor

E

Worn or damaged cylinder or motor

E

Sticking valve

D

Pilot filter clogged

See Table 5

Worn or damaged cylinder or motor

E

Remedies A.  check fluid temperature  check system fluid viscosity; change if necessary B.  locate bind and repair C.  adjust, repair, or replace part D.  clean and adjust or replace part  check condition of system fluid and filters E.  overhaul or replace part F.  repair command console or interconnecting wires G.  lubricate H.  adjust, repair, or replace counterbalance valve

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Troubleshooting ______________________________________________ Table 9: Restarting checklist Has the cause of the failure been remedied?

No

Carry out further investigation.

Yes

Clean or flush the system as required.

Yes Can dirt have entered the system by the unit failure or during replacement?

No Is the unit the correct one?

No

Modify or replace with correct unit.

No

Remedy installation.

No

Remedy installation.

Yes

Is the unit adjusted to a safe condition for start up?

Are all hydraulic connections correct?

Yes Are all electrical connections correct?

Yes Is the unit adjustable?

No

Adjust to a safe condition.

Yes No Have the cases of pumps and motors been filled?

No

Fill case.

Yes

Bleed or prime as necessary.

No

Remove safety interlocks.

No

Sound alarm or inform personnel.

Yes Will the system require bleeding or priming?

No Have all safety interlocks been removed

Yes Are all personnel aware the machine is restarting?

Yes Start machine (see Startup procedure in this chapter).

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© BUCYRUS AMERICA, INC.

Yes

_____________________________________________ Troubleshooting Bearings Table 11: Bearing troubleshooting Trouble, symptom or cause

Probable cause

© BUCYRUS AMERICA, INC.

overheating bearing  Wrong type of grease or oil.

Test, check and/or remedy  Consult the lubrication chart for the proper lubricant.

 Low oil level; loss of lubricant through seal; excessive grease.

 Oil level should normally be at the center of lowest ball or roller in bearing; check seals for signs of leaking.

 Insufficient clearance in bearing.

 Replacement bearing should be identical to original equipment to ensure proper internal clearance.

 Housing bore out of round; housing warped; excessive distortion of housing; undersized housing bore.

 Check and scrape housing bore to relieve pinching of bearing; be sure pedestal surface is flat and shims cover entire area of pillow block base when applicable.

 Shaft out of line.

 Correct alignment and be sure shafts are coupled in a straight line.

noisy bearing  Insufficient clearance in bearing.

 Replacement bearing should be identical to original equipment to ensure proper internal clearance.

 Foreign matter acting as abrasive.

 Clean bearing housing and replace worn seals.

 Housing bore out of round; housing warped; excessive distortion of housing; undersized housing bore.

 Check and scrape housing bore to relieve pinching of bearing; be sure pedestal surface is flat and shims cover entire area of pillow block base when applicable.

 Shaft and other parts of bearing assembly distorted.

 Replace bearing, shaft and other parts as needed.

vibrating bearing  Enlarged housing bore causing spinning of outer ring in housing.

 Re-bore housing and press steel bushing in bore, then machine bore to correct size.

 Foreign matter acting as abrasive.

 Clean bearing housing and replace worn seals.

 Unbalanced loading

 Check balance of rotating parts and rebalance as needed.

unsatisfactory performance  Chip in bearing housing; insufficient clearance in bearing; Ball or roller dented from extreme loading.

 Replace with OEM bearing; do not hammer on any part of bearing; clean housing and use fresh lube.

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Troubleshooting ______________________________________________ Control system troubleshooting The control system has visual troubleshooting aids to allow operators and maintenance personnel to quickly determine the cause of most operating faults.

IMPORTANT! All troubleshooting beyond observing the fault must be performed by qualified individuals.

The troubleshooting aids available are:  View panel display with both graphic and text messages.  Fault messages that appear for ten (10) seconds when the system detects a fault.

 Error messages that appear on the display whenever an action is prevented from execution due to a fault condition.  LED indicators located on various control system components.

When troubleshooting the system, note the following:  The remote control system does not recognize hydraulic system problems that are not related to the pump motor.  Most faults only affect one machine function. If multiple faults occur, the most significant fault is displayed first, then the next, and so on.  The system does not recognize power lost to the machine unless initiated by the machine control unit. If the system initiates the power loss, it will indicate such action when power is restored.

IMPORTANT! The following troubleshooting information is not intended to imply breaching any safety devices (methane barriers, hazardous isolation barriers, etc.). Do not attempt to access troubleshooting indicators (LEDs) or take measurements that may result in an unsafe working environment. All laws and regulations must be strictly adhered to.

WARNING! Only qualified personnel with approved training on this equipment and knowledge of MSHA safety requirements are permitted to perform troubleshooting on this system.

_________________________________________________________________ 5.305 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

 A permanent, time-stamped fault log that is a record of faults that have occurred. The fault log is a separate menu page.

_____________________________________________ Troubleshooting MCU status LEDs

© BUCYRUS AMERICA, INC.

Most status LEDs are located on the motor control unit (MCU). The layout of the connectors on the face plate group the pins, and therefore LEDs, in functional categories (Fig. 200, Tables 12 and 13).

_____________________________________________________________ A6474X326 VTSV/00 5.306

SPARE AC INPUT #2

NOTE: 5 VDC AND 12VDC SHOWN BY THESE LEDs IS EXTREMELY IMPORTANT TO FUNCTION OF MCU

LEFT CONVEYOR T-STAT

RIGHT CONVEYOR T-STAT

LEFT CUTTER T-STAT

RIGHT CUTTER T-STAT

PUMP T-STAT

FAN T-STAT

TRAM XFMR T-STAT

METH WARN RELAY OK

_________________________________________________________________ 5.307 Bucyrus – Model 30M4-NP Continuous Miner © BUCYRUS AMERICA, INC.

120 VAC LEAKAGE OK

REMOTE - N/U

MOTOR ENABLE (LOCAL) - N/U

CUTTER DISABLE - N/U

CUTTER RUN WITH FAN - N/U

FAN RUN - N/U

EMERGENCY TRAM

PRE-START ALARM

LED SELECT #4 - N/U

LED SELECT #3 - N/U

LED SELECT #2 - N/U

LED SELECT #1 - N/U

AUX#5 (MOMENTARY/PUMP)

AUX#4 (LATCHED/PUMP)

AUX#3 (MOMENTARY)

CONVEYOR FWD CONTACTOR

RIGHT CUTTER CONTACTOR

LEFT CUTTER CONTACTOR

PUMP CONTACTOR

HEADLIGHTS

R4-5 OUTPUT - N/U

TRAM CONTACTOR - N/U REVERSE MACHINE LIGHTING

DOWNLOAD/DEBUG RX

GATHERING HEAD RAISE SOLENOID

CNVYR SWING RIGHT SOLENOID

DOWNLOAD/DEBUG TX

UMBILICAL (PENDANT ACTIVITY)

OFF MACHINE COMM RX

+12V

OFF MACHINE COMM TX

STAB DOWN SOLENOID

MCU944 RX FROM TRACTION DRIVE

+5V

STAB UP SOLENOID

CNVYR SWING LEFT SOLENOID

CONVEYOR LOWER SOLENOID

CONVEYOR RAISE SOLENOID

CUTTER LOWER SOLENOID

GATHERING HEAD FLOAT SOLENOID

IR PENDANT TX RECEIVED HARDWARE FAILURE (TOGGLE) MODBUS COMM ERROR (TOGGLE) IR PENDANT COMM ERROR (TOGGLE) WRITE TO EEPROM (TOGGLE) MCU945 TX TO TRACTION DRIVE

DISPLAY RX

DISPLAY TX

CUTTER RAISE SOLENOID

LEFT BRAKE OPEN SOLENOID

FAN SPRAY SOLENOID

DUST SUPPRESSION SOLENOID

FAN CONTACTOR

CONVEYOR REV CONTACTOR

RADIO RECEIVER RX

350VAC EARTH LEAKAGE OK

RT BRAKE OPEN SOLENOID

ESTOP OVERRIDE

AUX OUTPUT #1 (MOMENTARY/PUMP)

AUX OUTPUT #2 (LATCHED/PUMP)

RADIO RECEIVER TX

12VAC EARTH LEAKAGE OK

HIGH OIL TEMP SW OK

CONVEYOR RUN - N/U

LOW OIL ALARM SW OK

LOW OIL SHUTDOWN SW OK

CUTTER RUN - N/U PUMP RUN - N/U

+12V AVAILABLE FOR INPUTS

LEFT ESTOP OK

CONTROL CASE ESTOP OK

12 VDC COMMON

TRAIL CABLE START

PRESTART LIGHT

FIRE ALARM

WATER PRESS SW OK

WATER FLOW SW OK

Troubleshooting ______________________________________________

Fig. 200: MCU945 status LEDs

_____________________________________________ Troubleshooting

© BUCYRUS AMERICA, INC.

Table 12: LED functional categories LED location

Description

R1 - R6

A contact output - either solenoid or relay. 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 outputs.

Bottom three LEDs are inputs.

R14

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

R15

Top LED: Flashes whenever MCU945 is transmitting. Currently, this only occurs 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. Only occurs if the mode is not LOCAL, checksum is valid, and proper transmitter is communication to MCU945.

R16

Top LED: Indicates when the display is transmitting.

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

R17

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

R18

Top LED: Flashes quickly (appears steady) when the MCU945 is transmitting.

Bottom LED: Flashes quickly (appears steady) when a valid message has been received from 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 present.

Middle LED: Indicates +12V present.

Bottom LED: Flashes when the MCU945 is in UMBILICAL mode with the transmitter.

Rotary Switch

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

Other three LEDs: Engineering use.

_____________________________________________________________ A6474X326 VTSV/00 5.308

Troubleshooting ______________________________________________ Table 13: MCU Status LEDs Description

R1-1

Not used

R1-2

Fan spray solenoid

R1-3

Left brake open solenoid

R1-4

Dust suppression solenoid

R1-5

Cutter raise solenoid

R1-6

Gathering head float solenoid

R2-1

Cutter lower solenoid

R2-2

Conveyor raise solenoid

R2-3

Conveyor lower solenoid

R2-4

Conveyor swing left solenoid

R2-5

Conveyor swing right solenoid

R2-6

Stab up solenoid

R2-7

Stab down solenoid

R2-8

Gathering head raise solenoid

R3-1

E-stop override

R3-2

Right brake open solenoid

R3-4

Conveyor reverse solenoid

R4-1

Tram contactor - N/U

R4-2

Reverse machine lighting

R4-3

R4-5 output - N/U

R4-4

Headlights

R4-5

Pump contactor

R4-6

Left cutter contactor

R4-7

Right cutter contactor

R4-8

Conveyor forward contactor

R5-1

Water flow switch OK

R5-2

Water pressure switch OK

R5-3

Aux Output #2 (Latched/Pump)

R5-4

Aux Output #1 (Momentary/Pump)

R6-1

Aux #3 (Momentary)

R6-2

Aux #4 (Latched/Pump)

R6-3

Aux #5 (Momentary/Pump)

R6-4

LED Select #1 - N/U

R6-5

LED Select #2 - N/U

R6-6

LED Select #3 - N/U

_________________________________________________________________ 5.309 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

LED

_____________________________________________ Troubleshooting Table 12, continued: MCU Status LEDs

© BUCYRUS AMERICA, INC.

LED

Description

R6-7

LED Select #4 - N/U

R6-8

Pre-start alarm

R11-1

Control case E-stop OK

R11-2

Left E-stop OK

R11-3

Cutter run - N/U

R11-4

Pump run - N/U

R11-5

Conveyor run - N/U

R11-6

12VAC Earth leakage OK

R11-7

350VAC Earth leakage OK

R11-8

Methane trip relay OK

R12-1

Meth warn relay OK

R12-2

Emergency tram

R12-3

Fan run- N/U

R12-4

cutter run with fan - N/U

R12-5

Cutter disable - N/U

R12-6

Motor enable (Local) - N/U

R12-7

Remote - N/U

R12-8

120VAC Leakage OK

R13-1

Fire alarm

R13-2

Prestart light

R13-3

Trail cable start

R13-4

12VDC Common

R13-5

+12V Available for inputs

R13-6

Low oil shutdown sw OK

R13-7

Low oil alarm sw OOK

R13-8

High oil temp sw OK

R14-1

spare AC input #2

R14-2

Tram xfmr t-stat

R14-3

Fan t-stat

R14-4

Pump t-stat

R14-5

Right cutter t-stat

R14-6

Left cutter t-stat

R14-7

Right conveyor t-stat

R14-8

Left conveyor t-stat

R15-1

Radio receiver TX

R15-2 Radio receiver RX _____________________________________________________________ A6474X326 VTSV/00 5.310

Troubleshooting ______________________________________________ Table 12, continued: MCU Status LEDs Description

R16-1

Display TX

R16-2

Display RS

R17-1

TR Pendant TX received

R17-2

Not used

R18-1

MCU945 TX to traction drive

R18-2

MCU945

R19-1

Off machine comm TX

R19-1

Off machine comm RX

R20-1

Download/debug TX

R20-2

Download/debug RX

R21-1

Not used

R21-2

Not used

R22-1

+5V -Extremely important to function of MCU

R22-2

+12V - Extremely important to function of MCU

R22-3

Umbilical (pendant activity)

Near rotary switch-1 Hardware failure (toggle) Near rotary switch-2 Modbus comm error (toggle) Near rotary switch-4 IR pendant comm error (toggle) Near rotary switch-5 Writ to EEPROM (Toggle)

_________________________________________________________________ 5.311 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

LED

_____________________________________________ Troubleshooting Transmitter LEDs The transmitter LEDs are located on the upper left side of the transmitter, beside the transmitter on and off buttons (Fig. 200). These LEDs indicate transmitter operation. A description of each LED is given in Table 13.

Fig. 200: Transmitter LEDs

“BATTERY”/ “UMB MSG”

“ERROR”

“TRAM ENBL”/ “INACTIVITY”

“LINK ACK”/ “CMND PDWN”

© BUCYRUS AMERICA, INC.

“LINK REQ”/ “SHUTDOWN”

“SW ACTIVE”/ “LOW BATT”

_____________________________________________________________ A6474X326 VTSV/00 5.312

Troubleshooting ______________________________________________ Table 13: Transmitter status LED response analysis LED Function “BATTERY”/ “UMB MSG”

Description Note: This LED has two (2) functions “BATTERY” transmitter mode: A flashing LED indicates good battery strength. A double blink - pause - double blink LED indicates that the batteries need changed (approximately 24 hours left). the transmitter will run until the batteries are dead but performance and range will diminish quickly and could be unsafe if operating from a long range. When the LED double blinks, the batteries should be changed without delay.

“UMB MSG”, Umbilical Message: LED blinks indicating that a message has been sent to the MCU. The blink rate should be steady at ten (10) times per second.

“ERROR’ “LINK REQUEST”/ SHUTDOWN

LED will briefly light up after power up. If LED is on after this, the transmitter should be returned for repair.

Note: This LED has two (2) functions

“SHUTDOWN”: When the transmitter switches of, the LED indicates that a shutdown is in progress and power down messages are being sent to the MCU. At the same time, one of the following LEDs will indicate why the transmitter is powering down: “LOW BATT”, “INACTIVITY”, or “CMND PDWN” (command power down).

“SW ACTIVE”/ “LOW BATT”

Note: This LED has two (2) functions “SW ACTIVE”, Switch Active: After power up, this LED is used to indicate an active switch.

 





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

If, after power up, LED lights and stays on (solid LED), there is a stuck switch. In this condition, no other switch on the transmitter will be operational. 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, the LED will be solid on while a switch is being operated. All switches can be verified locally at the transmitter. To verify that 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 to all switches. Also, while in normal operation, certain switches are time to maintain safety features, primarily as two-hand starts. If, for example, the “ENABLE” button is held down for more than twenty-five (25) seconds, the transmitter will enter an error mode. If this occurs, 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 release. Switches that are time are “ENABLE”, “SHIFT”, “TRAM ENABLE”, “PUMP START”, “CONV START”, “CONV REV”, and “CUTTER START”.

Note: In normal operation, all of these switches are operated for short periods of time only. A constantly held condition would be abnormal and would defeat two hand starts, thereby making other enable functions unsafe. Therefore, these switches are monitored and time during normal operation to prevent the possibility of a constantly on switch.

“LOW BATTERY”: If the transmitter shuts down due to a low battery, this LED will illuminate in conjunction with the “SHUTDOWN” LED.

_________________________________________________________________ 5.313 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

“LINK REQ”, Link Request: When the transmitter is connected umbilically, it will attempt to link to the MCU.

_____________________________________________ Troubleshooting Table 13, continued: Transmitter status LED response analysis LED Function “TRAM ENBL”/ “INACTIVITY”

Description Note: This LED has two (2) functions “TRAM ENBL”, 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, the tram levers are not active.

“INACTIVITY”: If the transmitter shuts down due to inactivity (no switch operation for five (5) minutes), this LED will light in conjunction with the “SHUTDOWN” LED.

“LINK ACK”/ “CMD PWDN”

Note: This LED has two (2) functions “LINK ACK”, Link Acknowledge: During the teach/learn process, this LED indicates that a link response (acknowledgement) has been receive3d back at the transmitter from the MCU. If the transmitter was re-linked back to the same MCU (machine), the LED will flash once. If this is a new link to a different MCU, the LED will flash twice.

© BUCYRUS AMERICA, INC.

“CMD PWDN”, Command Powerdown: If the transmitter shuts down as the result of the operator pressing either one of the machine stop buttons on the machine or the “TX PWR OFF” (transmitter power off) button on the transmitter, this LED will light in conjunction with the “SHUTDOWN” LED.

_____________________________________________________________ A6474X326 VTSV/00 5.314

Troubleshooting ______________________________________________ Radio receiver LEDs The radio receiver is located in the radio receiver case on the left hand side of the machine. There are eight LEDs located across the receiver (Fig. 200).

Fig. 200: Radio receiver LEDs

Table 14: Receiver LED descriptions LED

Function

Description

1

Watchdog

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

2

3

Pre-amble detected 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

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 MCU. Check the top right hand corner of the graphics display for the transmitter serial number.

4

Link received

5-8

Not used

This LED is steady on to indicate that a sufficient number of messages are being received from the transmitter to operate the system and the system should not drop out.

Reserved for future use.

_________________________________________________________________ 5.315 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

LEDs

_____________________________________________ Troubleshooting Capacitor backup power supply LEDs The back up power supplies, “CPS1” and “CPS2”, are located in the control case. When the machine has lost power, “CPS1” powers the 12VDC and 5VDC supply to the MCU and radio receiver. When power from the power center is lost, “CPS2” is used in series with “CPS1” to operate the 24VDC fire suppression solenoid and/or the 24VDC trailing cable start relay.

Each device has three LEDs to indicated mode operation (Table 15).

Fig. 200: Backup power supply LEDs

© BUCYRUS AMERICA, INC.

LEDs

Table 15: Backup power supply LED descriptions LED

Function

Description

1

+12VDC Output Active

Active in Battery Mode.

2

+5VDC Output Active

Active in Battery Mode.

3

120VAC Input Present

Active when not in Battery Mode.

_____________________________________________________________ A6474X326 VTSV/00 5.316

Troubleshooting ______________________________________________ Tram drive LEDs The tram drives, “LD” and “RD”, are located on the floor of the control case. The functions of the drive LEDs are listed in Table 16.

LED

Function

Description

1

Local FWD

Indicates forward direction command in LOCAL CTRL.

2

Local REV

Indicates reverse direction command in LOCAL CTRL.

3

Unused

4

Unused

AC

AC Present

Indicates when 120VAC power is available.

TX

Transmit Out

Indicates transmission by unit over serial COM port.

RX

Received In

Indicates reception by unit over serial COM port.

WDG

Watchdog

Indicates unit is active and operating code.

OUT

Proportional Out

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

RT (FWD)

Forward Direction

Indicates when commanded output direction is forward.

LT (REV)

Reverse Direction

Indicates when commanded output direction is reverse.

_________________________________________________________________ 5.317 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

Table 15: Backup power supply LED descriptions

_____________________________________________ Troubleshooting Emergency tram pendant LEDs The emergency tram pendant is used during times when the remote control is inoperable. The tram pendant cannot be used unless the MCU is disabled by turning the “MINER MODE” switch to the “OFF/ETRAM” position. There are LEDs in the upper right corner of the pendant (Fig. 202). The functions of these LEDs are given in Table 16.

© BUCYRUS AMERICA, INC.

Fig. 201: Emergency tram pendant LEDs

LEDs

Table 16: Emergency tram pendant LED descriptions LED

Function

Description

MODE

Mode

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

TRME

Tram Enable

Note: Tram enable is not possible unless all tram motion buttons are in the idle (inactive) position.

The LED is normally unlit. When the tram motions buttons are in the idle position and the “TRAM” button is pressed, tramming is enabled and the LED lights yellow. Tram enable will be active for a preset amount of idle time or as long as a tramming function is being performed. If no tramming function is performed during the preset amount of time, tram enable is turned off and the LED turns off.

TRML

Tram Left

Default for the LED is unlit. If the tram left function is initiated while the TRME LED is yellow (tram enabled), the TRML LED will light red, indicating directional movement is granted. The operator can select “TRAM FWD” or “TRAM REV”.

TRMR

Tram Right

Default for the LED is unlit. If the right tram function is initiated while the TRME LED is yellow (tram enabled), the TRML LED will light red, indicating directional movement is granted. The operator can select “TRAM FWD” or “TRAM REV”.

_____________________________________________________________ A6474X326 VTSV/00 5.318

Troubleshooting ______________________________________________ Alarms, warnings, and display information The system is capable of sensing many possible conditions that will result in an alarm or warning. Alarms have an “A” prefix and warning have a “W”. When such a condition is detected, an appropriate message is displayed on all screens for 10 seconds and is logged (see Control system section of this chapter). The display screen is shown in Fig. 202.

1.

2.

3.

4.

5.

6.

7.

8.

9.

Fault log, warning, and information message block Miner type - should always read 30M MCU945 mode Battery voltage Transmitter serial number Commanded input message indication block Messages per second form transmitter RF signal strength Active input indicator

_________________________________________________________________ 5.319 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

Fig. 202: Display screen messages (typical)

_____________________________________________ Troubleshooting Table 17: Alarm codes

© BUCYRUS AMERICA, INC.

Code #

Description

A001

120VAC loss from methane monitor relay, “MMR”

A002

Pump shutdown - left E-Stop 1 or 2 activated (R11-2)

A003

Pump shutdown - right E-stop 1 or 2 activated (R11-2)

A004

Transmitter shutdown - maximum switch/button active time exceeded

A005

Error - Internal backplane communication

A006

Future use

A007

Future use

A008

Future use

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 hydraulic oil temperature

A016

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

A017

Pump shutdown - 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 instantaneous current trip - 5 sec. to reset

A024

Pump shutdown - pump phase imbalance trip

A025

Pump shutdown - pump low current - 11 sec. 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

Conveyor shutdown - right motor jam current - 5 sec. to reset

A031

Conveyor shutdown - left motor jam current - 5 sec. to reset

A032

Conveyor shutdown - right motor over temperature (RTD)

A033

Conveyor shutdown - left motor over temperature (RTD)

_____________________________________________________________ A6474X326 VTSV/00 5.320

Troubleshooting ______________________________________________ Table 17, continued: Alarm codes Description

A034

Conveyor shutdown - right motor overload

A035

Conveyor shutdown - left motor overload

A036

Conveyor shutdown - right motor instantaneous current trip - 5 sec. to reset

A037

Conveyor shutdown - left motor instantaneous current trip - 5 sec. to reset

A038

Conveyor shutdown - right motor phase imbalance trip

A039

Conveyor shutdown- left motor phase imbalance trip

A040

Conveyor shutdown - right motor low current - 11 sec. to reset

A041

Conveyor shutdown - left motor low current - 11 sec. to reset

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

Future use

A048

Future use

A049

Future use

A050

Future use

A051

Cutter shutdown - right motor over temperature (RTD)

A052

Cutter shutdown - left motor over temperature (RTD)

A053

Future use

A054

Future use

A055

Future use

A056

Future use

A057

Future use

A058

Cutter shutdown - right motor overload

A059

Cutter shutdown - left motor overload

A060

Cutter shutdown - right motor instantaneous current trip - 5 sec. to reset

A061

Cutter shutdown- left motor instantaneous current 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

_________________________________________________________________ 5.321 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

Code #

_____________________________________________ Troubleshooting

© BUCYRUS AMERICA, INC.

Table 17, continued: Alarm codes Code #

Description

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 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

Future use

A078

Future use

A079

Future use

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

Future use

A087

Future use

A088

Future use

A89

Future use

A090

Future use

A091

Future use

A092

Future use

A093

Future use

A094

Future use

A095

Future use

A096

PLC to right drive COMM fault (all tram commands cleared)

A097

PLC to left drive COMM fault (all tram commands cleared)

_____________________________________________________________ A6474X326 VTSV/00 5.322

Troubleshooting ______________________________________________

Table 17, continued: Alarm codes Description

A098

Machine voltage below allowable range (<80% Vnom)

A099

Machine voltage above allowable range (>117% Vnom)

A100

Future use

A101

Right tram motor overload

A102

Left tram motor overload

A103

Tram enable switch held more than 3 se. with tram

A104

Tram enable switch stuck

A105

Future use

A106

Future use

A107

Future use

A108

Future use

A109

Future use

A110

Future use

A111

Future use

A112

Tram shutdown - left drive Phase A over current

A113

Tram shutdown - left drive Phase B over current

A114

Tram shutdown - left drive bus over voltage

A115

Tram shutdown - left drive over temperature

A116

Tram shutdown - right drive Phase A over current

A117

Tram shutdown - right drive Phase B over current

A118

Tram shutdown - right drive bus over voltage

A119

Tram shutdown - right drive over temperature

A120

Right drive limited - loss of voltage feedback

A121

Left drive limited - loss of voltage feedback

A122

Future use

A123

Future use

A124

Future use

A125

Future use

A126

Future use

A127

FCR data link loss

A128

Teach/Learn successful

A129

Teach/Learn failed

_________________________________________________________________ 5.323 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

Code #

_____________________________________________ Troubleshooting Table 17, continued: Alarm codes Code #

Description Future use

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 pushbutton stuck on transmitter

A336

Tram enable button stuck on transmitter

A337

Pump start pushbutton stuck on transmitter

A338

Conveyor start pushbutton stuck on transmitter

A339

Cutter start pushbutton stuck on transmitter

A348

Fan button stuck on transmitter

© BUCYRUS AMERICA, INC.

A130

_____________________________________________________________ A6474X326 VTSV/00 5.324

Troubleshooting ______________________________________________ Table 18: Warning codes 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

W007

Conveyor reverse won’t start - left conveyor overload

W008

Conveyor reverse won’t start - right conveyor instantaneous trip

W009

Conveyor reverse won’t start - left conveyor instantaneous 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 E-Stop 1 or 2 is open (R11-2)

W019

Pump won’t start - right E-Stop 1 or 2 is open (R11-1)

W020

Pump won’t start 350VAC/DC earth leakage detected (R11-7)

W021

Pump won’t start - high hydraulic oil temperature fault

W022

Pump won’t start - low oil level shutdown active for 5 sec. (R14-4)

W023

Pump won’t start - low current

W024

Pump won’t start - pump motor temperature above 150 (140 after trip)

W025

Pump won’t start - overload trip reset time not expired

W026

Pump won’t start - instantaneous trip reset time not expired

W027

Pump won’t start - machine voltage < 80% Vnom

W028

Pump won’t start - key switch is off

W029

Pump won’t start - 120VAC earth leakage detected (R9-2)

W030

Pump won’t start - conveyor forward start is operated

W031

Pump won’t start - conveyor reverse start is operated

W032

Pump won’t start - pump phase

_________________________________________________________________ 5.325 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

Code #

_____________________________________________ Troubleshooting Table 18, continued: Warning codes

© BUCYRUS AMERICA, INC.

Code #

Description

W033

Conveyor won’t start - pump off

W034

Conveyor forward won’t start - right conveyor 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

W044

Conveyor won’t start - right phase

W045

Conveyor won’t start - left phase

W046

Conveyor forward won’t start - left conveyor 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 methane monitor relay (MMR)

W064

Cutter won’t start - low oil

_____________________________________________________________ A6474X326 VTSV/00 5.326

Troubleshooting ______________________________________________ Table 18, continued: Warning codes Description

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 star t- 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 over voltage

W082

Tram won’t start - right drive bus over voltage

W083

Tram won’t start - left drive bus over temperature

W084

Tram won’t start - right drive bus over temperature

W085

Tram command without tram enable

W086

Tram - command without pump running

W089

Tram - left tram overload

W090

Tram - right tram overload

W091

Tram - left tram communication error

W092

Tram - right tram communication error

W093

Tram won’t start - left drive Phase A over current

W094

Tram won’t start - right drive Phase A over current

W095

Tram won’t start - left drive Phase B over current

W096

Tram won’t start - right drive Phase B over current

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 overtemp (RTD)

W106

Handheld address out of range

W107

No active link input

W108

MCU serial number out of range

W109

Cutter lower override due to right motor

W110

Cutter lower override due to left motor

W111

cutter raise override due to right motor

_________________________________________________________________ 5.327 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

Code #

_____________________________________________ Troubleshooting Table 18, continued: Warning codes

© BUCYRUS AMERICA, INC.

Code #

Description

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 ram 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

W135

Low battery

W136

Transmitter shutdown inactivity period expired

W137

Cutter shutdown - key switch off

W138

Switch active

W139

Cutter raise inhibit due to inclinometer

W140

Cutter lower inhibit due to inclinometer

W141

Forward conveyor inhibit due to test mode

W142

Reverse 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

_____________________________________________________________ A6474X326 VTSV/00 5.328

Troubleshooting ______________________________________________ Table 18, continued: Warning codes Description

W149

Ventilation only switch operated at startup

W150

Right tram reference present at startup

W151

Left tram reference present at startup

W152

Right tram forward contact closed at power up

W153

Right tram reverse contact closed at power up

W154

Left tram forward contact closed at power up

W155

Left tram reverse 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 position

W306

Breaker toggle switch stuck in on position

W307

Conveyor toggle switch stuck in lower position

W308

Conveyor toggle switch stuck in raise position

W309

Conveyor swing toggle switch stuck in left position

W310

Conveyor swing toggle switch stuck in right position

W311

Gathering head toggle switch stuck in float position

W312

Gathering 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

_________________________________________________________________ 5.329 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS AMERICA, INC.

Code #

_____________________________________________ Troubleshooting Table 18, continued: Warning codes

© BUCYRUS AMERICA, INC.

Code #

Description

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 pushbutton stuck

W326

Cutter toggle switch stuck in stop position

W327

Cutter toggle switch stuck in start position

W328

Shift pushbutton stuck

W329

MStop override pushbutton stuck

W330

Enable pushbutton stuck

W331

Tram high pushbutton stuck

W332

Tram low pushbutton 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

_____________________________________________________________ A6474X326 VTSV/00 5.330

_______________________________________________________________

Technical data

________________________________________________________________

________________________________________________________________

_________________________________________________________________

_______________________________________________ Technical data

Technical data This chapter contains the most important technical data on the 30M4NP Continuous Miner. Further data can be found in the spare parts lists. At the end of this chapter you will find information on the bolt tightening torques, HFA fluids, greases, etc. Read this chapter through carefully and pay particular attention in particular to the safety instructions.

IMPORTANT! The technical data listed in this chapter is for stock machines only. Customer specials may not be listed.

Components of the 30M4-NP Continuous Miner Note: All dimensions and rates are based on a 44 inch diamter cutting drum and a ground clearance of 14 inches.

© BUCYRUS AMERICA, INC.

Technical data sheet operating dimensions

Recommended mining range............................... approx. 90 to 183 in Minimum height over cutter boom assembly ....... approx. 85 in Maximum mining height ....................................... approx. 185 in Minimum mining height (Zero Cut) ...................... approx. 84 in Maximum reach ................................................... approx. 183 in Ground clearance (without 3 in lift kit) approx. 14 in Length (bumper to face) ...................................... approx. 325 in (27 ft)

transport dimensions

Width (outside of rub rails) ................................... approx. 132 in (11 ft) Overall length....................................................... approx. 443 in (37 ft) Height (cover line)................................................ approx. in Weight (total)........................................................ approx. 160,000 lbs

cutter unit

Cutter drum diameter ........................................... approx. 44 in Cutter drum width................................................. approx. 156 in (13 ft) Cutter head speed ............................................... approx. 675 fpm

loading unit

Loading method ................................................... 3 finger CLA Conveyor width .................................................... approx.30 in Conveyor speed................................................... approx. 442 fpm Conveyor depth (without sideboards) .................. approx. 12 in Loading capacity .................................................. approx. 12 to 30 tpm

traction unit

Crawler chain width.............................................. approx. 22 in Crawler assembly length...................................... approx. 107 in Ground pressure (average) ................................. approx. 34 psi Crawler speed...................................................... 0 - 65 fpm

______________________________________________________________ A6474X326 VTSV/00 6.3

© Bucyrus America, Inc.

Technical data ________________________________________________

_________________________________________________________________ 6.4 Bucyrus – Model 30M4-NP 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.

IMPORTANT! Use a calibrated torque wrench for accuracy!

© BUCYRUS AMERICA, INC.

Table 12: Grade 8 bolt torque specifications (calculated at 75% proof load) Bolt size (inches) 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1 1-1/8 1-1/4 1-3/8 1-1/2 1-3/4 2 2-1/4 2-1/2 2-3/4 3 3-1/4 3-1/2 3-3/4 4

Dry ft-lbs 12 25 44 70 107 154 212 376 606 909 1287 1875 2382 3161 4988 7500 10969 15000 17794 23507 30286 38266 47545 58100

Lubricated ft-lbs 6 12 22 35 53 77 106 188 303 454 644 938 1191 1581 2494 3750 5484 7500 8897 11753 15143 19133 23773 29085

______________________________________________________________ A6474X326 VTSV/00 6.5

Tightening torques ____________________________________________

Property Class

8.8

10.9

12.9

M6 - M16: 800 M20 - M30: 830

1040

1220

Minimum Tensile Strength (MPa) Nominal Size and Thread Pitch

Dry ft-lbs (in-lbs)

Lubricated ft-lbs (in-lbs)

Dry ft-lbs (in-lbs)

Lubricated ft-lbs (in-lbs)

Dry ft-lbs (in-lbs)

Lubricated ft-lbs (in-lbs)

M5 X 0.80 M6 X 1.00 M7 X 1.00 M8 X 1.25 M10 X 1.50 M12 X 1.75 M14 X 2.00 M16 X 2.00 M18 X 2.50 M20 X 2.50 M22 X 2.50 M24 X 3.00 M27 X 3.00 M30 X 3.50 M33 X 3.50 M36 X 4.00

(54) (92) (156) (2250 37 65 104 161 222 314 428 543 796 1079 1468 1886

(41) (69) (116) (169) 28 49 78 121 167 235 321 407 597 809 1101 1415

(78) (133) (222) (333) 53 93 148 230 318 449 613 776 1139 1543 2101 2699

(59) (99) (167) (242) 40 69 111 172 238 337 460 582 854 1158 1576 2024

(91) (156) (260) (377) 62 108 173 269 372 525 716 908 1331 1804 2455 3154

(68) (116) (195) (284) 47 81 130 202 279 394 537 681 998 1353 1842 2366

© BUCYRUS AMERICA, INC.

Table 13: Metric bolt torque specifications (calculated at 75% proof load)

_________________________________________________________________ 6.6 Bucyrus – Model 30M4-NP Continuous Miner

___________________________________________ Permissible media Permissible media Lubrication fluids and greases

© BUCYRUS AMERICA, INC.

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

IMPORTANT! The lubrication fluids and greases listed in the same table can be mixed. Other products may only be used if the supplier can guarantee that they are equivalent.

Differently composed fluids and greases must not be mixed as this may change the consistency, i.e. the mixture can become thinner so that the lubrication effect is not sufficient. It may also be dangerous to use lubricating greases and fluids having the same specification base but different origins.

In case of doubt, the manufacturer of the lubrication to be used should be contacted as to the compatibility of the lubrication in question.

IMPORTANT! Bucyrus America, Inc. expressly point out that the approval of the listed products relates only to the pure technical use in our mechanical and hydraulic systems. The responsibility for the constituents used in the hydraulic concentrates lies solely with the respective manufacturer.

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

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

______________________________________________________________ A6474X326 VTSV/00 6.7

Permissible media ____________________________________________ Approved suppliers: Table 14: Anti-wear hydraulic oil (Spec 100-1)

5 6 7 8 9 10 11 12 13

14 15 16 17 18

Supplier Amoco Oil Company Gulf Oil Mobil Oil Corporation Chevron U.S.A. Sun Oil Company Unocal 76 Shell Oil Company Century Lubricating Oils, Inc. Atlantic Richfield Company Texaco Lubricants Company Exxon Pennzoil Standard Oil Company Standard Oil Co. of Ohio Boron Oil Company BP Oil Inc. Lubricating Engineers Conoco Inc. Hydrotex Phillips Miners Oil

Brand name Amoco AW Oil No. 68 Harmony 68 AW Mobil DTE-16 Chevron hydraulic Oil Aw ISO 68 Sunvis 868 Unax AW 68 Shell Hydraulic Oil #33 Hydraulic AW 68 Duro AW S-315 Oil Texaco Rando Oil HD 68 Nuto 68 Pennzbell AW 68 Hydraulic Oil Industron 54 Industron 53 Energol HLP-C68 6120 Monolec Hydraulic Oil Super Hydraulic oil 68 Systems 5K 68 Maginus A Oils 81350 Hydraulic Oil 68AW

Table 15: Extreme pressure gear oils (Spec. 100-2) 1 2 3

Supplier Amoco Oil Company Gulf oil Mobil Oil Corporation

4

Chevron U.S.A.

5 6

Sun Oil Company Unocal 76

7 8

Shell Oil company Century Lubricating Oils, Inc.

9 10 11

Texaco Lubricants Company Exxon Pennzoil

12

Lubricating Engineers

13 14 15

Conoco Inc. Hydrotex Phillips

16

Miners Oil

Brand name Amoco Permagear EP 460 EP Lubricant HD 460 Mobil Gear 634 Mobil Gear 636 Chevron Gear Compound EP ISO 460 Sunep 460 Extra Duty NL Gear Lube 7 EP Extra Duty NL Gear Lube 8 EP Shell Omala 680 Hulbest EP-7 Powergear 460 Meropa 680 Spartan EP 460 Super Maxol EP 460 Gear Lube Super Maxol EP 460 Gear Lube 608 Almosal Vari-Purpose Gear Lubricant Gear oil 460 933 Industrial Gear Lubricant All Purpose Gear Oil 85W-90 5EP Gear Oil EP460

© BUCYRUS AMERICA, INC.

1 2 3 4

_________________________________________________________________ 6.8 Bucyrus – Model 30M4-NP Continuous Miner

___________________________________________ Permissible media

© BUCYRUS AMERICA, INC.

Table 16: Extreme pressure motor bearing grease (Spec. 100-3)

1

Supplier Amoco Oil Company

2 3 4

Gulf Oil Mobil Oil Corporation Chevron U.S.A.

5 6 7 8

Sun Oil Company Unocal 76 Shell Oil Company Century Lubricating Oils, Inc.

9 10 11 12 13

Texaco Lubricants Company Exxon Pennzoil Lubricating Engineers Conoco Inc.

14 15 16

Hydrotex Phillips Atlantic Richfield

Brand name Amolith Grease 2 EP Rykon Premium Grease 2 EP Gulfcrown Grease EP#2 Mobilux EP-2 Chevron Dura-Lith Grease EP-2 NLGI 2 Sun Prestige 742EP Multiplex EP2 Alvania EP-2 Hullith EP2 Multipurpose Grease, or Replex2, or Uniwrl 2, or Uniwrl EMB, or Hullith GP 2, or Hullith EP 2 Texaco Multifak EP 2 Lidok EP 2 Pennlith EP 712 Grease 3752 Almagard Vari-Purpose Lubricant EP Conolith Grease No. 2 or Super Sta Grease No. 2 LC-65 Hyplex Philube EP Grease Litholine H EP-2 Grease

Table 17: Semi-fluid grease (Spec. 100-4) 1 2 3 4 5 6

Supplier Texaco Lubricants Company Century Oils Limited Hydrotex Pennzoil Unocal Exxon

Brand name Novatex EP 000 Joy Loader Semi-Fluid Grease MPD-60 Ultra E.P. 000 Semi-Fluid 760 Grease MM Grease Lidok E.P. 000

______________________________________________________________ A6474X326 VTSV/00 6.9

Permissible media ____________________________________________ Table 18: Invert emulsion hydraulic fluid (Spec. 100-5)

12 13 14 15 16 17

Century Lubricating Oils Imperial Oil and Grease Mobil Oil Corporation National Oil and chemical Co. Pennzoil Quaker Chemical Company

18

22 23 24 25

Henery E. Sanson and Sons MFGE Company Southwest Grease and Oil Company, Inc. Southwest Petroleum Corp.

Standard Oil Company of Ohio (Boron Sohio) Sun Oil Company Tower Oil Company Wynn Oil Company Lubrication Engineers

26

Hydrotex

19 20 21

Brand name FR Fluid FR Hydraulic Fluid Duro FR-HD Brooks fire Resistant Hydraulic Fluid B Vulcon FR Fluid #1 Citgo Pacemaker Invert FR Fluid Aquacent Light Lubriplate HO-Retard Veedol Auburn FRH FR Fluid Houghto-Safe 5046 Houghto-Safe 5046W Hulsafe 600 Astrol 587 Pyrogard D Erifon 1, 2, and 3 Maxmul FRP/G Quintolubric 958 Series Quintolubric 958 Series Hydra-Mul Premium Emulsion Fluid Invert Emulsion Fire Resistant Hydraulic Fluid Swepco Fire Resistant Hydraulic oil #718 Staysol FR Sunsafe F Safoil Anti-Wear Hydraulic Fluid Hydra-Safe heavy Medium 6455 Monolec Fire Resistant Hydraulic Fluid HY-Guard

© BUCYRUS AMERICA, INC.

10 11

Supplier Unocal 76 Conoco Inc. Atlantic Richfield Company Brooks Oil Company Cincinnati – Vulcon Company Cities Service Oil company Century Oils Limited Fiske Bros. Refining Company Getty Oil Company (Veedol, Tidewater) Gulf Oil Company E.F. Houghton

1 2 3 4 5 6 7 8 9

Table 19: Extreme pressure gear oil, SAE 90 (Spec. 100-6) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Supplier Amoco Oil Company Gulf Oil Mobil Oil Corporation Chevron U.S.A. Sun Oil Company Unocal 76 Shell Oil Company Century Lubricating Oils, Inc. Texaco Lubricants Company Exxon Pennzoil Lubricating Engineers Conoco Inc. Hydrotex Phillips Atlantic Richfield Cities Service Pennzoil Miner Oil Texaco, Lubricants Company

Brand name Amoco Premagear EP 320 EP Lubricant HD 320 Mobil Gear 632 Chevron Gear Compound EP ISO 320 Sunep 320 Extra Duty NL Gear Lube 6EP Omala 75 Hulbest EP-6 Meropa 320 Spartan EP 320 Super Maxol EP 220 Gear Lube 605 Almasol Vari-Purpose Gear Lubricant Gear Oil 320 932 Industrial Gear Lube Philube All Purpose Gear Oil 85W-90 Pennant NL S-1000 Citgo EP Compound 110 Pen Gear #320 Gear Oil EP220 Texaco Multigear EP 80W-90

_________________________________________________________________ 6.10 Bucyrus – Model 30M4-NP Continuous Miner

___________________________________________ Permissible media

© BUCYRUS AMERICA, INC.

Table 20: Hydraulic and general purpose oil medium-heavy/R&O inhibited (Spec. 100-7) 1 2 3 4

Supplier Amoco Oil Company Gulf Oil Mobil Oil Corporation Chevron U.S.A.

5 6

Sun Oil Company Unocal 76

7 8 9 10 11 12 13

Shell Oil Company Century Lubricating Oils, Inc. Texaco Lubricants Company Exxon Pennzoil Lubricating Engineers Conoco Inc.

14 15 16 17 18

Hydrotex Atlantic Richfield Cities Service Miner Oil Texaco, Lubricants Company

Brand name American Industrial Oil No. 68 Harmony 68 DTE Heavy – Medium Chevron Turbine Oil ISO 68 or Chevron Machine Oil R&O ISO 68 Sunvis 754 Unax RX68 or Turbine Oil 68 Turbo 68 Centraulic R&O 68 Regal Oil R&O N-68 Tresstic 68 Pennzbell RO 68 6120 Monolec Turbine Oil Detol R&O 68 or Turbine Oil 68 Systems 1, System 5K 68 Duro 5.315 Citgo Pacemaker A/W68 Hydraulic Oil AW68 TDH 1893

Table 21: Hydraulic and general purpose oil heavy/R&O inhibited (Spec. 100-8)

1 2 3 4

Supplier Amoco Oil Company Gulf Oil Mobil Oil Corporation Chevron U.S.A.

5 6

Sun Oil Company Unocal 76

7 8

Shell Oil Company Century Lubricating Oils, Inc. Atlantic Richfield Company Texaco Lubricants Company Exxon Pennzoil Cities Service Lubrication Engineers Conoco Inc. Hydrotex Phillips Miner Oil

9 10 11 12 13 14 15 16 17 18

Brand name American Industrial oil No. 150 Harmony 150 DTE Oil EX. Heavy Chevron Machine Oil AW ISO 150M or Chevron Machine Oil R&O ISO 150 Sunvis 961 Unax RX 700 or Turbine Oil 700 Turbo 150 Centraulic R&O 150 Duro 600 or S-700 Regal Oil R&O 150 Teresstic 150 Pennzbell RO 150 Citgo Pacemaker 150 6405 Monolec Turbine Oil Dectol R&O 76 System 1 150, System 5k 150 Magnus Oils 700 ISO 150

______________________________________________________________ A6474X326 VTSV/00 6.11

Permissible media ____________________________________________ Table 22: Worm gear lubricant, compounded cylinder oil (Spec. 100-9) 1 2 3 4 5 6 7 8 9 10 11

Supplier Amoco Oil Company Mobil Oil Corporation Chevron U.S.A. Sun Oil Company Unocal 76 Century Lubricating Oils, Inc. Atlantic Richfield Company Texaco Lubricants Company Exxon Pennzoil Conoco Inc.

Brand name Cylinder oil No. 1000 Extra Hecla Super Cylinder Oil Chevron Cylinder Oil W ISO 1000 Sun Steam Cylinder Oil Worm gear Lube 250 or Stevalc Garwal 680 Modoc 195 650 T Cylinder Oil 1000 Cylesstic TK-1000 Cylinder Oil #1000 Inca Oil 1000

1 2 3 4 5 6 7

Supplier Amoco Oil Company Gulf Oil Mobil Oil Corporation Chevron U.S.A. Sun Oil Company Unocal 76 Shell Oil company

8 9 10

Century Texaco Lubricants Company Exxon

11 12 13

Pennzoil Lubricating Engineers Conoco Inc.

14 15

Hydrotex Phillips

Brand name Amoco 300 SAE 40 Super Duty 40 Delvac 1340 Chevron RPM Heavy Duty Motor Oil 15W-40 Sunoco Super C 40 Guardol Motor Oil SAE 40 Rotella Oil 40 (Automotive) Turbo Oil 150 (Industrial) Rimula CT40 (Foreign) Rotela SX40 (Foreign) Flexe SAE 40 Ursa Super plus SAE 40 XD-3 Extra SAE 40 or XD-3 SAE 40 Long Life SAE 40 Motor Oil 8440 Monolex GFS Engine Oil Fleet Heavy Duty Motor Oil SAE 40 Hyfilm SAE 40 Super HD II Motor Oil SAE 15W-40

© BUCYRUS AMERICA, INC.

Table 23: Light gear oil, SAE 40 motor oil (Spec. 100-10)

Table 24: Synthetic EP gear lubricants (Spec. 100-11) 1

Supplier Century Lubricants Company

Brand name Synthetic EP Gear Lubricants

Table 25: Multi-purpose tractor hydraulic fluid (Spec. 100-12) 1 2 3 4 5 6 7

Supplier Exxon / Mobil Century / Fuchs Shell Chevron BP Lubricants Quaker State Conoco

Brand name Mobilfluid 424 Multitran Donax TD Tractor Hydraulic Fluid Tractran UTH Quaker State FCI HD Powertran Fluid

_________________________________________________________________ 6.12 Bucyrus – Model 30M4-NP Continuous Miner

___________________________________________ Permissible media Table 26: Extreme pressure gear oil (Spec. 100-13) 1

Supplier Century Lubricants

Brand name Powergear H680

Table 27: High temperature lithium complex motor bearing grease (Spec. 100-14) 1 2 3

Supplier Mobil Conoco Phillips Shell

Brand name Mobilith SHC 100 Triton 100 Albida EMS 2

Table 28: High demulsibility EP gear oil (Spec. 100-15) Supplier Conoco

Brand name GLW Gear Oil 220

© BUCYRUS AMERICA, INC.

1

______________________________________________________________ A6474X326 VTSV/00 6.13

© BUCYRUS AMERICA, INC.

Permissible media ____________________________________________

_________________________________________________________________ 6.14 Bucyrus – Model 30M4-NP Continuous Miner

_______________________________________________________________

For your information

________________________________________________________________

________________________________________________________________

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_________________________________________________ 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

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

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Houston, PA 2045 West Pike Street Houston, PA 15342 Phone: (724) 743-1200 Fax: (724) 743-1201

Carrier Mills, IL 9580 State Route 13 West Carrier Mills, IL 62917 Phone: (618) 982-9000 Fax: (618) 982-9912

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Paonia, CO P.O. Box 566 719 Second Street Paonia, CO 81428 Phone: (970) 527-3151 Fax: (970) 527-6846

______________________________________________________________ A6474X326 VTSV/00 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

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© 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 30M4-NP 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.

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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.

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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

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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.

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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

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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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BUCYRUS®

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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

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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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BUCYRUS®

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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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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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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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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

2008 Cervis, Inc.

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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

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G005.1-TShoot_RCSysContMiners_In-M

Troubleshooting Guide

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2008 Cervis, Inc.

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