Cat Continuous Miner 25M3 Operator's Manual - PDF DOWNLOAD

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© Bucyrus All Rights Reserved

BUCYRUS R

Technical Manual

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25M3 OPERATOR’S MANUAL Contents Section 1 Section 2 Section 3 Section 4 Section 5 Section 6 Section 7 Section 8 Section 9 Section 10 Section 11

Handbook Objective Notes to the Operator Defects and Hazards and Safety Machine Description Controls and their Functions Pre-start Checks Start-up Procedure Operating Procedure Shutdown Procedure Emergency Shutdown Troubleshooting

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25M3 OPERATOR’S MANUAL SECTION 1

HANDBOOK OBJECTIVE

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Helensburgh 25M3 Operators Manual

TABLE OF CONTENTS HANDBOOK OBJECTIVES .....................................................................................................................................3

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HANDBOOK OBJECTIVES This manual is intended to provide basic operation information on Bucyrus 25M3 series continuous miners. Additional information can be obtained by referring to the Parts Book supplied with your machine, or by contacting your local Bucyrus representative. The illustrations, descriptions and procedures contained in this manual pertain to the machine as it was originally manufactured and delivered to your mine and when the manual was approved for printing.

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

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25M3 OPERATOR’S MANUAL SECTION 2

NOTES TO THE OPERATOR

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Helensburgh 25M3 Operators Manual

TABLE OF CONTENTS NOTES, CAUTIONS AND WARNINGS .....................................................................................................................3 OPERATING PROCEDURES ....................................................................................................................................3

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NOTES, CAUTIONS AND WARNINGS ALL applicable Notes, Cautions and Warnings listed in this Manual are to be included in the support documents following the same format as defined below.

Follow Notes, Cautions and Warnings found in the handout.

NOTE:

Indicates a procedure or condition that is essential for the operator to know.

CAUTION:

Indicates an action or condition that, if not followed, could cause damage to the vehicle or other equipment.

WARNING:

Indicates an action or condition that, if not followed, could cause injury to the operator or other personnel.

OPERATING PROCEDURES Operating procedures are written with the intention of being correct. If you do notice errors within the procedures, it is an important part of our company’s Quality Processes that we be notified quickly so that any problem can be corrected.

THOUGHT PROCESSES THAT WILL HELP TO KEEP OPERATORS INJURY FREE Is the procedure Correct?

YES

NO

Am I following the correct procedure?

STOP

YES

WAY TO GO

NO

Take corrective action!

If necessary consult with team members

STOP

Correction Resolved

WHY NOT

YES

NO

STOP ACT NOW! FOLLOW CORRECT PROCEDURE

Take corrective action!

Consult with Responsible Person/s Correction Resolved

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25M3 OPERATOR’S MANUAL SECTION 3

DEFECTS, HAZARDS AND SAFETY

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Helensburgh 25M3 Operators Manual

TABLE OF CONTENTS GENERAL INFORMATION.............................................................................................................................3 Introduction ...................................................................................................................................................3 Warnings and Symbols...................................................................................................................................3 SAFETY.............................................................................................................................................................4 Isolation Procedures......................................................................................................................................4 Main Isolator .................................................................................................................................................5 Safety Instructions and Precautions ..............................................................................................................5 Safety Instructions and Precautions ..............................................................................................................6 SAFE AND CONTROLLED ZONES................................................................................................................7 SAFETY INSTRUCTIONS FOR OPERATIONAL PHASES ..........................................................................8 Normal Operation..........................................................................................................................................8 Flitting Operation ..........................................................................................................................................9 Safety Instructions for Maintenance and Repair Procedures ........................................................................9 Safety Instructions for Maintenance and Repair Procedures ......................................................................10 HAZARDS .......................................................................................................................................................10 Electric Energy ............................................................................................................................................10 Hydraulics....................................................................................................................................................10 Noise ............................................................................................................................................................10 Oils, Greases and other Chemicals..............................................................................................................10 SAFETY EQUIPMENT ...................................................................................................................................11 Emergency Stop Buttons ..............................................................................................................................11 Emergency Stop Button Locations ...............................................................................................................11 Transmitter Emergency Stop Switch ............................................................................................................12 Audible Warnings.........................................................................................................................................13 Strobe Lights ................................................................................................................................................13 Cutter Head Stops ........................................................................................................................................14 Conveyor Boom Stops ..................................................................................................................................14 Cutter Stops..................................................................................................................................................15 Gathering Head Stops..................................................................................................................................15 Personal Safety Equipment ..........................................................................................................................16 RADIO REMOTE CONTROL SYSTEM ........................................................................................................16 General ........................................................................................................................................................16

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GENERAL INFORMATION Introduction The Bucyrus 25M3 Continuous Miner is an electrically powered, drum type, radio remote controlled miner. Before operating the machine for the first time, all personnel who are involved in the operation of the machine must be fully trained in the systems and the incorporated safety requirements.

Only personnel operating the machine must be at or near the machine while the machine is operating. Any person wishing to enter the area of the operating machine must do so in accordance with site safety procedures governing such activities.

Before using the remote control system for the first time, you must read and understand the operating instructions carefully.

This section outlines safety precautions and procedures that must be complied with to ensure the safe and efficient operation of the Bucyrus 25M3 Continuous Miner. This manual must always be available in the area, to which the machine will be operating in.

Warnings and Symbols Follow all Notes, Cautions and Warnings found throughout this manual. These are provided to bring your attention to safety aspects affecting the use of the machine.

NOTE:

Indicates a procedure or condition that is essential for the operator to know.

CAUTION:

Indicates an action or condition that, if not followed, could cause damage to the vehicle or other equipment.

WARNING:

Indicates an action or condition that, if not followed, could cause injury to the operator or other personnel.

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SAFETY Isolation Procedures The relevant Manager’s Rules, Safety Policy, Isolation Procedures and Safe Working Procedures of the individual mine site must be strictly adhered to.

The purpose of isolating machinery or equipment is to allow work to be undertaken safely by ensuring that there is no danger to life, or injury to people or possibility of damage.

Isolation requirements for individual items of machinery or equipment vary and specific requirements are listed in the Colliery’s Isolation Procedures. Check the isolation requirements and ensure compliance before starting the job.

The following guide to levels of isolation is extracted from MDG5002, Guidelines for the use of Remote Controlled Mining Equipment.

Guide to Levels of Isolation: Level of Isolation

When Required

LEVEL 1 - Isolate at the energy source.

Physically disconnect the energy source, e.g., unplug the cable, disconnect or break lines (hydraulic etc.).

Danger Tag as per Manager’s Rules.

LEVEL 2 - Isolate the energy source with local isolating device.

Non-visual break, e.g., machine circuit breaker / isolator turned off and handle removed, circuit breaker open, valves closed. Danger Tag as per Manager’s Rules.

Wherever full body contact with an energy source is possible. Work on electrical circuits having voltages above extra-low voltage.

Wherever full body contact with an energy source is possible. Work on electrical circuits having voltages above extra-low voltage.

LEVEL 3 - Secondary isolation. Turn off control devices, e.g. conveyor stop switches. Danger Tag as per Manager’s Rules.

When full body contact with an energy source is not involved.

LEVEL 4 - Immobilisation of energy source.

To be used in conjunction with either levels 1 or 2 above and as indicated by conditions.

Packing, staying to prevent movement, barriers to prevent collision, neutralising pressure.

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Main Isolator Being an electrically powered continuous miner, you must ensure all electrical power has been disconnected from the machine before adjustments, repairs, or parts replacement procedures are started.

The Main Isolator for the electrical supply to the machine is located on the Operator’s Enclosure. The Operators Enclosure is located on the right hand rear corner of the machine. Turning this isolator handle, located on the side wall, as indicated, will isolate all power to the machine.

When power is disconnected a visual inspection of the machine is to be carried out to ensure the machine is isolated.

Check that: The machine phase indicator lights are not illuminated.

The screen is blank.

Test Isolation by attempting to start the machine’s hydraulic pump.

WARNING: To ensure no unintentional movement of the machine is possible, the correct Isolation Procedures must be carried out prior to any maintenance or repair work being carried out. Do not rely on the Emergency Stop switches as isolation.

Manual Start & Stop Buttons

Isolator Handle Fits in Side of Enclosure Phase Indication

CH4 Bypass - Lockable

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Safety Instructions and Precautions

All personnel must be aware of the Manager’s Rules, Safety Policy, Isolation Procedures and Safe Working Procedures applicable to the operation of this machine prior to commencement of work. This also applies to personnel who work at the machine only occasionally, for example, during set-up, maintenance and flitting.

This is a radio remote controlled Miner. Only fully trained and authorised personnel must operate the Miner. Only personnel operating the Miner must be at, or near, the machine.

All personnel working around the machine must be appropriately attired and have the correct PPE. All personnel working on, or around the machine, shall be made aware of the safety and danger signs on the machine. These signs shall be kept clean and readable at all times.

Before starting the machine, the operator must make sure that nobody in the area will be endangered by the machine and by the associated equipment.

During operation of the machine do not stand in front of the machine, in the range of the cutter drum, stand on the gathering head or within the range of the conveyor. (See the diagram of dangerous areas on page 7) Before tramming the machine, the operator must warn all persons in the vicinity. In case of danger the machine may be stopped immediately by pushing one of the Machine Emergency Stop buttons.

Before putting the machine out of operation ensure it is in a safe position and that the cutter and conveyor booms are fully lowered or supported by the appropriate boom stops.

Repairs or maintenance work must never be carried out when the machine is operating.

Before the commencement of maintenance or trouble shooting work, proper isolation procedures must be carried out. This will prevent unintentional starting or movement during repair and maintenance work.

Ensure that all elevated components are secured against unintentional lowering before commencement of work in these areas.

Repair and maintenance work must never be carried out in dangerous areas or under unsupported roof.

Work on the electrics, electronics and hydraulic systems of the Bucyrus 25M3 Continuous Miner must be carried out by trained and authorised personnel only.

Never alter, remove, or bypass any of the machine’s safety features. Failure to comply with this warning could result in injury or death, since these items may be all that separates a worker from danger in an emergency.

The operator must be in visual contact with other personnel, within the vicinity of the machine, at all times. The right side Emergency Stop is located near the Operator’s enclosure. The left side Emergency Stop is located at the Dust Extractor motor. The third Emergency Stop is located on the Radio Remote Transmitter.

In case of danger, the Emergency Stops may be used to stop the machine.

It is essential that all personnel familiarise themselves with the fire fighting equipment available when working on, or around, the machine.

NOTE:

Emergency Stop buttons are no protection against unauthorised starting of the machine. Always follow the correct isolation procedure before repairs, maintenance, or troubleshooting, is performed.

NOTE:

The indications ‘left’ and ‘right’, used in this documentation, refer to the line of sight from the rear end of the machine (conveyor boom) towards the front to the cutter.

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SAFE AND CONTROLLED ZONES WARNING:

Unintentional actuation of the tramming drive may cause turning movements of the machine. Persons or equipment adjacent to the machine may get squashed or overrun.

Refer to MDG 5001 for appropriate safe zones regarding continuous miners and a site risk assessment should be conducted to ascertain the correct safe and controlled work zones for specific colliery applications. See below for some examples of recommended safe zones and controlled areas.

No Go Zones

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In front of, on and beside the gathering head.

In front of, on, beside and under the cutting drum.

On the chain conveyor.

Behind and under the transfer point.

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SAFETY INSTRUCTIONS FOR OPERATIONAL PHASES Normal Operation

No risky or endangering procedures shall be carried out. The machine must solely be used for the intended purpose, i.e. for cutting, loading and conveying of coal by the integrated chain conveyor, but not as a crane, towing vehicle or handling device.

It is very important to ensure that the machine is maintained and operated in a safe and functional condition only.

The machine must never be put into operation unless all protection and safety devices, i.e. the removable protection devices, Emergency Stop buttons, covers, are available and operative.

The machine must only be started and operated with one transmitter. Provision has been included in the software to lock out any additional transmitters brought into the area and to stop the machine. Starting and stopping procedures, as well as the supervision of controls and indicators must be carried out according to the operator's manual.

Before the operation is started and/or the first movements are made, the correct functioning of all audible and visual signals and lighting equipment must be checked.

Before setting the machine into operation all tools and mounting devices must safely be stored, so as not to risk any accidents.

Do not carry out any operation affecting the stability of the machine.

WARNING: To ensure no unintentional movement of the machine is possible, the correct Isolation Procedures must be carried out prior to any maintenance or repair work being carried out. Do not rely on the Emergency Stop switches as isolation.

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Flitting Operation

If the machine is to be flitted, and or by using auxiliary equipment, ensure all personnel are aware of appropriate signals to be used during this procedure.

All personnel must be clear of the designated dangerous areas when flitting of the miner occurs.

Before starting the flit, ensure the entire route of the flit must be clear of debris and idle equipment.

When the machine is ready to flit ensure all personnel are clear of the machine and the associated equipment.

Before tramming the machine, the operator must warn all persons in the vicinity. In case of danger the machine may be stopped immediately by pushing one of the Emergency Stop buttons.

Prior to flitting, place the machine into Flit Mode. This is achieved by, pulling the Flit Mode lever up to the off position as shown below. Flit Mode is indicated by a green flashing strobe at the rear of the machine, and is clearly displayed on the display.

Flit Mode Isolator – Isolates Cutters & Conveyors

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Safety Instructions for Maintenance and Repair Procedures

All personnel involved in maintenance and repair procedures must be fully trained in the operating systems of the Bucyrus 25M3 Continuous Miner.

Before maintenance and repair procedures are undertaken all safe working procedures must be read and understood by the personnel.

At no time are personnel carrying out maintenance and repair procedures, permitted to enter designated dangerous areas without following the required colliery isolating procedures.

Working on or near the gathering pan must only be carried out after the correct isolation procedures are carried out and the cutter head is sufficiently supported.

HAZARDS Electric Energy The Bucyrus 25M3 Continuous Miner is an electrically powered machine. Before adjustments, repairs, or parts replacement procedures are commenced all relevant isolation procedures should be carried out.

WARNING:

Work on the electric/electronic equipment may be carried out by trained electricians only.

WARNING:

Work on the hydraulic system may be carried out by skilled tradesmen only.

Hydraulics

All flexible hoses and screwed fittings must be checked at regular intervals for leakage and damage.

Defective components must be replaced. Leaking hydraulic fluid can causes injuries. If it becomes necessary to remove flexible hoses, or other hydraulic components, it is essential to de-pressurise the respective system according to the isolation procedure.

Noise In order to prevent long-term harm to personnel, wearing of ear protection is recommended. All sound insulation equipment at the machine must be in place during the operation of the machine.

Oils, Greases and other Chemicals When handling oils, greases and other chemicals, the safety regulations for the respective product must be observed.

WARNING:

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Special care must be taken when dealing with hot material (e.g. hydraulic fluid).

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SAFETY EQUIPMENT Emergency Stop Buttons Independent Emergency Stop buttons are arranged on the machine at the locations indicated below.

By operating either of these buttons, all machine functions will stop. These two emergency Stop buttons are actuated by pressing and are released by pulling them out.

NOTE:

If either of the machine mounted Emergency Stop buttons are pushed in they will latch in position, and the machine cannot be restarted until the switch is released.

Emergency Stop Button Locations

On the main electrical enclosure, right hand rear side of the machine.

On the left hand rear corner adjacent to the Dust Extractor Motor.

The machine cannot be restarted until the emergency STOP button(s) have been released.

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Transmitter Emergency Stop Switch A stop switch STOP is located on the radio transmitter, by operating this switch all machine functions will be stopped. This switch is red in colour and does not latch in position, as soon as this switch is released the machine can re-started.

WARNING:

Note that Emergency Stop Buttons are no protection against unauthorised starting of the machine.

NOTE:

To restart the machine after the STOP button on the radio transmitter has been used to stop the machine, the transmitter will must be turned OFF and then ON again.

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Audible Warnings An audible warning can be heard before the start-up of the following electric motors and functions:

Hydraulic Pump.

Cutter motors.

Conveyor and CLA’s.

Scrubber fan.

Tramming (forward or reverse).

Emergency tram.

WARNING: Unintentional actuation of the tramming drive may cause turning movements of the machine. Persons or equipment adjacent to the machine may get squashed or overrun.

Strobe Lights There are four (4) strobe lights fitted to the Helensburgh 25M3, these lights are used to inform or warn personnel of problems with the machine or with the environment they are working in.

The strobe lights indicate the following: AMBER STROBE Tramming Mode The amber strobe light will flash whenever the 25M3 is tramming; this is an indication to all personnel that the machine is moving.

GREEN STROBE Flit Mode The green strobe light will flash whenever the 25M3 is switched into flit mode. The flit mode switch disconnects the cutter and conveyor functions. This is full current isolation.

RED STROBE Methane Warning The red strobe light will flash when the 25M3 is in a high methane level. It will work in conjunction with the methane detection system to shut the machine down at the required level.

CLEAR STROBE Pump Running The clear strobe will flash whenever the pump motor is running.

Pump

CH4

Flit Mode

Tram

All relevant safety procedures must be carried out when in Flit Mode.

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Cutter Head Stops These are to be fitted to the Cutter Head during maintenance work to prevent the unintentional lowering of the cutter head. These are stored on the machine.

WARNING:

Do not remove load locking cartridges from the cylinders unless the cutter head is securely supported with the cutter head stops or adequate blocking.

Conveyor Boom Stops These are to be fitted to the Conveyor during maintenance work to prevent the unintentional lowering of the conveyor boom. These are stored on the machine.

WARNING:

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Do not remove load locking cartridges from the cylinders unless the conveyor boom is securely supported with the conveyor boom stops or adequate blocking.

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Cutter Stops The Cutter Stops are fitted to the Bucyrus 25M3 Continuous Miner to ensure the cutter head and gathering head cannot collide. If the gathering head is fully raised and the cutter boom lowered, the Cutter Boom Stops will push the gathering head down.

Cutter Stop

WARNING:

The Cutter Stops are a pinch point. No personnel are allowed within the designated dangerous area when the machine is operating.

Gathering Head Stops These are to be fitted to the gathering head during maintenance work to prevent the unintentional lowering of the gathering head. These are stored on the machine.

WARNING:

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Do not work under an unsupported load. Work under the gathering head requires adequate support, from either the gathering head stops or adequate blocking.

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Personal Safety Equipment All PPE shall comply with relevant colliery requirements.

NOTE:

Individual mine sites will have differing requirements for personal protective equipment. Please refer to the relevant Manager's Rules.

RADIO REMOTE CONTROL SYSTEM General When using the radio remote control system make sure to observe all applicable safety rules and accident prevention regulations. This means operation within the rules of:

Coal Mines Regulations

Certification

Mine Manager

Operator’s Manual Radio control of machinery can be of great assistance, but it needs a certain amount of practice, therefore only authorised personnel who have been fully trained should use the remote control.

Check the built-in safety functions at regular intervals. Depending on the frequency of use, this should be done under normal circumstances at least once per week using the control panel on the receiver.

The cable handler must be in full view of the operator at all times, and only proceed forward after the machine operator has been informed.

Only one transmitter should be available to control the machine at any time.

At the beginning of each shift, or after maintenance work, the Bucyrus 25M3 Miner should be tested for correct function by the operator. No personnel other than the operator should be within the operating range during test procedures.

WARNING: Initial operation of the remote control system should include a test period where machine response to operator switch actions may be verified in a safe environment.

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25M3 OPERATOR’S MANUAL SECTION 4

MACHINE DESCRIPTION

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Helensburgh 25M3 Operators Manual

TABLE OF CONTENTS GENERAL DESCRIPTION...............................................................................................................................3 Machine Layout .............................................................................................................................................3 Specifications .................................................................................................................................................4 Motors............................................................................................................................................................4 COMPONENT DESCRIPTIONS ......................................................................................................................5 Main Chassis..................................................................................................................................................5 Cutting Head Assembly..................................................................................................................................5 Gathering Head Assembly .............................................................................................................................6 Conveyor Assembly........................................................................................................................................6 Traction Drive System....................................................................................................................................7 Hydraulic System ...........................................................................................................................................8 Water System..................................................................................................................................................8 Water System..................................................................................................................................................9

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GENERAL DESCRIPTION The Bucyrus 25M3 is an electrically powered, radio remote controlled drum type continuous miner.

Overall the miner is 12 metres long and 3.5 metres in the width of the body. The miner has a cutting width of 3.7 metres and is capable of mining seams from 1800 mm to 3500 mm thick.

The machine is mounted on crawler tracks that provide full mobility and sharp turning radius in both board and pillar and long wall development mining plans. The ranging cutting head mines material from the solid face using a chainless rotating drum, and a CLA-type gathering head with high speed conveyor efficiently moves mined material to a haulage system behind the miner.

The machine's weight and balance is designed to mine most efficiently by sumping into the face at the top and ripping material to the bottom of the seam.

The figure below shows a general arrangement of major mechanical components. A brief description of the various major sub-systems of the 25M3 follows.

Machine Layout

Plan View

Side View

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Specifications Recommended Mining Range Overall Length

1800 to 3500 mm 11931 mm

Cutting Head Width Cutter Head Reach Drum Diameter Drum Speed Pick Height Height Over Covers Inc Headlights Frame Width over Rub rails

3700 mm 3900 mm 1118 mm 47.5 rpm 216 mm 1760 mm 3350 mm

Machine Weight – Approx.

Ground Clearance Ground Pressure Tracks Track Width Track Length Tramming Speed

62000 kg 305 mm 208 kPa Crawler Type LH & RH Independent 508 mm 2921 mm st 1 = 0 – 10 Metres/Minute 2nd = 13 Metres/Minute 3rd = 22 Metres/Minute

Conveyor Overhang Conveyor Width Conveyor Depth Conveyor Speed Conveyor Capacity – Struck

3623 mm 914 mm 305 mm 145 m/min 36 t/min

Brakes Drives Steering

Oil Flushed Spring Applied Park Brake Electrical - Mechanical Skid Steer NOTE:

Dimensions are valid for machines not fitted with a lift kit. A lift kit will add 75mm to all height dimensions.

Motors Type

Quantity

kW Rating

HP Rating

Cutter

2

150

200

Gathering Head

2

30

40

Pump

1

30

40

Traction – DC

2

32

43

Scrubber Fan

1

22

30

NOTE:

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All motors are water cooled.

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COMPONENT DESCRIPTIONS Main Chassis The main chassis of the machine is a robust box-type structure of high-strength steel construction that provides the following: Mounting of the RH and LH crawler tracks and their independent drive systems and take-up provisions as follows: Independent pivots for mounting the cutting head and gathering head and conveyor components and their associated hydraulic cylinders for articulation.

An integral hydraulic oil tank along with one electric motor/hydraulic pump assembly and associated valves and piping.

A rear stabiliser and with two articulating hydraulic cylinders for improving leverage forces during shear-down in the cutting sequence.

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

Cutting Head Assembly The cutting head assembly is attached to the main chassis at RH and LH independent pivot points around which the assembly is articulated for vertical-ranging cutting of the coal seam.

The independent pivots allow removal of the cutting head assembly without disturbing the gathering head or conveyor components.

The left and right hand gear drives are connected together at the cutting head by the main drive shaft.

This arrangement allows the power of both motors to be available at any point along the cutting head.

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Gathering Head Assembly

The gathering head assembly is attached to the main chassis at RH and LH independent pivot points around which the assembly is articulated to adjust the gathering head for uneven floor conditions and for tramming the miner from place to place. The independent pivots allow removal of the gathering head assembly without disturbing the cutting head or discharge conveyor.

Conveyor Assembly The conveyor assembly is attached to the main chassis at RH and LH independent pivot points around which the assembly is articulated vertically to assist in optimum loading into the haulage vehicle. Independent pivots allow removal of the conveyor assembly without disturbing the cutting head or gathering head components.

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Traction Drive System

The traction drive system provides the necessary mobility for the 25M3 miner to mine coal and to tram from place to place as needed. The traction speeds are infinitely variable from 0 to 22 metres per minute. Speeds 1 to 3 are used for tramming and when the cutters are running the miner reverts to Sump speed which is set to a percentage of speed 1.

The drive train originates at the two traction motors located inside the crawlers on either side of the machine. Power is then passed forward to a gear transmission driving the planetary gear cases, which then drives the 20” crawler tracks.

The traction drive control system provides the operator with the capability to run either RH or LH crawler chain in forward or reverse independently for maximum manoeuvrability, i.e. the miner may be pivoted about its central vertical axis. The RH and LH drive trains are each 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 soft and hard floor conditions.

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Hydraulic System The machine hydraulics are operated by one two-stage, fixed displacement gear pump. One stage supplies 121 L/Min @ 3500 psi to the cylinder functions and the other section supplies 15 L/Min @ 600 psi to the pilot functions.

The main hydraulic reservoir is designed and constructed within the main frame and has a total oil capacity of 304 Litres. In addition to the main reservoir the 25M3 miners use a header tank with a capacity of 83 Litres located on the scrubber side of the machine.

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Water System The water distribution system on the 25M3 miner serves several purposes: a) It is circulated through the electric motors for the hydraulic pumps, cutting head, gathering head and traction system, the main control case and traction transformer case, to provide cooling. This is at inlet pressure only and is discharged through sprays under the cutter head. b) It feeds water sprays around the cutting head, scrubber, gathering head and conveyor to help control and contain dusty air.

Piloted Operated Check Valves

Flow Control Valves

Bypass Control Valves

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25M3 OPERATOR’S MANUAL SECTION 5

CONTROLS AND THEIR FUNCTIONS

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TABLE OF CONTENTS CIRCUIT ISOLATORS..................................................................................................................................... 4 Main Circuit Breaker (Q1)............................................................................................................................ 4 Flit Mode Circuit Breaker (Q2) .................................................................................................................... 4 PUSH BUTTONS & SWITCHES ..................................................................................................................... 5 Control E/L Test ............................................................................................................................................ 5 Control and Lights E/L Reset ........................................................................................................................ 5 Traction Earth Leakage Test......................................................................................................................... 5 Traction Earth Leakage Reset....................................................................................................................... 5 Pump Start..................................................................................................................................................... 5 Pump Stop ..................................................................................................................................................... 5 Radio/Manual Selector.................................................................................................................................. 6 Holville CH4 Reset Selector.......................................................................................................................... 6 Holville CH4 Remote Reset. .......................................................................................................................... 6 MACHINE EMERGENCY STOPS .................................................................................................................. 7 Left Side Machine Emergency Stop............................................................................................................... 7 Right Side Machine Emergency Stop ............................................................................................................ 7 RADIO REMOTE CONTROL SYSTEM .................................................................................................................... 8 Remote Control Transmitter.......................................................................................................................... 8 Transmitter Timeout ...................................................................................................................................... 8 Multiple Transmitters .................................................................................................................................... 8 Radio signal continuity................................................................................................................................ 10 Turn the Transmitter on .............................................................................................................................. 10 Turn the Transmitter off .............................................................................................................................. 10 Stop.............................................................................................................................................................. 10 Siren ............................................................................................................................................................ 10 Hydraulic Pump – Start............................................................................................................................... 10 Hydraulic Pump – Stop ............................................................................................................................... 10 Raise Cutter................................................................................................................................................. 10 Lower Cutter ............................................................................................................................................... 10 Conveyor up ................................................................................................................................................ 10 Conveyor down............................................................................................................................................ 11 Conveyor left ............................................................................................................................................... 11 Conveyor right............................................................................................................................................. 11 Apron Down ................................................................................................................................................ 11 Apron up...................................................................................................................................................... 11 Lower stabiliser........................................................................................................................................... 11 Raise stabiliser ............................................................................................................................................ 11 Water ........................................................................................................................................................... 11 Cutters ......................................................................................................................................................... 11 Start Cutters ................................................................................................................................................ 11 Stop Cutters ................................................................................................................................................. 11 Tramming .................................................................................................................................................... 12 Tramming Speeds ........................................................................................................................................ 12 Gathering Heads – Conveyor...................................................................................................................... 12 Conveyor Forward ...................................................................................................................................... 12 Conveyor Reverse........................................................................................................................................ 13 Conveyor Stop ............................................................................................................................................. 13 Lights........................................................................................................................................................... 13 Shift/Shear Down......................................................................................................................................... 13 Transmitter Maintenance & Battery Charger ............................................................................................. 14 Display Unit ................................................................................................................................................ 14 Main Monitor Screen .................................................................................................................................. 15 Production Monitor Screen No.1 ................................................................................................................ 16 Production Monitor Screen No 2 – Boom Monitor .................................................................................... 17 MODES OF CONTROL.................................................................................................................................. 18 Radio / Manual Mode Switch ...................................................................................................................... 18

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Radio Mode ................................................................................................................................................. 18 Manual Mode .............................................................................................................................................. 18 Pendant ....................................................................................................................................................... 18

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CIRCUIT ISOLATORS WARNING:

The main circuit breaker does not remove power from the trailing cable or the incoming line side of the breaker. Always disconnect power from the machine at the power centre before major electrical repairs or maintenance.

WARNING:

Never attempt to start or move this machine unless you are familiar with all controls and emergency stop devices. Be certain the area around the machine is clear of other mine personnel whilst operating.

The 25M3 has (2) two external Circuit Breaker operating handles: 1. Main Circuit Breaker - opens all circuits.

2. Flit Mode Circuit Breaker - opens Cutters and Conveyor Motors

Main Circuit Breaker (Q1) The Main Circuit Breaker is located in the isolator compartment of the Main Enclosure located on the right hand side of the machine. The operating handle is located on the left hand side of the enclosure.

The operating handle can be turned to the “OFF” position and removed.

This handle is used to unlock the Operator Compartment and the Transformer Enclosure.

Push the handle to turn “ON” and pull the handle to turn “OFF”.

Flit Mode Circuit Breaker (Q2) The Flit Mode Circuit Breaker is located on the right hand side of the operator compartment in the Main Enclosure located on the right hand side of the machine. The operating handle can be turned to the “OFF” position and locked in the “OFF” position.

This circuit breaker is used to provide whole current isolation for the Cutter motors and Conveyor motors.

When the circuit breaker is in the “OFF” position the machine is in “FLIT” mode and when the circuit breaker is in the “ON” position the machine is in normal operation.

NOTE:

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This circuit breaker must be isolated to operate in flit mode

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PUSH BUTTONS & SWITCHES

2

1

6

7

3

SP

9

1 2 3 4 5 6 7 8 9 10

Control Earth Leakage Test Lights Earth Leakage Reset Traction Earth Leakage Test Traction earth Leakage Reset Lights & Control E/L Reset Hydraulic Pump Start Hydraulic Pump Stop Radio – Manual Mode Switch Holville Methane Battery Selector Holville Methane Battery Remote Reset

1

5 4

10 Control E/L Test This is used to carry out an earth leakage test on the 110V control circuit and to prove the operation of the Control Earth Leakage device (K21).

Control and Lights E/L Reset This is used to resets both the Control and Lighting Earth Leakage devices after testing or a fault condition.

Traction Earth Leakage Test This is used to carry out an earth leakage test on the Traction circuit and to prove the operation of the Traction Earth Leakage device (K20).

Traction Earth Leakage Reset Resets the Traction Earth Leakage device after testing or a fault condition.

Pump Start Manual Start for Hydraulic Pump. Only operational when machine is in manual mode. To be used to start pump when using emergency pendant.

Pump Stop Manual Stop for Hydraulic Pump. Only operational when machine is in manual mode.

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Radio/Manual Selector This selector is used to select the mode of operation for the miner. Manual mode is used, if in the event the transmitter or radio is inoperable, the miner can be operated manually using the pendant to move the miner to safe location.

Holville CH4 Reset Selector This selector is used to reset the methane battery to enable the miner outlet on the DCB to be turned on and provide power to the machine. It is also used to turn off the battery when the machine is left not powered up for a number of shifts.

Holville CH4 Remote Reset.

This push button is located at the rear right hand side of the machine and enables resetting of the methane battery using a long piece of conduit or similar if the machine is left in unsupported roof and requires powering.

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MACHINE EMERGENCY STOPS There are (2) two Machine Emergency Stops available around the machine.

•

Left Side Machine Emergency Stop

• Right Side Machine Emergency Stop Operation of any of the Machine Emergency Stops will result in the pumps stopping. If a pump start is attempted whilst a Stop is latched, the message “Machine Emergency Stop Pressed” will be displayed to indicate the condition.

Left Side Machine Emergency Stop The Left Side Lanyard Machine Emergency Stop is located at the left side rear of the machine above the scrubber motor.

E/Stop

Right Side Machine Emergency Stop The Right Side Machine Emergency Stop is located at the right side rear of the machine adjacent to the flameproof Main Enclosure.

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Radio Remote Control System WARNING:

At all times, the machine must be operated in a safe manner. This means operating within the rules stipulated by the mine management and regulatory authorities. Refer to Mines Remote Control Management Plan and Managers Rules.

Operators must fully familiarise themselves with the radio control functions and how they operate.

The cable handler must be in full view of the operator at all times, and only proceed forward of the operator after the operator has been informed.

Only one transmitter should be available to control the machine at any one time.

The control system automates the mining operation and enables remote control, so that the operator can operate machines from the best vantage point. The system also has a series of interlocks to prevent incorrect operating sequences.

Remote Control Transmitter The remote control transmitter provides control of the machine’s functions. The portable remote control unit uses a sophisticated communications protocol to protect against interference and spurious operation of the miner. It communicates with the microprocessor control unit mounted on the miner using radio signals in the UHF band.

The remote control unit has rechargeable batteries that have enough capacity for up to 18 hours of continuous use.

The remote control transmitter has 12 switches. All of these are spring-loaded in the centre position.

Transmitter Timeout The transmitter has a time out feature that can be set using the battery charger. The transmitter will turn itself “OFF” after this preset period, if no keys have been pressed. The default value is 15 minutes but a typical setting is 5 minutes.

NOTE: This timeout period is not to be confused with the timeout that stops the machine after 2 minutes of inactivity. The 2 minute timeout does not turn off the transmitter only the pump.

Multiple Transmitters If a second transmitter is turned “ON” and it is brought into range of the miner, the first transmitter will be locked out and the pump will shutdown. The miner will be unable to restart until the second transmitter is turned “OFF”.

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Caution For some functions, such as turning on the cutters, you need to press the switch only momentarily. For other functions you need to press and hold the switches while the operation continues, such as tramming.

Most switches have two (2) functions - these functions are identified and selected as follows: Primary function - the switch operation is coloured black. To activate the primary function of a switch, you need to press only that switch.

Secondary function - the switch operation is enclosed in square brackets. To activate a secondary function, you need to first press the switch [SHIFT] and then, while still holding the [SHIFT] switch, press the other switches within two (2) seconds. The [SHIFT] switch should always be pressed slightly before the other switches. The switches can then be released in any order.

Emergency or stop functions are coloured red.

Motor Start Functions are coloured Green.

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Radio signal continuity If the remote control is turned off or stops transmitting for any reason, the receiver unit will detect the loss of the radio signal and stop the machine. If no function is selected for five (5) minutes, the console will automatically turn itself off, causing the machine to stop as well.

Turn the Transmitter on Press the “ON” switch and hold it for two seconds until transmitter number and the message “ON” are displayed.

Each transmitter has a unique Serial Number which is recognised by the receiver when the transmitter has been switched “ON”. Once the receiver has recognised a transmitter, it will only accept commands from that particular transmitter until the receiver is powered down.

On powering up the system the radio and the transmitter must be switched on within 1 minute of each other, if not the system will lock out and display a message prompting the operator to cycle the power supply.

Transmitter must be turned on beside the machine. If power is lost, the transmitter must be turned off and then on again

Turn the Transmitter off Press the OFF switch.

This will also stop any machine that is turned on or operating after a delay of one second.

Stop Pressing the STOP switch in either direction will cause all functions on the mining machine to cease immediately. The hydraulic pump will be turned off.

Siren The 25M3 miners are equipped with a warning siren that sounds when you select certain functions, such as starting the pump. The duration of the siren sound is adjustable.

The selected function will not operate until after the siren has stopped.

Hydraulic Pump – Start Press and hold the [SHIFT] and [PUMP ON] switches together. The Siren will sound for two seconds and then the pump will start.

Release both switches.

Be careful to release the pump switch before the select switch or you will turn the pump off.

From here, you can perform either tramming or cutting operations.

Hydraulic Pump – Stop Press [PUMP OFF] NOTE:

The pumps will also stop immediately if the STOP is activated

Raise Cutter Press the SHEAR UP switch.

The cutter will rise until the preset upper boom limit is reached or the switch is released.

Lower Cutter Press the SHEAR DWN switch.

The cutter will lower until the preset lower boom limit is reached or the switch is released.

Conveyor up Press the CONVEYOR UP switch. The conveyor will continue to rise until it reaches the upper limit or you release-the switch.

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Conveyor down Press the CONVEYOR DWN switch. The conveyor will continue to lower until it reaches the lower limit or you release the switch.

Conveyor left Press the CONVEYOR LEFT switch. The conveyor will continue to move left until it reaches the left limit or you release the switch.

Conveyor right Press the CONVEYOR RIGHT switch. The conveyor will continue to move right until it reaches the right limit or you release the switch.

Apron Down Press the APRON DOWN switch to lower the apron. The apron will continue to lower until it is fully down or you release the switch.

Apron up Press and hold the APRON UP switch to raise the apron. The apron will keep rising until it is fully up or the switch is released.

Lower stabiliser Press and hold the STAB DWN switch to raise the machine.

The stabilisers will keep lowering until they are fully extended or the switch is released.

Raise stabiliser Press and hold the STAB UP switch to lower the machine.

The stabilisers will keep rising until they are fully extended or the switch is released.

Water There is one (1) water circuit for the cutter head sprays. You can start and stop the head sprays manually.

To start the head sprays: Toggle WATER switch to start the high-pressure water jets.

Toggle WATER switch again to stop the high-pressure water jets.

Cutters Starting of the Cutter motors is staggered to avoid excessive current inrush that might result if both motors were started at the same time. After the first motor is started, there is a delay of two or three seconds before the second motor starts.

The first motor to be started is chosen automatically by the control system and alternates from left to right for successive starts.

Start Cutters Press the [SHIFT] and [CUTTER ON] switches.

The siren will sound for a period of time before the cutters are started.

The water sprays will come on automatically.

Release both switches.

Stop Cutters Press CUTTER OFF switch.

Release both switches.

Machine sprays stop.

NOTE:

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The cutters will stop immediately whenever the STOP is activated or the hydraulic pumps are stopped

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Tramming Tramming mode can be engaged only, by pressing or moving the TRAM 2-3 switch for about ½ second. A siren beep will sound acknowledging that tramming mode has been enabled, then you have 10 seconds to move the 2 tram toggles.

The left and right tramming switches can only be used once in tramming mode: Together (same direction) Singularly (one at a time, for turning) Differentially (opposite directions, for pirouetting).

If the miner looses power the machine will default to flit mode.

NOTE:

Tramming mode will be disengaged after a 10 second delay after tram toggles are released

Tramming Speeds The miner can tram at any of three speeds, both in the forward direction and in reverse. Each of these speeds are adjustable by varying the left/right tracks control voltage, however these are factory preset.

NOTE:

Adjustment to tracks control voltage should only be performed by trained personnel

NOTE:

Access to track control voltages are password protected.

The miner is always in speed 1 when tramming mode is first selected. To engage the next speed, press the TRAM 2-3 switch while operating one or both tramming switches.

When speed 3 has been reached, continued operation of TRAM 2-3 switch will cause the speeds to toggle between 2 and 3.

If the miner is in either speed 2 or speed 3, it will only return to speed 1 when the tramming switches are released.

Provided that you hold at least one of the switches, the miner will keep its current speed even if the other switch is released or pressed in the other direction.

If you hold the TRAM 2-3 switch when the miner has reached speed 2, the machine will begin tramming in speed 2 each time a tramming switch is pressed.

The miner will always stop when the tramming switches are released, irrespective of its current speed range.

The machine is fitted with a tram brake, which is always on when there are no tramming switches pressed.

When cutting coal, the miner only has 2 speeds, they are called clean-up speed and sump speed.

These only work when the cutters are turned on. Sump speed is about half the speed, of speed 1 in normal mode. Clean-up speed is about the same as speed 1 in normal mode.

Gathering Heads – Conveyor The Gathering Head motors spin the CLA’s and also drives the chain conveyor in the same direction.

Conveyor forward and reverse functions on the transmitter start the gathering heads.

Conveyor Forward Press the [SHIFT] and CONVEYOR [ON] switches together.

The siren will sound for two (2) seconds before conveyor starts.

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Conveyor Reverse Press and hold the [SHIFT] and CONVEYOR [REV] switches together.

After a short delay, the conveyor will start running in the reverse direction and continue to do so until the switches are released.

Conveyor Stop If the conveyor is already operating in forward, pressing the CONVEYOR OFF switch will stop it.

Lights The lights can be operated on and off by [SHIFT] and [LIGHTS].

Shift/Shear Down Clears green faults on operator’s page.

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Transmitter Maintenance & Battery Charger

Before taking the transmitter off charge, ensure the green light is on the appropriate channel of the charger to indicate the battery has been fully charged and is in good order.

Switch on the transmitter and ensure the battery/charger is receiving a signal from the transmitter.

Operate each switch to ensure each function is indicated on the battery charger screen.

Ensure all dirt and moisture is removed from the top of the transmitter before it is placed on charge after each shift. Inspect transmitter for any damage.

Every week the top plate should be removed from the transmitter and all material removed from around the switches by soft brush and all switches inspected for any damage including membrane around switches.

When transporting to machine ensure transmitter is secured to prevent damage. Also ensure whenever transmitter is put down at face that it is located in safe position.

NOTE:

Observe the Procedures listed in Mine Management Plans.

Display Unit A display screen is provided on the right hand side rear of the machine. This provides the operator/tradesman with fault information, machine modes and performance information. The screen is not visible in Manual mode.

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Main Monitor Screen

This Main Monitor display screen includes:1. Machine statuses indicated by Fault (red), Trip (orange), or OK (green).

2. Machine Mode Selected – Mining, Power Fill or Flit Mode is indicated in blue.

3. Radio frequency channels 1 through to 8 indicated under remote graphic and red.

4. Page title, page number plus time and date in the top section.

5. Transmitter functions in use indicated in yellow and by top right remote graphic (toggle turns red) 6. Faults and Trips (scrolling if more than one) indicated in red 7. Motor States, if running lit in red to indicate warning of operation 8. Pump current (Amps) and Motor Thermistor Resistance (Ohms) 9. Left and Right cutter currents (Amps) and Motor Thermistor Resistance (Ohms) 10. Scrubber current (Amps) and Motor Thermistor Resistance (Ohms) 11. Left and right gathering head currents (Amps) and Motor Thermistor Resistance (Ohms) 12. Left and right traction currents (Amps) and Motor Temperature (Celsius) 13. Machine Voltage and Oil Temperature and Level.

14. Remote indications including :

SIGNAL: Indicates green when transmitter signal is healthy.

BATTERY: Indicates flashing red when transmitter battery is low.

STOP: Indicates red when transmitter remote stop activated.

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Production Monitor Screen No.1

The Production Monitor is Page 2 on the display screen menu and this screen includes: Left and right Cutter motor currents by phase and displays overall current on a real time graph.

Indicates the % speed of the Traction, and gives the ability to monitor Traction ramp up and down relative to Cutter Load when cutting

Indicates roof and floor clearance of the cutting drum via onboard Inclinometer. These values are for indication only.

Running status of cutting drum via animation and colour, if running, the drum animation spins, and is red. If drum colour is flashing, this indicates the drum is outside inclinometer values.

Direction arrows, change red to represent the drum travelling vertically up or down.

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Production Monitor Screen No 2 – Boom Monitor

The production monitor is found on page 9 The changes incorporate:

Large numerical display

The diameter of the Cutter Drum has been included in the readout.

As shown on the example, when the Cutter Drum is on the floor (0 cm) the roof reference will read 106 cm (Cutter Drum diameter).

The display will display a negative reading when the Cutter Boom is taken below 0 cm (floor reading).

The maximum negative reading will be -30cm.

The Cutter drums can be zeroed in the setup pages. This page is to assist the operator with a visual indication of the cutter drum location with reference to the floor and the roof.

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MODES OF CONTROL Radio / Manual Mode Switch The miner can be operated in (2) two modes of control: Radio Mode

Manual Mode The mode selector switch is located on the left hand door of the Operator Compartment in the Main Enclosure and has an “OFF” position between the two modes.

Radio Mode When the miner is in Radio mode, it is controlled via the radio system and transmitter. The pendant circuits are isolated via the mode switch.

Manual Mode The Manual mode provides the ability to start the pump and tram at sump speed in both forward and reverse directions in the event of an EMERGENCY ONLY. It does not provide for production or maintenance operation.

NOTE: The mode switch has an off position that isolates power to the control system The pendant is required to be plugged in prior to starting the pump in manual mode to allow for tramming.

Pendant The Pendant consists of four tramming buttons:•

Left Tram Forward

•

Right Tram Forward

•

Left Tram Reverse

• Right Tram Reverse.

All tramming buttons are spring return to the off / neutral position. There is also a latched Machine stop button, which is normally in the “in” position when not in use. This stop button is only in use when the pendant mode is selected.

To activate the Pendant, turn the mode selector switch to Manual. When the Pendant stop button is pulled out, the pump can be started by operating hydraulic pump start on panel. and the tramming buttons are ready for operation. The pump must be stopped using the pump stop button on the panel or by an emergency stop if necessary.

NOTE:

The siren will sound continuously while Pendant mode is selected.

The two deadman switches must be held in at all times whilst operating the pendant. These lift the brakes also.

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Front View

Rear View

Side View Plug View

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25M3 OPERATOR’S MANUAL SECTION 6

PRE-START CHECKS

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TABLE OF CONTENTS PRE-START FUNCTIONS .......................................................................................................................................3 Inspections .....................................................................................................................................................3

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PRE-START FUNCTIONS Prior to starting the machine at the beginning of each shift, the machine must be inspected and tested for correct operation.

The checks must be carried out to ensure the machine is safe to operate and no foreseen problems will occur during the shift. The checks will also ensure the correct operation of all functions and safety devices incorporated on the machine.

NOTE:

Appropriate Mine’s Managers Rules for Pre Start Checks to be followed.

List provided is a generic example only.

WARNING:

Ensure that the working face has been inspected in accordance with the Coal Mines Regulations before proceeding to with miner checks.

WARNING:

Check around machine to ensure that there are no persons who will be in danger if the machine is operated.

Inspections The inspections should include the following items prior to starting the miner:1. Ensure that you are aware of section plan and at what stage the mining sequence is up to.

2. Ensure the machine has a power supply of 1000V. 3. Ensure there is water available to the machine. Check hose condition.

4. Check the Remote Transmitter has been tested for correct operation.

5. A visual inspection of the machine should be done to ensure the machine is safe to operate.

6. Check all scheduled preventative maintenance has been carried out.

7. Check with previous operator for status report regarding any problems or faults with the miner or conditions.

8. Check the condition of roof and face in the immediate area of operations and check the state of ventilation.

9. Check that there are no “Out of Service” or “Danger” locks on the machine.

10. Ensure all guards are in correct position and are secure.

11. Ensure that miner is free of large amounts of coal and debris.

12. Ensure that all exposed hoses and cables are safely positioned and free from damage.

13. Ensure lights are secure and lenses are clean and not cracked or broken.

14. Ensure stop buttons are in the correct position.

15. Ensure that no foreign items (eg. service tools and equipment) have been left on and/or in the miner and/or in front or at the rear of the miner.

16. Check scrubber screen for excess build up.

17. Check that fire extinguisher is in position and in a serviceable condition.

18. Ensure all visible flameproof equipment including cables and glands are not damaged which may render miner not flameproof.

19. Ensure operator service points have been checked: a) Cutter head has a full complement of sharp picks. No damaged pick blocks. b) All oil levels register the correct amount of fluid. c) The water back flush filter is clean. d) Water sprays are in place and clear. e) Hydraulic filter indicators. (If fitted)

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25M3 OPERATOR’S MANUAL SECTION 7

START-UP PROCEDURE

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TABLE OF CONTENTS START UP FUNCTIONS .........................................................................................................................................3

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NOTE:

Pre-Start Procedures listed in the Mines Management Plan are to be followed. Once Pre-Start checks have been completed miner can be started and placed in production.

START UP FUNCTIONS

Check main circuit breaker is on.

Check handle on inlet water filter handle is in the correct position.

Check if display is lit and finished booting up.

Using the radio transmitter: Activate the headlights.

Ensure all personnel are well clear of miner before starting.

Audible alarm.

Start the pump motor.

Check the operation of the stop switch. Restarting the miner, check that the following functions operated correctly.

Stand well clear of the miner and ensure all personnel are well clear when checking for the following functions after resetting Q2 (Flit Mode Circuit Breaker): 1. Cutter head – raise and lower.

2. Shovel – raise and lower.

3. Stabiliser – raise and lower.

4. Conveyor – raise and lower.

5. Conveyor Swing – right and left.

6. Traction – forward and reverse (in all three (3) speeds).

7. Water Sprays – on and off.

Check the following operations: 1. Pump – on and off.

2. Cutter Head – on and off.

3. Conveyor – on and off.

4. Scrubber – on and off NOTE:

CAUTION:

Whilst each of these items should be checked before starting the miner at the beginning of each shift, it is also necessary to maintain a constant awareness of these points each time the miner is restarted in the course of the shift Never operate the miner if any picks are missing, blunt or damaged. These must be replaced immediately.

Failure to do so may cause. Damage to cutter drums.

Providing the items in sections “Pre-Start Functions” and “Start-Up Functions” have been checked positive, the miner is now ready for coal production.

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25M3 OPERATOR’S MANUAL SECTION 8

OPERATING PROCEDURES

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TABLE OF CONTENTS USING 25M3 MINER........................................................................................................................................3 Precautions ....................................................................................................................................................3 Transmitter Start Up Time .............................................................................................................................3 MINING MODE ................................................................................................................................................4 General ..........................................................................................................................................................4 Cutting Coal...................................................................................................................................................4 Emergency Tram............................................................................................................................................7 E/Stop Override Emergency Tram.................................................................................................................7 FLIT MODE ..........................................................................................................................................................8 POWER FILL MODE ........................................................................................................................................9 Entering Power Fill Mode .............................................................................................................................9 Exiting Power Fill Mode..............................................................................................................................10

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USING 25M3 MINER Before starting coal production in any environment, a procedure will have to be in place and all members of the crew must be aware of their tasks and when each member is required to perform the task ensuring the system operates safely and effectively.

Precautions To operate the 25M3 miners efficiently in this type of coal cutting system a number of items are required to be in place: 1. Correct power supply to Section.

2. Correct Colliery ventilation supply.

3. Ensure water is on machine.

NOTE: Pre-Start Procedures listed in the Mines - Remote Control Operations - Continuous Miner - Document – Energy Control and Isolation Management Plan is to be followed.

Transmitter Start Up Time When power is first put onto the miner, you have 1 minute to turn the transmitter on. The transmitter sends a signal to the receiver in the form of a Serial Number. This Serial Number is registered with the receiver until you have a power loss or the main isolator is turned off, and then turned back on again. If the signal is not received in the first minute of powering up the machine, the radio/pendant switch will need to be cycled to allow re-handshaking the transmitter. The transmitter remains locked to the receiver until it is switched off or the power is cycled, any other transmitter that is turned on in the same vicinity will cause the pump to stop and the transmitter to be locked out until one of them is switched off and the power is cycled.

A beep will sound when transmitter is recognised by the receiver.

After initial handshake, it is not necessary to cycle power for further handshaking if transmitter is tilted or turned off inadvertently. Just turn transmitter to off, wait 2 seconds and turn on and hold until LED display flashes “ON”. A beep will sound and transmitter can be used as normal.

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MINING MODE General No risky or dangerous procedures shall be carried out. The machine must solely be used for the intended purpose, i.e. for cutting, loading and conveying of coal by the integrated chain conveyor, but not as a crane, towing vehicle or handling device.

It is very important to ensure that the machine is operated in a safe and well functioning condition only. The machine must never be put into operation unless all protection and safety devices, i.e. the removable protection devices, Emergency Stop buttons, sound insulation, coverings, suction device are available and operative.

Before any work is started the crew shall investigate the environment e.g. any obstacles in the working and traversing area, as well as the angle of incline and necessary site guards against other machines.

Cutting Coal The following procedure covers the basic operations required to operate the Bucyrus 25M3 Continuous Miner. It does not cover all possible scenarios that can occur during machine operation.

Site specific procedures must be set-up to cover all contingencies at a particular mine site.

NOTE:

It is recommended that the machine be used to cut from the roof to the floor.

Operation 1.

Start the Pump Motor Press and hold the [SHIFT] and PUMP [ON] switches together.

The Banshee will sound for approximately 3 seconds and the pump will start.

WARNING:

Before starting of any motor functions, ensure all personnel are clear of the designated dangerous areas.

No personnel should be near these areas when it is operating.

2.

Raise or lower the cutter boom for adequate clearance and visibility.

Operate and hold the SHEAR DWN or SHEAR UP switch to move the cutter head.

3.

Raise or lower the conveyor boom for adequate clearance and visibility.

Operate and hold the CONVEYOR DWN or CONVEYOR UP switch to move the conveyor boom.

4.

Put the gathering head into float position.

Operate and hold the APRON DWN switch, the gathering pan will remain in the float position until APRON UP is selected.

NOTE:

5.

For maximum clean up efficiency, the gathering head should rest on the floor and be set in the free floating position.

Select Tram Enable Operate the TRAM 2 -3 switch. The banshee will sound and tramming mode is enabled. The tramming strobe light will flash.

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WARNING:

Before tramming is commenced, ensure all personnel are clear of the designated dangerous areas. No personnel should be near these areas when the machine is operating.

6.

Slowly tram the miner in toward the face until the cutter head touches the face.

Operate and hold the LEFT & RIGHT FWD tramming switches together.

The banshee will sound while the machine is tramming.

Release both switches to stop tramming.

7.

Raises and swing the conveyor boom to allow the shuttle car under the transfer point.

Operate and hold the CONVEYOR DWN or CONVEYOR UP switch to move the conveyor boom up or down.

WARNING:

Ensure all personnel are clear of the designated dangerous areas. No personnel should be near these areas when the machine is operating.

8.

Raise the cutter boom to the desired cutting height.

Operate and hold the SHEAR DWN or SHEAR UP switch to move the cutter head

9.

Start the conveyor motors.

Press and hold the [SHIFT] and the CONV [ON] switches together.

The Banshee will sound for approximately 3 seconds and the conveyor and CLA’s will start.

10.

Start the cutter head.

Press and hold the [SHIFT] and the CUTTER [ON] switches together.

The Banshee will sound for approximately 3 seconds and the cutter head will start The water sprays will start when the Banshee sounds.

The speed of the machine will now be regulated to ‘clean-up’ speed. This is now the only speed available in forward.

NOTE:

The rear stabiliser can be used to steady the miner during sumping and shearing operations.

11.

Tram the miner forward so that the cutter head advances into the coalface to a depth of 500 mm.

When the cutter heads start, the speed of the machine will automatically drop to sumping speed.

12.

When required sumping depth is reached, shear the cutter head down the coalface.

13.

Stop Shearing when the haulage unit is full.

14.

When the haulage unit returns repeat process until floor height is reached.

NOTE:

November 2008

This procedure covers the basic operations required to operate the Bucyrus 25M3 Continuous Miner. It does not cover all possible scenarios that can occur during machine operation. Site-specific procedures must be set-up to cover all contingencies at a particular mine site.

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Page 6 of 10

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Helensburgh 25M3 Operators Manual

Emergency Tram The 25M3 Miner is fitted with a function to allow emergency tramming without the hydraulic system operating.

This function is to be used when the machine is out under unsupported roof and the hydraulic pump stops and is unable to be started. Two possible reasons for this are either pump failure or an emergency stop has been operated by rib fall.

NOTE: This function is not to be confused with the tramming pendant mode which is designed for supported roof situations and when the hydraulic functions are available.

NOTE:

This function is only available when the miner is in normal production mode NOT in Flit Mode.

When using this procedure, it should be noted that the following assumptions have been made: The machine has been operating under production conditions and the pump motor has recently stopped operation.

There is still power on the miner and the transmitter is still operational and turned on.

If all these assumptions are true then follow the procedure below, if not, then other alternative measures must be taken into account to retrieve the miner.

To select the Emergency Tram Mode the following procedure must be followed.

Operate simultaneously the: 1. ON/OFF toggle to the [SHIFT] position.

2. The [TRAM] 3 toggle.

3. And the Tram Speed toggle to the [MENU] position. On some transmitter plates [MENU] is replaced with [PAGE].

After a short time period the Tram Contactor will close, allowing the 25M3 to be operated in tram mode as normal. The floor conditions will determine the distance of travel until the accumulator drains and the brakes are automatically applied, but a distance of 10-20 metres is achievable and would be considered the nominal length of travel.

If the tramming levers are not operated for more than 20 seconds or the transmitter is turned off then the miner will revert to its normal mode of operation.

NOTE: The Emergency Tram function is reliant on the Brake Accumulator being charged to a minimum of 1850 psi.

If the Accumulator is discharged it will be necessary to use an external hydraulic device (maximum pressure of 3000 psi) to release the brakes.

E/Stop Override Emergency Tram The EMERGENCY TRAM E/STOP OVERRIDE is a function fitted to the 25M3 miner whereby if an emergency stop button is pressed in whilst cutting (by a rib fall or some accidental circumstance other than an emergency situation) the machine can be trammed back to supported roof by using the same sequence of toggles above.

Both ETRAM and ETRAM E/Stop Override operate without using the pump motor, so the accumulator must be charged to lift the brakes on the traction.

NOTE: The E/Stop Override Emergency Tram function must be enabled in the setup software before the operation will function.

Emergency Tram enabled is a default factory setting but E/Stop override is disabled as default.

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Flit Mode Flit mode is used in cut and flit operations when the miner is being positioned from one heading to another without having the hazard of the cutters or conveyors operational.

Flit Mode allows for flitting of the miner with full hydraulic functions available to the operator. Flit Mode is indicated by a green flashing strobe on the rear of the machine The following points should be taken into account when using Flit Mode.

1. Ensure the cutter and gathering head circuit breakers are isolated by opening the Q2 – Flit Mode circuit breaker and tagged as per mine managers rules.

2. Ensure all personnel are clear of machine prior to start up.

3. Operate machine to suit conditions - flit machine in slow speed. If flitting on grades up or down - ensure extra distance and time is allowed to stop. Poor floor conditions could cause machine to slip.

4. Ensure cable handlers and cable is clear and free from possible damage.

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POWER FILL MODE Entering Power Fill Mode To enter the Power Fill mode, the miner must first be in Flit Mode. Hold both the [SHIFT] and TRAM2 toggles over simultaneously. A siren will sound and the mode change light on the display screen will change from Flit Mode to Power Fill Mode.

Once in Power fill mode, this isolates everything from moving and all protection devices are still enabled, thus the Spool monitoring and inadvertent motor protections are still active in Power fill mode.

The Hydraulic oil fill hose needs to be put into an oil drum, before activating the Power Fill Mode.

To activate the Power Fill simply start the pump and the solenoid will activate after a small time delay, approximately 1-2 seconds.

To stop filling, stop the pump. A sight glass is provided to ensure the tank is not overfilled.

Ensure no one is in a dangerous position.

Enter Power Fill

Start Filling

If the flit mode lever has not been turned off and you are attempting to enter the PFM mode, a message will appear on the screen; this will read, “NOT IN FLIT MODE”.

If you are in PFM mode and the miner stops or looses power, when the miner is restarted or repowered, it will default back to the PFM mode. If in normal mining mode, it will default back to normal mining mode.

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NOTE:

When you are already in Power fill mode, the transmitter will not operate ANY other functions.

If the hydraulic functions are operated manually the miner will stop

WARNING:

If the flit mode is disengaged, while in PFM mode, the pump stops and the following messaged is displayed, PUMP STOPPED NOT IN FLIT MODE.

Exiting Power Fill Mode To exit Power Fill mode first stop the pump, then operate the [SHIFT] and TRAM 1 toggles simultaneously. A siren will sound and the mode change light on the display screen will change from Power Fill Mode to Flit Mode. The operator can now continue to flit the miner or reset the Flit Mode circuit breaker and begin production.

Stop Filling

Exit Power Fill

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25M3 OPERATOR’S MANUAL SECTION 9

SHUTDOWN PROCEDURE

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TABLE OF CONTENTS SHUTDOWN FUNCTIONS ......................................................................................................................................3 Parking...........................................................................................................................................................3 Shutdown Checks ...........................................................................................................................................3

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SHUTDOWN FUNCTIONS Parking On completion of the shift, the miner should be parked in an area where the following conditions prevail: 1. The roof and rib have been secured.

2. The area is well ventilated.

3. The miner will not be affected by a slow or sudden influx of water.

Shutdown Checks Before shutting the miner down, the following items should be completed: 1. The shovel lowered to the ground and empty.

2. The cutter head lowered to the ground.

3. The conveyor lowered.

4. Ensure the stabiliser is up.

5.Stop the pump motor using the off toggle on the transmitter or by using one of the (2) two different points around the miner (if a stop button is used, be sure to reset the stop button when the miner has stopped, that is pull stop buttons out to reset).

6. Turn off or remove the water supply to the miner.

7.Any unusual noises or vibrations are to be reported to the section supervisor and/or to maintenance personnel.

8.Any components or part of the miner that has been damaged or partly dislodged during the shift should be reported to the section's supervisor or maintenance personnel.

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25M3 OPERATOR’S MANUAL SECTION 10

EMERGENCY SHUTDOWN

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TABLE OF CONTENTS EMERGENCY SHUTDOWN ...........................................................................................................................3 Transmitter Stops ...........................................................................................................................................3 Emergency Stop Locations.............................................................................................................................4 EMERGENCY PROCEDURES ........................................................................................................................5 Fire.................................................................................................................................................................5 General ..........................................................................................................................................................5

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EMERGENCY SHUTDOWN In the event of an emergency, the miner can be shutdown in a number of ways.

1. The electrical power is removed from all drive motors, resulting in all moving parts coming to rest and the tram brakes being applied. a) By toggling the STOP key on the radio transmitter. b) By operating either side E/Stops. c) By operating the handle of the main circuit breaker to the OFF position.

2. Following a 2 second time delay for this function to active, the electrical power is removed from all drive motors resulting in all moving parts coming to rest and the tram brakes being applied. a) By toggling the [SHIFT] key on the radio transmitter to the OFF position for (2) two seconds.

NOTE:

This is not an instantaneous shutdown. There is a 2 second time delay.

Transmitter Stops Transmitter Stop

Transmitter can also be switched OFF with this Switch

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Emergency Stop Locations

E/Stop 1

E/Stop 2

E/Stop 4

E/Stop 3

ODS E/Stop

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EMERGENCY PROCEDURES Below are generic emergency procedures. Mine site specific procedures are to be followed for all emergencies.

Fire In the case of fire on or around the miner: 1. Stop all face equipment immediately.

2. Have the power to the face isolated at the D.C.B. 3. If it is safe to do so, retrieve the fire extinguisher from the miner and move to the intake side of the fire zone.

4. If it is not safe, then collect an extinguisher from the nearest location.

5. Attempt to extinguish the fire from the intake side. If unable to extinguish the fire, commence mine fire fighting procedures.

6. If able to extinguish the fire:

Do not attempt to move the miner

Place a “Danger Tag” on the miner and the D.C.B.

Advise the Mining Official and the control room immediately.

NOTE: The miner should be equipped with one (1) dry chemical fire extinguisher with a rating of 80 BE. Always check that it is serviceable as part of the miner’s pre-start checks. Report any deficiencies.

General The Coal Mining Act defines an “emergency situation” as any set of circumstances occurring at a mine which involves the loss of life, or injury to any person, or a real or apparent immediate danger of the loss of life of or injury to any person and which requires a co-ordinated response.

If a person becomes aware of any situation which requires, or may require, prompt first aid and/or emergency assistance, that person should put into effect the emergency procedure at the mine to report the incident.

NOTE: Refer to the mine’s procedures. Do not hang up immediately as you may be required to give further information or receive instructions on dealing with the emergency.

MINIMISE THE USE OF COMMUNICATION SYSTEMS TO LEAVE THE LINES CLEAR FOR EMERGENCY COMMUNICATIONS TRAFFIC.

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25M3 OPERATOR’S MANUAL SECTION 11

TROUBLESHOOTING

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Table of Contents TROUBLESHOOTING .....................................................................................................................................3 Pumps.............................................................................................................................................................3 Traction..........................................................................................................................................................3 Cutters............................................................................................................................................................3 Conveyor ........................................................................................................................................................4 WATER TROUBLESHOOTING GUIDE .........................................................................................................5

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TROUBLESHOOTING Pumps There are a number of safety and machine protection interlocks that will stop the machine pumps or prevent it from starting: Transmitter must be logged on.

Machine Emergency Stop is operated.

Electronic Module fault.

Lost radio signal.

Pump overload (4 min.reset).

Over-temperature (RTD) fault.

Incorrect Transmitter frequency.

NOTE: Turning off power to the miner or control circuits will not reset the 4 minute overload reset timers. If power is removed during an overload reset time period, the reset timer will restart at the time remaining when power was removed.

Traction There are a number of safety and machine protection interlocks that prevent tramming.

Pumps - these have to be running.

Earth leakage detected in traction circuit.

Traction transformer over-temperature (RTD) has tripped.

Either left or right traction motors have overloaded (Reset time is 4 minutes).

A shutdown in SCR traction drives electronics.

Deadman pressure - the brake solenoid has not operated or the pressure switch is closed. This has to be energised to allow tramming.

Traction circuit breakers tripped.

Traction transformer Overload trip. (Reset time is 4 minutes).

If any of these conditions are not satisfied, a corresponding message will be displayed.

NOTE: Turning off power to the miner or control circuits will not reset the 4 minute overload reset timers. If power is removed during an overload reset time period, the reset timer will restart at the time remaining when power was removed.

Cutters There are a number of safety and machine protection interlocks that prevent the cutters from being started, or stop them if they are already operating:

Pumps - these have to be running.

Either left or right cutter motor has overloaded (i.e. the motor current is too high). Reset time is 4 minutes.

Either left or right cutter motor over-temperature (RTD) has tripped.

Water spray for cutter head has failed (low flow) or has been turned off.

Tramming SPEED 2 or SPEED 3 has been selected whilst in reverse.

Low oil level

High oil temperature.

Variation above 50% between current of each cutter motor.

The machine has to be in mining mode not flit mode.

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NOTE:

Turning off power to the miner or control circuits will not reset the 4 minute overload reset timers. If power is removed during an overload reset time period, the reset timer will restart at the time remaining when power was removed.

Conveyor There are a number of safety and machine protection interlocks that prevent the conveyor from being started, or stop it when it has already been started.

Pumps - these have to be running.

Gathering Heads reverse has to be stopped, to start the gathering heads in forward.

Gathering Heads forward has to be stopped, to start the gathering heads in reverse.

Either left or right gathering head motor is overloaded (i.e. the motor current is too high).

Either left or right gathering head motor over-temperature (thermistor) has tripped.

Variation of 50% in motor currents.

The machine has to be in mining mode not flit mode.

NOTE: Turning off power to the miner or control circuits will not reset the 4 minute overload reset timers. If power is removed during an overload reset time period, the reset timer will restart at the time remaining when power was removed.

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WATER TROUBLESHOOTING GUIDE PROBLEM: Lack of water reaching miner - water sprays

WATER ISISWATER FROM REEL CONNECTED TO CONNECTED TO MINER? MINER?

CONNECT HOSE AND OPEN WATER VALVE

NO

YES NO

WATER ISISWATER PRESSURE

NO

PRESSURE AT SUPPLY SOURCE AT HOSE REEL

CORRECT WATER PRESSURE AT MINER? 100 PSI MINIMUM.

MECHANICAL SKILLS REQUIRED

YES

NO

ISISWATERFLOW PASSING WATER FLOW THROUGH BAG PASSINGINLET THROUGH FILTER? LTER.CHECK FLOW AT FIINLET FLOW AT ASHDOWN HOSES? WCHECK

NO

REPLACE FILTER BAG CLEAN FILTER

MECHANICAL SKILLS REQUIRED

WASH DOWN HOSES

YES

IS WATER PASSING THROUGH PILOT OPERATED WATER VALVES?

NO

REFER HYDRAULIC SHEET

YES

ARE MINER WATER SPRAYS OPERATING

November 2008

NO

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MECHANICAL SKILLS REQUIRED

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