Cat DBT CONTINUOUS MINER 25M Series Operation Manual (1)

Operation Manual DBT- CONTINUOUS MINER ® Model - 25M Series Doc. No.:

03-29-05

DBT America ________________________________________________ 2045 WEST PIKE STREET HOUSTON, PA 15342-1010

Internet: www.dbtamerica.com

Table of __________________________________________________________ contents _________________________________________________ preface

This manual is intended to provide basic operating information on DBT 25M Series class continuous miners. Additional information can be obtained by referring to the Parts Book supplied with your machine, or by contacting your local DBT representative. The illustrations, descriptions and procedures contained in this manual pertained to the machine as it was originally manufactured and delivered to your mine, and when the manual was approved for printing. DBT reserves the right to discontinue or revise machine models at any time, or change specifications, designs or procedures, without notice and without incurring obligations.

The machine was manufactured under the guidelines, procedures and requirements of the appropriate government regulatory agencies. At the completion of manufacturing, this machine was issued the appropriate approval numbers and nameplates indicating that it met the technical requirements of the appropriate agencies. Any change to the design or structure of this machine, without the consent of DBT and these agencies, may void these approvals and render the machine illegal or dangerous for use.

Strict compliance with all local and national laws, regulations and practices regarding the safe operation and maintenance of underground mining equipment is necessary to ensure the personal safety of those working on, or around, this machine.

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 DBT America Service Representative immediately.

This work contains information protected under trade secret and other intellectual property laws, and is protected under the U. S. Copyright Act of 1976, as amended. This work is provided under license and the license is non-transferable.

Distribution and access is limited only to authorized personnel.

Disclosure, reproduction, distribution or unauthorized use may be a violation of federal and state laws and may subject the unauthorized user to criminal liability.

________________________________________________ Table of contents

Table of contents ABOUT THIS MANUAL

1.0

right operating manual

1.3

type

1.3

new operating manual

1.3

efficiency

1.4

service

1.4

safety

1.4

YOUR SAFETY

2.0

state of the art

2.3

further operating manuals

2.3

safety precautions for operating the continuous miner

2.4

training

2.4

operating conditions

2.5

storage and transport

2.6

pre-start inspection

2.6

operation

2.6

inspection

2.6

maintenance

2.6

instruction and safety

2.6

operator’s compartment

2.6

canopy

2.6

stopping

2.7

operator’s compartment

2.7

parking

2.7

securing

2.7

replacing components

2.7

original parts

2.7

lifting

2.7

handling hydraulic fluids

2.7

permissible hoses

2.8

STORAGE AND TRANSPORT

3.0

corrosion protection

3.3

no direct exposure to sunlight

3.3

short term storage

3.3

_______________________________________________________________ DBT – 25M SERIES CONTINUOUS MINER ©

VUVR / 03

Table of contents _________________________________________________ long term storage

3.3

plastic deformation

3.3

random sample inspection

3.4

natural aging

3.4

HFA fluids

3.4

before transport

3.5

temperature below freezing

3.5

antifreeze measures for oil cooler

3.5

electrical and electronic components

3.5 4.0

special tools

4.3

general safety rules

4.4

general safety maintenance

4.5

lubricate every shift

4.7

inspect daily

4.7

lubricate weekly

4.7

lubricate daily

4.7

check daily

4.7

replace when necessary

4.8

electric motor maintenance

4.8

every month

4.8

electrical motor maintenance

4.10

every three months

4.10

every six months

4.10

annually

4.10

notes on installation

4.11

installation plan

4.11

superbolt installation and specifications

4.12

tightening procedures

4.12

loosening procedures

4.13

lubricants

4.14

safety features

4.16

panic strip (s)

4.16

canopy

4.16

________________________________________________________________ DBT – DASH SERIES CONTINUOUS MINER ©

© DBT AMERICA 2005

INSTALLATION

Fire suppression

4.16

Guards and covers

4.16

Circuit breaker reset

4.16

OPERATION

5.0

Cutter head assembly

5.3

Boom pivot pin

5.4

Drum drive torque limiting switch

5.5

Drum drive motor—dash-0 & dash-1

5.5

Drum drive motor—dash-2 & dash-3

5.6

Shear cylinder—dash-0, dash-1 & dash-2

5.7

Shear cylinder—dash-3

5.8

Cutter drums—dash-0

5.8

Center cutter drums

5.8

End cutter drums

5.9

Main cutter drums

5.9

Cutter drums installation / removal—dash-1

5.10

Center cutter drum

5.10

End cutter drum

5.11

Main cuter drum

5.11

Cutter drums installation / removal—dash-2

5.12

End cutter drums

5.13

Center cutter drum

5.14

End cutter drum

5.14

Gear case installation / removal—dash-0

5.15

Gear case installation / removal—dash-1

5.16

Gear case installation / removal—dash-2 & 3—see figures 21 & 22

5.17

Figure 21

5.18

Figure 22

5.19

Cutter boom gear case—dash-2 & 3

5.20

Gathering head assembly installation / removal—see figure 14 & 15

5.21

CLA installation / removal—see figure 16

5.22

Gathering head motor installation / removal

5.23

Foot shaft installation / removal

5.23

Gear case installation / removal

5.24

Lift cylinder installation / removal—see figure 23

5.25

Tractor frame assembly—see figure 1

5.26

Tram primary planetary gear installation / removal—see figure 3

5.27

________________________________________________________________ DBT – DASH SERIES CONTINUOUS MINER ©

© DBT AMERICA 2005

________________________________________________ Table of contents

Table of __________________________________________________________ contents _________________________________________________ tram secondary planetary gear installation / removal—see figure-4

5.28

tram case installation / removal

5.29

stabilizing cylinder installation / removal—see figure-7

5.30

tram sprocket assembly installation / removal—see figure-8

5.31

tram track adjustment—see figure-9

5.32

tram track front idler installation / removal—see figure-10

5.34

front idler take-up jack assembly

5.35

hydraulic pump installation / removal—see figure 12

5.35

hydraulic pump motor installation / removal—see figure 13

5.36

conveyor assembly installation / removal—see figure 38 & 39

5.37

swing cylinder installation / removal—see figure-40

5.38

swivel pin installation / removal—see figure-41

5.39

tail roller installation / removal—see figure-42

5.40

tail shim adjustment—see figure-43

5.40

lift cylinder installation / removal—see figure-44

5.41

chain installation / removal—see figure-45

5.42

chain tension adjustment—see figure-46

5.42

scrubber system—see figure-47

5.44

scrubber cleaning—see figure-48

5.45

fan motor assembly—see figure-49

5.45

power schematic—see figures 50, 51, 52, 56, 57 & 58

5.46

motor overloads

5.46

motor control

5.47

motor contactors—see figure-67

5.47

cutter motor feedback

5.47

radio control schematic—see figure-53

5.48

tram dead man—see figure-54

5.48

methane monitor

5.49

low oil level

5.49

e-stop bypass—see figure-55

5.49

battery back-up

5.49

scrubber fan

5.49

cutter motor feedback adjustment—see figure-59

5.50

armature voltage—see figures 60 & 61

5.51

________________________________________________ Table of contents radio remote control—see figures 62, 70 & 71

5.52

receiver, power supply and module traction case—see figure-69

5.52

diagnostic display—see figure-63

5.53

transmitter—see figures 64 & 65

5.53

battery charger

5.53

permissibility

5.53

troubleshooting

5.54

dual systems

5.54

diagnostic display

5.55

component change out

5.55 6.0

tractor frame assemblies—figure-1

6.4

tractor frame-tractor motor—figure-2

6.5

tram preliminary planetary gear—figure-3

6.6

tram secondary planetary gear—figure-4

6.7

tram case—figure-5

6.8

tram case—figure-6

6.9

stabilizing cylinder—figure-7

6.10

tram sprocket—figure-8

6.11

tram track adjustment—figure-9

6.12

tram track front idler—figure-10

6.13

front idler take-up jack—figure-11

6.14

hydraulic pump—figure-12

6.15

hydraulic pump motor—figure-13

6.16

gathering head—figure-14

6.17

gathering head assembly—figure-15

6.18

gathering head CLA installation / removal—figure-16

6.19

gathering head motor installation / removal—figure-17

6.20

gathering head foot shaft installation / removal—figure-18

6.21

foot shaft assembly—figure-19

6.22

gathering head gear case installation / removal—figure-20

6.23

gathering head gear case assembly—figure-21

6.24

gathering head gear case assembly—figure-22

6.25

gathering head lift cylinder installation / removal—figure-23

6.26

cutter head assemblies—figure-24

6.27

cutter head book assemblies—figure-25

6.28

________________________________________________________________ DBT – DASH SERIES CONTINUOUS MINER ©

© DBT AMERICA 2005

TECHNICAL DATA

cutter head—dash 0, 1 & 2 boom pivot pin—figure-26

6.29

cutter head—dash-3 boom pivot pin—figure-27

6.30

cutter head dash 2 & 3 drum drive torque limiting clutch—figure-28

6.31

cutter head dash 2 & 3 drum drive motor—figure-29

6.32

cutter head—dash 0 & 1 drum drive motor—figure-30

6.33

cutter head—dash 0, 1 & 2—figure-32

6.34

cutter head—dash 3 shear cylinder—figure-33

6.35

cutter boom—dash 0 cutter drums—figure-34

6.36

cutter boom—dash 1 cutter drums

6.37

cutter boom—dash 2 cutter drums—figure-36

6.38

cutter doom—dash 3 drums—figure-37

6.39

conveyor—figure-38

6.40

conveyor—figure-39

6.41

swing cylinder—figure-40

6.42

swivel pin—figure-41

6.43

tail roller—figure-42

6.44

tail shim—figure-43

6.45

FOR YOUR INFORMATION

7.0

our service

7.3

service addresses

7.3

________________________________________________________________ DBT – DASH SERIES CONTINUOUS MINER ©

© DBT AMERICA 2005

Table of contents _________________________________________________

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1

About this manual

________________________________________________________________ _______________________________________________________________ 1.0 VUVR / 03___ DBT – 25M SERIES CONTINUOUS MINER ©

______________________________________________________________

_____________________________________________________________

___________________________________________ About this manual About this manual This chapter contains important information, which will simplify work with this manual for you. In addition, it contains information about the structure of the manual and on the characters and symbols used. right operating manual

type

Before starting work If you use an operating manual which has not been written for your conveyor type, you will endanger yourself and others. Ensure that the data on the Continuous Miner corresponds to those in this operating manual.

This operating manual belongs to: DBT America—Dash Series Continuous Miner Serial No.: 02-14-05 The operating manual is to be used only for the Dash Series Continuous Miners.

© DBT AMERICA 2005

new operating manual

An operating manual for the conveyor must always be available at the place of operation.

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

Who is this operating manual intended for?

This operating manual is intended for all persons working with or on the Continuous Miner .

All persons working at the face, at the edge of the face or in the entry must have read this operating manual.

This includes persons: ¾ responsible for transport, ¾ developing the raise, ¾ carrying out erection / disassembly, ¾ operating the conveyor, ¾ eliminating faults, ¾ carrying out daily routine work at the face or in the entry, ¾ carrying out maintenance operations, ¾ carrying out repairs. supervisory persons: ¾ instructing and/or ¾ supervising the above activities.

_____________________________________________________________ DBT – 25M SERIES CONTINUOUS MINER © VUVR / 03 1.3

About this manual _____________________________________________ What is the purpose of this operating manual? efficiency

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

Read this operating manual completely and carefully. In particular, pay attention to the safety instructions.

Note the appearance and meaning of the safety and warning symbols.

service safety

If any points are not clear, please contact our Service Department.

You will find our Service address in chapter 7 ”For your information”.

Pay particular attention to the chapter ”Your Safety”. It contains important information drawing your attention to possible sources of danger.

Observe the information and follow the instructions contained in this operating manual.

Characters and symbols used

DANGER

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

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

WARNING

C CAUTION

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

NOTICE

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

IMPORTANT

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

¾ Points in sub-lists are marked with a square at the start of the

line describe individual work steps. Follow these instructions step-by-step.

________________________________________________________________ 1.4 VUVR / 03____________ DBT – 25M SERIES CONTINUOUS MINER ©

© DBT AMERICA 2005

The following characters and symbols are used for safety instructions and important information in the operating manual.

Pay particular attention to these points.

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2

Your safety

________________________________________________________________ _______________________________________________________________ 2.0 VUVR / 03___ DBT – 25M SERIES CONTINUOUS MINER ©

______________________________________________________________

_____________________________________________________________

________________________________________________ Your safety

Your safety This chapter provides vital information for your safety.

Pay special attention to this chapter. The safety instructions and rules of procedure will help you to avoid hazardous situations and to perform the necessary work as safely as possible. state of the art

The machine has been manufactured in accordance with the state of the art and generally recognized safety standards and regulations.

You and others can nevertheless be exposed to dangerous situations e.g. as a result of environmental influences, machine damage or operator errors.

Do not make any alterations or modifications which could impair the safety of the machine. All modifications and changes must be approved by DBT America.

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

© DBT AMERICA 2005

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

Observe the safety and accident prevention regulations:

further operating manuals

■

of the mine.

■

of the Mines Inspector and

■

of the mining supervisory authorities

Please read also the operating manuals of the components required for operation, e.g. of Continuous Miner, electric motors, etc., carefully and thoroughly. Clarify any questions before starting work.

_____________________________________________________________ DBT – 25M SERIES CONTINUOUS MINER © VUVR / 03 2.3

Your safety _________________________________________________ Safety precautions for operating the continuous miner training

The miner should not be operated until the operator has read and understood the operating instructions for the machine and is thoroughly familiar with the location, operation, and function of all controls.

Miner should not be operated without all covers and guards properly mounted and secured.

Ensure everyone is clear before starting or moving any part of the miner.

Carefully test all machine functions before operating the miner.

Always wear safety glasses. Not only for your protection but for the protection of fellow workers. Should dust, etc. temporarily blind the operator the machine may become a hazard to both the workers and other equipment.

Disconnect main breaker to do any maintenance work. Observe all Federal, State, and Mine safety regulations. · Report any malfunctions or damage to supervisory personnel.

Ensure cutter boom and tail conveyor boom are lowered before leaving machine unattended. · Ensure adequate ventilation prior to machine operation.

Obey all safety regulations set forth by MSHA, State, Local, and Mine Management.

Do not leave machine running unattended. ·Shut off main electrical power, unplug and lock out electrical cables/receptacles prior to performing any type of electrical repairs. · Never work or travel underneath a raised cutter boom, conveyor boom, stabilizer shoe, or gathering pan unless they are properly supported.

________________________________________________________________ 2.4 VUVR / 03___ DBT – 25M SERIES CONTINUOUS MINER ©

© DBT AMERICA 2005

Check work area for loose roof scale, remove as necessary.

________________________________________________ Your safety operating conditions

Intended use The feeder breaker has been designed and manufactured purely for transporting and crushing mined material from a continuous miner to the main conveying system for transporting outside.

Intended uses include: ¾ the transport and crushing of mined material between continuous miner and main conveying system

Unauthorized use Applications not expressly listed as intended uses are unauthorized uses and are not allowed to be performed with the machine. ¾ the transport of persons

© DBT AMERICA 2005

DBT America accepts no liability for any damage resulting from any such unauthorized use.

_____________________________________________________________ DBT – 25M SERIES CONTINUOUS MINER © VUVR / 03 2.5

Your safety _________________________________________________ storage and transport Maintain the prescribed storage periods and observe the instructions for storage.

Do not store materials or parts in the travel way or in your working area.

Inform the persons involved about the intended transport route and the anticipated duration of the transport.

Ensure that the transport safety devices are correctly fitted.

Fix all moving parts with transport locks.

Never stand under unsupported parts or suspended loads.

Connect the lifting equipment only to the points of attachment provided for that purpose. Observe the different load limits of the attachment points. Also observe the instructions on the transport sheet.

For round components use transport straps, only. Never use chains or steel cables for this purpose.

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

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

Pre-start inspection operation

Read this entire guide before attempting to operate this machine.

inspection

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

maintenance instruction and safety operator’s compartment canopy

Verify that all maintenance has been performed.

Verify that all instruction and safety tags are in place and readable.

These are as important as any other equipment on the machine.

Clean any foreign material from the operator’s compartment.

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

________________________________________________________________ 2.6 VUVR / 03___ DBT – 25M SERIES CONTINUOUS MINER ©

© DBT AMERICA 2005

Only use means of attachment which are in good condition and have been designed for the loads to be handled.

________________________________________________ Your safety Stopping operator’s compartment

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

parking

Always park the unit on solid, level ground. If this is not possible, park the unit at a right angle to the slope to prevent accidental movement of the machine.

Use proper flags, warnings or barriers when parking in areas of traffic.

Chock all four (4) wheels in both directions whenever possible.

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

Inform the supervisory personnel and the face crew of any maintenance and repair operations. Give them information on the intended operations and the anticipated duration.

© DBT AMERICA 2005

securing

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

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

Protect your work area against falling rocks.

replacing components

Disconnect the battery from machine to prevent from restarting before replacing any defective components.

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

original parts

lifting

Use only spare parts which satisfy the specified technical requirements.

This is only ensured with original DBT America spare parts.

Please refer to the spare parts lists for the order numbers.

For raising the feeder breaker use only: ¾ crib blocks with adequate load-holding capacity. ¾ hoists, jacks or cranes with adequate load-carrying capacity.

Avoid direct contact between the skin and hydraulic fluids.

handling hydraulic fluids Hydraulic fluid can penetrate the skin and cause serious infection.

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

_____________________________________________________________ DBT – 25M SERIES CONTINUOUS MINER © VUVR / 03 2.7

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

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

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

permissible hoses

Use only hydraulic hoses approved for the prevailing pressures.

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

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

© DBT AMERICA 2005

Observe the date of manufacture stamped on the hydraulic hoses.

Never use hydraulic hoses which are more than 2 years old, even if they have no visible signs of damage.

1. manufacturer 2. hose type 3. date of manufacture 1st quarter 2000

4. nominal diameter 5. flame-resistant and antistatic

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

Never try to repair damaged hydraulic hoses.

Replace hydraulic hoses at the first suspicion of damage.

________________________________________________________________ 2.8 VUVR / 03___ DBT – 25M SERIES CONTINUOUS MINER ©

________________________________________________ Your safety ■

always have a little slack.

Fig. 5: Laying hydraulic hoses, crossing Right

■ ■ ■ ■

Wrong

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

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

© DBT AMERICA 2005

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

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

Fig. 6: Laying hydraulic hoses, connections on moving parts Right

Wrong

_____________________________________________________________ DBT – 25M SERIES CONTINUOUS MINER © VUVR / 03 2.9

Your safety _________________________________________________ Fig. 4: Laying hydraulic hoses, bending RIGHT

Ø

WRONG

Cannot chafe.

Fig. 5: Laying hydraulic hoses, crossing

Ø Ø Ø Ø

WRONG

Are not kinked.

Do not have to withstand tensile strains.

Are protected against thermal radiation.

Are accessible at all times.

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

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

Torn out, Kinked, Crushed, Driven over or Twisted (Fig.: 6) by the movement of the conveyor

________________________________________________________________ 2.10 VUVR / 03___ DBT – 25M SERIES CONTINUOUS MINER ©

© DBT AMERICA 2005

RIGHT

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3

Storage and transport

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________________________________________ Storage and transport

Storage and transport This chapter contains important information on the correct storage and transport of the Dash series Continuous Miner ®.

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

Storage corrosion protection

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

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

© DBT AMERICA 2005

Storage of the machine and spare parts no direct exposure to sunlight Store the equipment indoors or cover with a tarpaulin to protect against direct exposure to sunlight. Store the electrical equipment, electronic components, spare parts of rubber or plastic – such as seals and hoses – and hydraulic fluids only in closed rooms at temperatures of 60° F (15° C) to 77° F (25°C).

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

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

short-term storage

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

long-term storage

If the equipment is to be stored more than six months, the hydraulic components must be completely filled with a corrosion inhibiting/frostproofing fluid such e.g. CV 50.

Fill the hollow areas of hydraulic components (e.g. the piston chambers) in horizontal position (ports facing upwards) until they start to overflow.

Then seal the ports with plastic or steel plugs.

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

_____________________________________________________________ DBT – 25M SERIES CONTINUOUS MINER © VUVR / 03 3.3

Storage and transport plastic deformation

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

random sample inspection

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

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

natural aging

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

HFA fluids

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

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

IMPORTANT

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

Dimensions

■

Weight

■

lifting points, etc.

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

WARNING

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

________________________________________________________________ 3.4 VUVR / 03___ DBT – 25M SERIES CONTINUOUS MINER ©

© DBT AMERICA 2005

Transport

________________________________________ Storage and transport Transport Load Units; Dimensions and Weights Observe the transport sheets for the various transport units. They contain information on: Ø Ø Ø Ø

Dimensions Weight Lifting points Center of gravity, etc.

Where technically possible, the load units have suitable lifting points for transport and erection.

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

© DBT AMERICA 2005

Before Transport temperatures below freezing Transport of equipment at temperatures between –21° C and -40°C is only permissible when certain measures were taken, to meet these conditions, at the design and manufacturing stages. Nevertheless, the individual parts and devices of this equipment must not be subjected to sudden impact loads at low temperatures.

During transport of this equipment, measures must be taken to ensure that the parts and devices are not subjected to sudden impact loads. At very low temperatures and on poor roads, the transport vehicle speed must therefore be limited to maximum of 25 kph for truck transport. antifreeze measures for oil cooler Before transporting, the oil cooler must be flushed with anti-freeze. electrical and electronic components

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

If the electrical cables remain in the equipment, they must be carefully protected against transport damage and soiling of the connections.

_____________________________________________________________ DBT – 25M SERIES CONTINUOUS MINER © VUVR / 03 3.5

© DBT AMERICA 2005

Storage and transport

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4

Installation

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_________________________________________________ Installation

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

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

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

And

© DBT AMERICA 2005

the hydraulic equipment (cylinders, directional control valves, hoses etc.) should only be carried out by DBT America service engineers or by specially trained personnel.

Which tools are required for installation? special tools

No special tools are required to put the Continuous Miner ® into service.

The receptacles come with a special wrench for connecting and disconnecting receptacles.

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

These include i.e.:

¢ Blocking ¢ Hammer ¢ Screwdriver ¢ Retaining ring pliers ¢ Pliers ¢ Wire cutters ¢ Pry bar ¢ Chisel ¢ Punch ¢ Rose gun ¢ Welding equipment ¢ Chain falls

_____________________________________________________________ DBT – 25M SERIES CONTINUOUS MINER © VUVR / 03 4.3

Installation ___________________________________________________ ¢ Slide hammer (provided by DBT America) with the following

general safety rules

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

A scheduled preventative, maintenance, lubrication, and inspection system should be followed.

Only qualified and authorized personnel should be permitted to maintain, repair, adjust and inspect the miner.

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© DBT AMERICA 2005

adapters:

¢ 1”-8 ¢ 5/8”-11 ¢ 3/8”-16 ¢ An adjustable wrench ¢ 7/16” wrench ¢ 3/4” wrench ¢ 1 1/8” wrench ¢ 1 1/2” wrench ¢ 7/16” socket wrench ¢ 9/16” socket wrench ¢ 3/4” socket wrench ¢ 15/16” socket wrench ¢ 1 1/8” socket wrench ¢ 1 1/2” socket wrench ¢ 1 7/8” socket wrench ¢ 15/16” torque wrench ¢ 1 1/2” torque wrench with 20-to-1 multiplier ¢ 1 7/8” torque wrench with 20-to-1 multiplier ¢ 7/8” torque wrench with 20-to-1 multiplier ¢ 3/8” Allen wrench ¢ 5/16” Allen wrench ¢ 5/8” Allen wrench ¢ 3/4” Allen wrench ¢ 7/8” Allen wrench ¢ 3/8” hex torque wrench

_________________________________________________ Installation Before beginning any maintenance on the miner, perform the following procedures: 1. Visually disconnect the miner from the power source.

2. Block any and all elevated assemblies before working under them.

Make sure that the blocking can support the weight of the assembly without slipping or failing.

3. Relieve all hydraulic pressures.

4. Position all levers and controls in NEUTRAL or OFF. 5. Work on the miner only in an area where the roof is properly supported.

6. Test the air for methane before beginning any maintenance work.

Perform all procedures in accordance with accepted practices and applicable regulations.

general maintenance safety The following general safety precautions should be observed:

¢ Any operation to check performance of the miner must be conducted in an area with sufficient safe clearance.

¢ Methane monitoring of the air must occur before and during all maintenance © DBT AMERICA 2005

¢ Avoid fire hazards and have fire protection equipment present whether working above or below ground.

¢ Do not use open pans of fuel or flammable cleaning fluid for cleaning parts.

¢ Control mechanisms, lights, overload devices, guards, and ¢ ¢ ¢

safety devices must be inspected regularly and maintained in safe operating condition.

All parts of component assemblies and frame members must be carefully and regularly inspected and maintained in safe operating condition.

The original approved safe operating features of the miner must be maintained.

Operation, warning, and maintenance instruction plates, tags or decals must be maintained in a legible condition.

_____________________________________________________________ DBT – 25M SERIES CONTINUOUS MINER © VUVR / 03 4.5

Installation ___________________________________________________

¢

¢

¢ ¢ ¢

¢ ¢ ¢ ¢ ¢ ¢ ¢

be performed without prior written approval from DBT America. Warning, operations, and maintenance instruction plates, tags, or decals must be changed accordingly.

The hydraulic system should be regularly inspected and maintained in conformance with accepted practices. Cylinders, valves, and other similar parts should be checked to ensure that “drift” has not developed to the extent that it could create a hazard.

Motors, controllers, switches, protective devices, electrical conductors, and connections should be inspected and maintained in conformance with accepted practices and applicable regulations. Special attention should be paid to the condition of electrical insulation.

The miner should be kept as clean as possible to minimize fire hazards and to help in the detection of loose or defective parts.

Care should be taken to ensure that all replacement parts are interchangeable with the original parts and are of quality equal to that provided in the original equipment.

When performing maintenance, do not wear rings, watches, loose shirt sleeves, worn or tattered gloves, loose jackets, neck ties, or other apparel that could become entangled in the miner.

Always wear the proper, approved safety clothing.

Maintenance personnel must know how to properly operate the miner in order to perform test and inspection procedures.

The miner must be maintained in “Permissible” condition, where applicable.

When working on or operating a miner from the Operator’s Platform area, do not reach out of the cab with your foot.

Never touch a rotating or moving assembly or component.

Be careful to avoid pinch points while operating or maintaining the miner.

Be careful when working around high-pressure hydraulics. The high-pressure jet of fluid from a pinhole leak in a hydraulic hose can penetrate through skin and into the tissue below, causing serious problems such as blood poisoning.

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© DBT AMERICA 2005

¢ Modifications and additions that affect safe operation must not

_________________________________________________ Installation lubricate every shift

inspect daily

¢ Cutter head shear cylinder ¢ Cutter head shear cylinder pin (left and right) ¢ Cutter head shear cylinder to frame pin (left and right) ¢ Cutter head pivot pin (left and right) ¢ Conveyor roller ¢ Trailing cable for breaks or cracks in the cable cover ¢ Lighting systems for damage ¢ Conveyor flights for excessive wear or damage, and replace as necessary

¢ Cutter head mining bits for wear or damage, and replace as necessary

¢ Scrubber spray nozzles for blockage ¢ Check the lubrication levels of all the following components and fill as necessary:

¢ Gear cases (drum drive, gathering head, tram primary planetary, tram secondary planetary, tram idler)

© DBT AMERICA 2005

¢ Tram drive (left and right) ¢ Drum drive (front and back, left and right) ¢ Front roller (left and right, tram idler) ¢ Lubricant levels of the oil reservoir ¢ Hydraulic fluid levels lubricate weekly

lubricate daily

¢ Gathering head lift cylinder ¢ Gathering head hinge pin ¢ Gathering head foot shaft ¢ Conveyor chain take-up pin ¢ Conveyor chain take-up locknut ¢ Conveyor swivel pin (upper and lower) ¢ Conveyor swing cylinder jack pins (front and rear) ¢ Conveyor-to-tractor frame pin ¢ Tractor frame stabilizer shoe pins (left and right) ¢ Clean and remove accumulated sludge: ¢ Scrubber filter screens ¢ Scubber inlet duct work ¢ Mist eliminator and sump ¢ All seals for leakage ¢ Gear case breathers (primary, gathering head) for airflow ¢ ¢ ¢ ¢ ¢

obstructions Entire front end for damage, and tighten all hardware Tram track for missing parts, wear, or damage All sprockets and idlers for wear or damage Hydraulic lines for wear and damage Drive sprocket shear pin bushings for wear/ damage

_____________________________________________________________ DBT – 25M SERIES CONTINUOUS MINER © VUVR / 03 4.7

Installation ___________________________________________________ ¢ Electrical system for damage, malfunctioning components, and loose or corroded connections

¢ The methane monitor is maintained according to manufacturers and regulatory specifications.

¢ Trailing cable connection at the power center of r permissibility according to Federal Regulations ( Part 75, Title 30 ).

¢ All lubrication fittings and plugs for proper installation as well as damage

check daily

¢ All bolts and capscrews, and tighten as necessary ¢ All chain tensions, and adjust as necessary ¢ Drum drive clutch, and adjust as necessary ¢ Tram track tension, and adjust track take-up cylinder as needed ¢ Required hydraulic pressures, and make corrections to the hydraulic system by readjusting the appropriate relief valves

¢ Gathering head hinge pins for excessive movement, and adjust as necessary

¢ Conveyor tension springs for proper expansion and contraction during conveyor operation, and adjust as necessary.

electric motor maintenance

¢ Return filter element ¢ Pilot circuit primary oil filter ¢ Clean all debris from motor frames ¢ Clean all heat exchangers ¢ Inspect motor bearings for lubricant leakage ¢ Check temperatures of bearings and frames ¢ Start motor and confirm that it accelerates to operating speed in an appropriate time

¢ Listen to the running motor for any unusual noises every month

Drain and Fill lubricant in all gear cases (drum drive, gathering head, tram primary planetary, tram secondary planetary). Take oil sample prior to draining. Send Sample to DBT America for analysis. To gather the oil Sample for analysis please follow the following steps outlined on the following page.

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© DBT AMERICA 2005

replace when necessary

_________________________________________________ Installation This process applies to the CLA Gear case and Pot Lube Check.

Presently, the lube checks require the removal of the check plugs, which are beside the fill port, and observation of the gear’s lube flow from the check port. It has been found that this does not insure the true gear lube level. To assure the proper gear lube level apply the following procedure.

1. Remove all plugs.

2. Using a rose gun or lube bucket force gear lube in the fill port until lube flows from the check port.

The diagram below gives a description of the location of the ports for both the upper and lower ports.

© DBT AMERICA 2005

Inspect CLA’s for excessive wear and damage, and replace as necessary.

¢ Cutter gear case mounting is secure, and tighten as necessary ¢ CLAs for looseness, and tighten as necessary Lubricate scrubber fan motor.

_____________________________________________________________ DBT – 25M SERIES CONTINUOUS MINER © VUVR / 03 4.9

Installation ___________________________________________________ electrical motor maintenance

¢ Clean motors thoroughly. ¢ Inspect couplings, belts, belt guards, mounting frame bolts, ¢ ¢ ¢ ¢

every three months every six months

end-shield bolts, and mechanical fastenings for mechanical soundness and tightness Check end play of rotor shaft Operate motors at normal load and temperature Measure and record motor insulation resistance and temperature The DC tram motors require regular preventive maintenance.

Inspect the commutator, cable rigging, and brushes. The commutator should be dark brown with no signs of burning.

Check for brush wear and spring tension. replace all of the brushes when replacement is necessary.

Replace oil reservoir breather.

Lubricate the right and left cutterhead motor bearings (front and rear).

¢ Clean motor thoroughly. ¢ Lubricate ball bearings, if required. Record the date the motor was lubricated. as needed.

¢ Check operating speed. ¢ Inspect and tighten all electrical connections ¢ Inspect fans for loose or damaged blades ¢ Run motor and examine drive for smooth operation and lack of excessive Vibration.

¢ Check current readings and compare with normal value on motor nameplate and previously recorded values

¢ Check motor mounts, end-shields, couplings, and shaft keys for looseness.

¢ Inspect all covers, belt guards, and other guards for damage, and tighten until securely fastened.

annually

Drain, flush, and refill the entire hydraulic system.

¢ Inspect all windings and insulation ¢ Clean and repair insulation as needed ¢ Measure resistance and record ¢ Check for and remove any magnetic particles

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© DBT AMERICA 2005

¢ Inspect all gaskets, particularly lubricant seals, and replace

_________________________________________________ Installation Notes on installation C CAUTION

installation plan

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

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

© DBT AMERICA 2005

IMPORTANT

Serious damage can be caused to the continuous miner ® as a result of incorrect installation. The unit should therefore only be installed under the instruction of specialists from DBT America.

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Installation ___________________________________________________ superbolt installation and specifications tightening procedures

¢ Thread Diameter ¢ Jackbolt Diameter ¢ Jackbolt Socket Size ¢ Required Jackbolt Torque

1 1/4” 5/16” 1/4” 35 (in./lb.)

Read all these instructions completely before you begin.

This procedure is typical for the majority of SUPERBOLT products.

Specific installation procedures that are shipped with all products may supersede this general procedure. Use the appropriate instructions shipped with the product you are installing. Contact SUPERBOLT, Inc. at (412) 279-1149 with any questions.

1. SUPERBOLT products are designed for use with hardened surface washers.

Slide the washer onto the bolt or stud first.

2. VIEW A - Check the base of the tensioner(s) and verify that all jackbolts are flush with the bottom of the tennsioner body.

3. VIEW A - Clear any dirt or chips from the threads of the bolt or stud and from the main internal thread of the tensioner 4. VIEW A - Spin the tensioner body down on the main thread of the bolt or stud by hand. The tensioner body should be in light contact with the hardened washer.

5. Determine the target jackbolt torque value for the desired preload, either from the installation sheets shipped with the product or the catalog tables, or by calling SUPERBOLT, Inc. The jackbolt torque value stamped on the tensioner is a standard value for that part, and may not be appropriate for your specific application. Since jackbolt torque is directly proportional to the tension load, you can easily figure other values as required (e.g., 1/2 preload = 1/2 jackbolt torque).

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© DBT AMERICA 2005

IMPORTANT

Air or electric power wrenches of the appropriate size may be used for running up jackbolts. Attempt to tighten as consistently as possible and remove the power wrench frequently; do not tighten all at once. Use a standard torque wrench to verify final torque values.

_________________________________________________ Installation 6. Start by snugging the jackbolts to 10% of the target jackbolt torque value from step 5. This seats the thread and eliminates clearances. The star pattern shown in VIEW B should be used for this initial tightening sequence.

7. VIEW B - Tighten the jackbolts in the star pattern to 50% of the target jackbolt torque value.

8. VIEW C - Change to a circular pattern and torque the jackbolts to 75% of the target jackbolt value.

9. VIEW C - Continue one more pass in the above circular pattern with 10% more torque than that of the target jackbolt torque value.

10. VIEW C - Long bolts will stretch, so by the time you get back to the first jackbolt, it will be loose again.

11. VIEW C - Set the torque wrench for the final torque value and continue to repeat the circular pattern until all jackbolts are torqued to the same value. do not exceed the torque value stamped on the tensioner without specific approval from SUPERBOLT, Inc.

© DBT AMERICA 2005

loosening procedures

Jackbolts should be loosened with care. For longer bolts and studs, this procedure is even more important. Loosening can be accomplished quickly, but do not rush to completely loosen individual jackbolts. Remember that the intent is to slowly release the preload force. All jackbolts should be loosened uniformly, and usually there is no need to remove any jackbolt from the tensioner body during loosening.

1. Turn the first jackbolt counter-clockwise until it feels loose (no more than one half turn). The idea is just to unload each jackbolt, not to completely loosen it.

2. Move in a circular pattern to the next jackbolt and repeat step 1.

3. Continue repeating until all jackbolts have been unloaded.

4. By the time you get back to the first jackbolt, it will be tight again. Repeat the process moving in a circular pattern.

5. Usually after two or three passes, the tensioner can be spun off the bolt or stud by hand. Long bolts or studs that stretch more may require extra passes.

_____________________________________________________________ DBT – 25M SERIES CONTINUOUS MINER © VUVR / 03 4.13

Installation ___________________________________________________ 6. Before reusing any tensioner, the jackbolts should be removed in the appropriate manner. The body and jackbolts should be cleaned and re-lubricated with SUPERBOLT approved lubricant to ensure proper jackbolt torque vs. preload performance upon reinstallation.

lubricants

The torque-preload relationship of SUPERBOLT tensioners depends on the tension body and jackbolt materials, heat treatment, plating, lubricants and many other factors. SUPERBOLT engineers have performed extensive tests to determine the best lubricants for the various materials utilized by SUPERBOLT, Inc. Two custom lubricants, JL-G and JL-M, are offered by SUPERBOLT, Inc.

prime mineral oil. It has a relatively uniform friction factor of 0.130 under widely varying conditions. JL-G is used in the assembly of most SUPERBOLT products. ¢ A number of commercially available graphite - or nickel - based lubricant compounds such as Fel-Pro C102 or Fel-Pro N5000 can be used for re-lubrication in the field. Copper bearing compounds have not performed well as jackbolt lubricants.

JL-M is a lubricant paste made from molybdenum-disulifide powder and pure mineral oil. It has a friction factor of 0.045 to 0.070. Tests have shown that when jackbolts are tightened the first time, the friction of JL-M is approximately 0.070. Each subsequent tightening reduces the friction factor lower until at the fourth tightening it levels out at approximately 0.050. SUPERBOLT, Inc. uses an average friction factor of 0.055 for torque calculations. It must be emphasized that the tensioners must be tightened several times to stabilize at the low values. After many repeat tightenings, the friction factor can be as low as 0.045. Due to these variations in friction factor, molybased lubricants are used instead of graphite-based lubricants only in the following cases.

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© DBT AMERICA 2005

¢ JL-G is a lubricant paste made from selected flaky graphite and

_________________________________________________ Installation 1. On very large jackbolts when the torque required for a specific preload would be too high; or, 2. Where space restrictions prohibit the use of sufficiently large torque wrenches.

In some cases, SUPERBOLT tensioners are “broken in” at the factory to lower the friction factor for field installation.

© DBT AMERICA 2005

Fel-Pro C-870 molybdenum-disulfide paste has performed similarly to JL-M. Other molybdenum pastes and greases tested had much high friction factors. Testing for friction factor is recommended for all critical installations where lubricant and/or bolt and nut materials are unknown.

_____________________________________________________________ DBT – 25M SERIES CONTINUOUS MINER © VUVR / 03 4.15

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

NOTICE

panic strip (s)

The machine is equipped with panic strips. The panic strip(s) are used to break the control circuit only in emergency situations, stopping all motors. Striking with a small amount of force will actuate either panic strip.

canopy

The machine was shipped from the factory with a protective canopy.

Ensure that the canopy is in place and secure at all times to protect the operator from fall debris.

fire suppression

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

WARNING

guards and covers

DANGER

circuit breaker reset

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

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

Do not operate the machine any of the guards or covers removed.

You or other personnel could be seriously injured from moving or rotating parts.

The machine is equipped with a circuit breaker reset. The circuit breaker reset may be used to shutdown the machine in emergency situations.

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© DBT AMERICA 2005

Safety features include:

_______________________________________________________________

5

Operation

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______________________________________________________________

______________________________________________________________

__________________________________________________ Operation

Operation This chapter contains important information on the operation of various components of the miner. It also includes instructions on the replacement of wear parts.

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

cutter head assembly

C

© DBT AMERICA 2005

CAUTION

C

The cutter head assembly for each Dash Series miner model is unique.

Therefore the procedures in this section are identified by miner model Dash Zero, Dash One, Dash Two, and Dash Three.

Lower the gathering head and the cutter head to the floor. Position the conveyor tail section level with the floor. Remove and lock-out the electrical power ti the miner.

1. Disconnect the power cables and water hoses from the cutter motors - follow the procedure in CUTTER MOTOR. Be sure to tape up the power cables since electrical power will be connected to the miner.

2. Disconnect the water hoses to the dust suppression sprays.

3. VIEW A -Remove both boom pivot pins - follow that procedure.

4. Disconnect electrical power to the miner.

5. Extend the shear cylinders to push the boom pivots out of their tractor frame clevises.

6. Block the shear cylinders to keep them stationary during their pin removal.

Provide support and lift to the cutter boom assembly.

CAUTION

Never work under any raised assembly without proper blocking.

DANGER

7. Remove the shear cylinder boom clevis pins - follow the procedure in SHEAR CYLINDER. 8. Connect electrical power to the miner.

9. Retract the shear cylinders to pull their bearings free from the boom clevises. Disconnect electrical power.

10. VIEW B -Raise the rear of the boom assembly until it is above the top edge of the gathering head backboard. Reconnect electrical power.

11. Slowly tram the miner backwards until the cutter boom pivot points clear the front of the gathering head.

12. To install the boom assembly - reverse the above procedure.

______________________________________________________________ DBT – 25M SERIES CONTINUOUS MINER © VUVR / 03 5.3

Operation ____________________________________________________ boom pivot pin

C CAUTION

Dash Zero, Dash One, Dash Two Removal / Installation.

Lower the gathering head and the cutter head to the floor, position the conveyor tail section with the floor. Remove and lock-out the electrical power to the miner.

1. VIEW A -Remove the capscrew and lock washer that secures the front rub rail to the tractor frame and open the front rub rail.

2. VIEW B -Remove the front idler take-up jack bracket -follow the FRONT IDLER TAKE-UP JACK procedure in SECTION 5, TRACTOR FRAME. 3. VIEW C -Remove the pivot pin retaining plate and its support block.

4. Connect electrical power to the miner.

5. VIEW C -Insert the slide hammer’s 1”-8 NC adapter into the end of the pivot pin.

C

When the pivot pin pull point is found, block the cutter boom to prevent it from dropping or moving when the pivot pin is removed.

CAUTION

6. VIEW D -Attach the slide hammer to its adapter and pull the boom pivot pin.

7. To install a boom pivot pin - reverse the above procedure.

C CAUTION

Lower the gathering head and the cutter head to the floor.

Position the conveyor tail section level with the floor. Remove and lock-out the electrical power to the miner.

1. VIEW A -Remove covers or scrubber duct work to access the boom pivot.

2. VIEW B -Remove the pivot pin grease line and retaining plate.

3. VIEW B -Insert the slide hammer’s 1”-8 adapter into the end of the pivot pin.

4. Connect electrical power to the miner.

NOTICE

C

Pressure from the cutter boom onto the pivot pin can make its removal very difficult. The shear cylinders can be used to find the boom position that puts the least pressure on the pin.

When the pivot pin pull point is found, block the cutter boom to prevent it from dropping or moving when the pivot pin is removed.

CAUTION

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© DBT AMERICA 2005

NOTICE

Pressure from the cutter boom onto the pivot pin can make its removal very difficult. The shear cylinders can be used to find the boom position that puts the least pressure on the pin.

__________________________________________________ Operation

drum drive torque limiting switch

C CAUTION

5. VIEW B -Attach the slide hammer to its adapter and pull the boom pivot pin.

6. To install a boom pivot pin - reverse the above procedure.

Position the conveyor tail level with the floor. Lower the gathering head to the floor. Raise and block the cutter head assembly. Remove and lock-out the electrical power to the miner.

Never work under any raised assembly without proper blocking.

DANGER

© DBT AMERICA 2005

Remove necessary covers to access the clutch at the rear of the cutter motor.

1. VIEW A -Remove the eight capscrews and lockwashers that secures the clutch cover to the motor frame.

2. VIEW A -Remove the clutch cover to expose the clutch assembly.

3. VIEW A -Remove the retaining ring that secures the motor shaft inside the clutch assembly.

4. VIEW A -Pull the motor shaft from the motor and clutch assembly.

Store the motor shaft in a clean place.

5. VIEW B -Remove the sixteen locknuts on the out side of the pressure plate.

6. VIEW B -Remove the pressure plate and the out put hub assembly ( with seal and bearing ) from the clutch.

7. VIEW C -Remove the retaining ring found on the exterior of the keeper plate.

8. VIEW C -Remove the three capscrews and serrated washers that secures the keeper plate to the input hub.

9. VIEW C -Remove the keeper plate and disc spring to reveal the motor shaft secured by a retaining ring.

C

The remaining clutch assembly is very heavy. Verify the weight can be supported..

CAUTION

10. VIEW D -Remove the retaining ring from the motor shaft.

The input assembly of the clutch is unattached and can be slipped off the motor shaft.

11. VIEW D -Remove the final retaining ring from the motor shaft.

12. To install the Drum Drive Torque Limiting Clutch - reverse the above procedure.

C drum drive motor dash-0 & dash-1 CAUTION

Position the conveyor tail level with the floor. Lower the gathering head to the floor. Raise and block the cutter head assembly. Remove and lock-out the electrical power to the miner.

Never work under any raised assembly without proper blocking.

DANGER

______________________________________________________________ DBT – 25M SERIES CONTINUOUS MINER © VUVR / 03 5.5

Operation ____________________________________________________ 1. VIEW A -Remove brackets and covers to access the drum drive motor.

2. VIEW B -Remove the capscrews and lock washers that secure the cover for the drive shear shaft. Remove the cover and o-ring.

3. VIEW B -Remove the retaining ring, the plug and the o-ring. Pull the drive shaft out of engagement with the gear case. Replace the shaft cover. Keep the shear shaft in a clean place.

4. VIEW C -Remove the capscrews on the motor junction box cover and remove the cover and o-ring.

5. VIEW D -Mark the motor and power cable leads and disconnect the leads.

6. VIEW E -Remove the stuffing box clamp and slide the power cables out of the motor junction box.

7. Disconnect the cooling water hoses from the motor. Plug the motor and hose ends to keep them clean.

The drum drive motor is very heavy. Verify its weight can be supported.

8. VIEW A -Remove the four bolts which mount the drum drive motor to the gear case.

9. VIEW A -Slide the motor out of the gear case.

10. To install a drum drive motor - reverse the above procedure. Be sure to isolate and jog the new motor to check for correct rotation.

Note: Reuse top and bottom water manifolds.

drum drive motor dash-2 & dash-3

1. VIEW A -Remove brackets and covers to access the drum drive motor.

2. Remove the torque limiting clutch assembly - follow that procedure.

3. VIEW B -Remove the four capscrews and lock washers on the motor junction box cover and remove the cover and o-ring.

4. VIEW C -Mark the motor and power cable leads and disconnect the leads.

5. VIEW C -Remove the stuffing box clamp and slide the power cables out of the motor junction box. Replace the junction box cover and o-ring.

6. Disconnect the cooling water hoses from the motor.

Plug the motor and hose ends to keep them clean. -

C

7. VIEW D -Remove the caps from the Superbolts and remove the four Superbolts that secure the drum drive motor to the boom follow the procedure in SUPERBOLT. 8. To install a drum drive motor - reverse the above procedure. Be sure to isolate and jog the new motor to check for correct rotation.

CAUTION

Position the conveyor tail level with the floor. Lower the gathering head to the floor. Raise and block the cutter head assembly. Remove and lock-out the electrical power to the miner.

DANGER

Never work under any raised assembly without proper blocking.

The drum drive motor is very heavy. Verify its weight can be supported.

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© DBT AMERICA 2005

DANGER

__________________________________________________ Operation shear cylinder dash-0, dash-1 & dash-2

1. Advance the conveyor chain so that a conveyor flight does not block the shear cylinder piston end pin access plate in the conveyor bed.

2. VIEW A -Remove covers to access both ends of the shear cylinder.

3. VIEW B -At the Cutter boom clevis remove two capscrews and lock washers and remove the retaining plate.

4. VIEW B -Using the slide hammer with a 1”-8 adapter pull the pin from the clevis bushing.

5. Connect electrical power to the miner.

C Stand clear of the blocked cutter head assembly during contraction of the shear cylinders..

CAUTION

6. Slowly contract the shear cylinder until the rod comes free from its cutter boom clevis.

C Remove and lout-out the electrical power ti the miner.

© DBT AMERICA 2005

CAUTION

7. Raise and lower the shear cylinder control lever to release any pressure from the shear cylinder.

8. VIEW C -At the tractor frame clevis, remove the two capscrews and lock washers that secure the pin retaining plate to the frame. Remove the retaining plate.

C CAUTION

The shear cylinder is very heavy. Verify its weight can be supported.

9. VIEW C -Using the slide hammer with a 1”-8 adapter pull the pin from the clevis busing.

10. Mark for reconnection then disconnect and cap the hoses to the shear cylinder.

11. The shear cylinder can now be removed.

12. To install a shear cylinder - reverse the above procedure.

______________________________________________________________ DBT – 25M SERIES CONTINUOUS MINER © VUVR / 03 5.7

Operation ____________________________________________________ shear cylinder dash-3

1. VIEW A -Access both ends of the shear cylinder.

2. VIEW B -At the Cutter boom clevis remove two capscrews and lock washers and remove the retaining plate.

3. VIEW B -Using the slide hammer with a 1”-8 adapter pull the pin from the clevis bushing.

4. Connect electrical power to the miner.

The shear cylinder is very heavy. Verify its weight can be supported. Remove and lock-out the electrical power to the miner.

DANGER

5. Slowly contract the shear cylinder until the piston end comes free from its cutter boom clevis.

7. Mark the hoses for reconnection then disconnect and cap them.

8. VIEW B -At the tractor frame clevis, remove the two capscrews and lock washers that secures the pin retaining plate to the frame. Remove the retaining plate.

9. VIEW B -Using the slide hammer with a 1”-8 adapter pull the pin from the clevis bushing.

10. The shear cylinder can now be removed.

11. To install a shear cylinder - reverse the above procedure.

cutter drums dash-0

1. Manually rotate the cutter head drums slowly until the center drum connecting flanges are parallel to the mine floor. .

2. Before you do any disassembly, familiarize yourself with the position of the cutter drum alignment marks / arrows.

DANGER

center cutter drums

The cutter drums are extremely heavy. Verify its weight can be supported. Remove and lock-out the electrical power to the miner.

1.

2.

3.

4.

5.

6.

VIEW A -At the split line of the two halves remove the weld straps using a cutting torch.

VIEW A -Remove the twelve capscrews and retainer plates holding the center drum flanges together. Store the capscrews and retainer plates for reinstallation.

Attach lifting chains or other lifting device to the top half cutter drum.

Break the seal between the center drum’s halves with a pry bar.

Lift the upper half of the center drum and move it away from the miner.

Connect electrical power to the miner.

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© DBT AMERICA 2005

6. Raise and lower the shear cylinder control lever to release any pressure from the shear cylinder.

__________________________________________________ Operation 7. Raise the cutter head assembly slowly until it is completely clear of the lower half of the center drum and tram the miner away from the drum halves.

8. To Install the center cutter drum - reverse the above procedure.

Remember to torque the twelve capscrews to 1700 lb.-ft. alternating front to back starting from one end and working toward the other.

C CAUTION

Verify the lifting device is capable of listing the drum’s weight.

Use care when handling the cutter drum.

C CAUTION

end cutter drums

Follow welding safety instructions.

1.

Drain the gear case oil before starting to remove the drums.

© DBT AMERICA 2005

2. VIEW F -Remove the long capscrews and nuts on the two studs which secure the end drum to the cutter drum drive assembly.

C CAUTION

main cutter drums

3.

4.

5.

6.

7.

8.

Remove plug and center drum input shaft.

VIEW D -Remove the drum sliding it off of the hub.

Remove the key and store for reinstallation.

To install the end drum - reverse the above procedure.

Be sure the match timing arrows are aligned.

VIEW F -Torque the capscrews to 350 lb.-ft.

The end cutter drums are very heavy. Verify the supports can support its weight.

1. The end cutter drum must be removed. Follow that procedure.

2. VIEW E -Using a cutting torch remove the straps tack welded to the strut capscrews.

3. VIEW E -Remove the eight strut capscrews.

4. VIEW F -Remove the remaining nuts on the two studs.

5. Slide the strut and hub assembly from the gear case over the two studs.

6. VIEW B -Remove the capscrews from the main cutter drum..

C

7. VIEW C -The cutter drum can now be removed from the output shaft by sliding it off the hub and two dowel pins.

8. To install the main cutter drum reverse the above procedure. Apply red loctite and torque the capscrews to 350 lb.-ft.

CAUTION

The main cutter drums are very heavy. Verify the supports can support its weight.

______________________________________________________________ DBT – 25M SERIES CONTINUOUS MINER © VUVR / 03 5.9

Operation ____________________________________________________ cutter drum installation / removal dash-1

1. Manually rotate the cutter head drums slowly until the center drum connecting flanges are parallel to the mine floor.

2. Before you do any disassembly, familiarize yourself with the position of the cutter drum alignment marks / arrows.

C CAUTION

Position the conveyor tail section level with the floor.

Lower the gathering head until it is level with the floor.

Raise and block up the cutter head assembly. Allow for removal of the cutter drums. .

DANGER

Never work under any raised assembly without proper blocking.

Remove and lock-out the electrical power to the miner.

CAUTION

C CAUTION

center cutter drum

The cutter drums are extremely heavy. Verify its weight can be properly supported and use extreme case when handling.

1. VIEW A -At the split line of the two halves remove the weld straps with hammer and chisel.

2. VIEW A -Remove the sixteen capscrews and retainer plates holding the center drum flanges together. Store the capscrews and retainer plates for reinstallation.

3. Attach lifting chains or other lifting device to the top half cutter drum.

4. Break the seal between the center drum’s halves with a pry bar.

5. Lift the upper half of the center drum and move it away from the miner.

6. Connect electrical power to the miner.

7. Raise the cutter head assembly slowly until it is completely clear of the lower half of the center drum and tram the miner away from the drum halves.

8. To Install the center cutter drum - reverse the above procedure.

Remember to torque the sixteen capscrews to 1900 lb.-ft. alternating front to back starting from one end and working toward the other.

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© DBT AMERICA 2005

C

__________________________________________________ Operation end cutter drums

1. Drain the gear case oil before staring to remove the drums.

2. Remove the lock-ring tack welded to the capscrews using a cutting torch.

3. VIEW F -Remove the long capscrews and nuts on the two studs which secure the end drum to the cutter drum drive assembly.

4. Remove plug and center drum input shaft.

5. VIEW D -Remove the drum sliding it off of the hub.

6. Remove the key and store for reinstallation.

7. To install the end drum - reverse the above procedure.

8. Be sure the match timing arrows are aligned.

9. VIEW F -Torque the capscrews to 900 lb.-ft. Tack weld the lockring.

The end cutter drums are very heavy. Verify their weight can be supported. Follow welding safety procedures.

DANGER

© DBT AMERICA 2005

main cutter drums

1. The end cutter drum must be removed. Follow that procedure.

2. VIEW E -Using a cutting torch remove the retainer tack welded to the strut capscrews.

3. VIEW E -Remove the eight strut capscrews.

4. VIEW F -Remove the remaining nuts on the two studs.

5. Slide the strut and hub assembly from the gear case over the two studs.

6. VIEW B -Remove the capscrews from the main cutter.

7. VIEW C -The cutter can now be removed from the output shaft by sliding it off the hub and two dowel pins.

8. To install the main cutter drum reverse the above procedure.

Torque capscrews to 500 lb.-ft. If never size is used reduce the torque value to 300 lb.-ft. ( If loctite is used reduce the torque value to 425 lb.-ft. ) 9. Tack weld the lock-ring and capscrew retainer.

The strut and hub assemblies are very heavy. Be prepared to supports its weight.

DANGER

The main cutter drum is extremely heavy. Verify its weight can be supported..

DANGER

______________________________________________________________ DBT – 25M SERIES CONTINUOUS MINER © VUVR / 03 5.11

Operation ____________________________________________________ 1. Manually rotate the cutter head drums slowly until the center drum connecting flanges are parallel to the mine floor.

2. VIEW C - Before you do any disassembly, familiarize yourself with the position of the cutter drum alignment marks / arrows.

3. VIEW A -At the capscrews remove the weld straps with hammer and chisel.

4. VIEW C -Remove the twenty capscrews and retainers holding the center drum flanges together. Store the capscrews and connecting plates for reinstallation.

5. VIEW B -Attach lifting chains or other lifting device to the top half cutter drum.

6. Break the seal between the center drum’s halves with a pry bar.

7.

8. VIEW B -Lift the upper half of the center drum and move it away from the miner.

9. VIEW C -Remove the center drum alignment keys from the keyway if the cuttting drums are key driven ( not square drive ). Store for reinstallation.

10. Connect electrical power to the miner.

11. Raise the cutter head assembly slowly until it is completely clear of the lower half of the center drum and tram the miner away from the drum halves.

12. To Install the center cutter drum - reverse the above procedure.

Remember to torque the twenty capscrews to 1850 lb.-ft. alternating front to back starting from one end and working toward the other.

C CAUTION

Position the conveyor tail section level with the floor. Lower the gathering head until it reaches the floor. Raise and block the cutter head assembly. Allow space for the removal of the cutter head.

Never work under any raised assembly without proper blocking.

DANGER

C

Remove and lock-out the electrical power to the miner. Follow welding safety procedures.

CAUTION

C CAUTION

C

The cutter drums are extremely heavy. Verify the supports willhandle its weight.

Verify the lifting device is capable of lifting the drum;s weight.

Use care when handling the cutter drum.

CAUTION

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© DBT AMERICA 2005

cutter drums dash-2 installation / removal

__________________________________________________ Operation end cutter drums

C CAUTION

C CAUTION

1. VIEW D -Remove the weld straps between capscrews using a cutting torch.

2. VIEW D -Remove the twelve capscrews which secure the end drum to the cutter drum drive assembly.

3. VIEW D -Remove the drum from the miner.

4. To install the end drum - reverse the above procedure.

5. VIEW C -Be sure the match timing arrows are aligned.

6. VIEW D -Torque the twelve capscrews to 1200 lb.-ft. Tack weld the straps.

The end cutter drums are very heavy. Verify the supports can handle its weight. Follow welding safety procedures.

Position the conveyor tail section level with the floor. Lower the gathering head until it reaches the floor. Raise and block the cutter head assembly. Allow for removal of the cutter drums.

Never work under any raised assembly without proper blocking.

© DBT AMERICA 2005

DANGER

C CAUTION

Remove and lock-out the electrical power to the miner.

1. Manually rotate the cutter head drums slowly until the center drum connecting flanges are parallel to the mine floor.

2. VIEW C -Before you do any disassembly, familiarize yourself with the position of the cutter drum alignment marks / arrows.

C CAUTION

The cutter drums are extremely heavy. Use extreme care when handling.

______________________________________________________________ DBT – 25M SERIES CONTINUOUS MINER © VUVR / 03 5.13

Operation ____________________________________________________ center cutter drum

C

1. VIEW A -At the capscrews remove the weld straps using a cutting torch.

2. VIEW C -Remove the eighteen capscrews holding the center drum flanges together. Store the capscrews for reinstallation.

3. VIEW B -Attach lifting chains or other lifting device to the top half cutter drum.

4. Break the seal between the center drum’s halves with a pry bar.

5. VIEW B -Lift the upper half of the center drum and move it away from the miner.

6. VIEW C -Remove the center drum alignment keys from the key way if the cuttting drums are key driven ( not square drive ). Store for reinstallation.

7. Connect electrical power to the miner.

8. Raise the cutterhead assembly slowly until it is completely clear of the lower half of the center drum and tram the miner away from the drum halves.

9. To Install the center cutter drum - reverse the above procedure.

Remember to torque the eighteen capscrews to 1850 lb.-ft. alternating front to back starting from one end and working toward the other.

Follow welding safety procedures.

C

Verify the lifting device is capable of lifting the drum’s weight. Use case when handling the cutter drum.

CAUTION

end cutter drum

C

1. VIEW D -Remove the weld straps between capscrews using a cutting torch.

2. VIEW D -Remove the twelve capscrews which secure the end drum to the cutter drum drive assembly.

3. VIEW D -Remove the drum from the miner.

4. To install the end drum - reverse the above procedure.

5. VIEW C -Be sure the timing arrows are aligned.

6. VIEW D -Torque the twelve capscrews to 1200 lb.-ft. Tack weld the strap across the capscrews.

Follow welding safety procedures.

CAUTION

C

The end cutter drums are very heavy. Verify the supports can handle its weight.

CAUTION

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© DBT AMERICA 2005

CAUTION

__________________________________________________ Operation gear case dash-0 installation / removal

C CAUTION

1. Remove the cutter drums - follow that procedure.

2. Remove the covers and water spray manifolds, hosing, and remove cutter motor power leads attached to the gear case.

3. Securely block the cutter drum drive gear case to support it when it becomes separated from the boom.

4. VIEW A -Remove the two capscrews which adjust the special key.

5. Remove the strapping from the capscrews securing the gearcase to the boom using a cutting torch.

6. VIEW D -Remove the fourteen hex head capscrews that secure the cutter drum drive gear case to the cutter drum.

7. Remove the cutter motor.

8. Connect electrical power to the miner.

9. Slowly tram the miner in reverse away from the blocked gear case.

10. VIEW B -Remove the special key and store for installation.

11. To install a gear case - reverse the above procedure. Torque the fourteen capscrews to 1700 lb.-ft.

Position the conveyor tail section level with the floor. Lower the gathering head to the floor. Raise and block-up the cutter head assembly. Allow for removal of the cutter drums.

© DBT AMERICA 2005

Never work under any raised assembly without proper blocking.

DANGER

C

Remove and lock-out the electrical power to the miner.

CAUTION

C

The gear case is very heavy. Verify the supports can handle its weight. .

CAUTION

C Stand clear of the gear case and the miner when tramming.

CAUTION

C Follow welding safety procedures.

CAUTION

______________________________________________________________ DBT – 25M SERIES CONTINUOUS MINER © VUVR / 03 5.15

Operation ____________________________________________________ gear case dash-1 installation / removal

C CAUTION

1. Remove the cutter drums - follow that procedure.

2. Remove the covers and water sprays attached to the gear case.

Note: Same as Dash Zero.

3. Securely block the cutter drum drive gear case to support it when it becomes separated from the boom.

4. VIEW B -Remove the strapping from the capscrews securing the gear case to the boom using a cutting torch.

5. VIEW B -Remove the sixteen hex head capscrews that secure the cutter drum drive gear case to the cutter drum.

6. Remove cutter motor.

7. Connect electrical power to the miner.

8. Slowly tram the miner in reverse away from the blocked gear case.

9. VIEW B -Remove the two keys and store for installation.

10. To install a gear case - reverse the above procedure. Torque the sixteen capscrews to 1900 lb.-ft.

Position the conveyor tail section level with the floor. Lower the gathering head to the floor. Raise and block-up the cutter head assembly. Allow for removal of the cutter drums.

DANGER

C Remove and lock-out the electrical power to the miner.

CAUTION

C

The gear case is very heavy. Verify the supports can handle its weight. .

CAUTION

C Stand clear of the gear case and the miner when tramming.

CAUTION

C Follow welding safety procedures.

CAUTION

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© DBT AMERICA 2005

Never work under any raised assembly without proper blocking.

__________________________________________________ Operation

© DBT AMERICA 2005

gear case dash –2-3 installation / removal See figures—21 & 22

C CAUTION

1. Remove the center cutter drum and the end cutter drum - follow that procedure.

2. VIEW A - On the rear of the cutter drum drive motor, locate the clutch housing and the motor shaft access cover plate.

3. VIEW A - Remove the four capscrews that secure the motor shaft access cover plate to the clutch housing. Remove the access cover plate to expose the end of the motor drive shaft.

4. VIEW A - Remove the retaining ring that secures the motor shaft in the clutch assembly.

5. VIEW A - Pull the motor shaft from the motor and clutch assembly.

6. Store the motor shaft in a clean, safe place.

7. To protect the clutch from damage and dirt, replace the access cover plate. .

8. Securely block the cutter drum drive gear case to support it when it becomes separated from the boom.

9. VIEW B -Remove the strapping from the twenty-one capscrews securing the gear case to the boom using a cutting torch.

10. VIEW C - Remove the twenty-one 1 1/4” hex head capscrews that secure the cutter drum drive gear case to the cutter boom.

11. Connect electric power to the miner.

12. Slowly tram the miner in reverse away from the blocked gear case.

13. Remove the three face keys and save for installation.

14. To install a gear case -reverse the above procedure except for the following steps.

15. VIEW D -Insert four 1 1/4” dowel guides into the cutter boom face, spacing them equally over the boom face.

16. VIEW D -Mark the holes on the exterior of the gear case mounting brace that correspond to the positions of the guides on the boom face.

17. VIEW D -Apply RTV silicon sealer to the gear case center alignment key and install the key into the boom face. Also install the gear case’s two larger side alignment keys into the boom face.

18. VIEW C -Torque the twenty-one capscrews to 1850 lb.-ft. beginning with the inner capscrews and working to the outside.

Remember to fill the gear case with approved lubricant.

Position the conveyor tail section level with the floor. Lower the gathering head to the floor. Raise and block-up the cutter head assembly. Allow for removal of the cutter drums. Remove and lock-out the electrical power to the miner.

C CAUTION

The gear case is very heavy. Verify the supports can handle its weight. Stand clear of the gear case and the miner when tramming

Never work under any raised assembly without proper blocking.

DANGER

C Follow welding safety procedures.

CAUTION

______________________________________________________________ DBT – 25M SERIES CONTINUOUS MINER © VUVR / 03 5.17

Operation ____________________________________________________

© DBT AMERICA 2005

cutter boom dash-0 gear case—Figure 21

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__________________________________________________ Operation

© DBT AMERICA 2005

cutter boom dash-1 gear case—Figure 22

______________________________________________________________ DBT – 25M SERIES CONTINUOUS MINER © VUVR / 03 5.19

Operation ____________________________________________________

© DBT AMERICA 2005

cutter boom dash-2, 3 gear case

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__________________________________________________ Operation gathering head ass’y installation / removal See figure—14 & 15

The gathering head assembly has two Continuous Loading Arms ( CLA ) which rotate to load the cut material on to the conveyor. Two electric motors drive the CLA gear cases and the conveyor foot shaft.

The electric motors are called either “gathering head” or “conveyor” motors.

© DBT AMERICA 2005

1. View A - Place blocking under the rear of the gathering head to stabilize its position during and after the removal of the pivot pins and disconnection of the lift cylinders.

2. Remove the electric motor cable and cooling water lines from the gathering head. Disconnect these from the motor. Refer to the motor removal procedure.

3. View B - Access the gathering head pivot point by removing the forward tram rub rail.

4. View C - Remove the two 3/4” capscrews and lock washers that secure the pin retaining plate to the tractor frame.

5. View C - Remove the two 1” capscrews and lock washers that secure the pin retaining plate to the pivot pin.

6. View D - Using the slide hammer with a 1”-8 adapter remove the pivot pin.

7. Repeat steps 3 through 7 for the opposite side.

8. Disconnect both lift cylinders from the gathering head by pulling the piston end pins. Refer to the lift cylinder replacement procedure.

9. Lower the gathering head control lever at the valve bank. The weight of the lift cylinder pistons should cause the piston ends to come free from the gathering head.

10. Connect electrical power to the miner.

11. View E - Lift the cutter head off of the blocking and slowly tram the miner in reverse until the cutter head clears the backboard of the gathering head.

12. To install the gathering head - reverse the removal procedure.

C CAUTION

C CAUTION

Lower the conveyor tail until it is level with the floor. Lower the gathering head until it rests on the floor. Raise and block up the cutter head assembly. Remove and lock-out electrical power to the miner. Be sure to tape up the motor cable leads. There will be electric power on the miner before the motors are reconnected.

Check the blocking of the gathering head assembly so it w ill not drop w hen the pivot pins are removed and the lift cylinders are disconnected. W hen separating the gathering head from the tractor frame, insure that the disconnected ends of the conveyor chain slide out of the gathering head.

Never work under any raised assembly without proper blocking.

DANGER

______________________________________________________________ DBT – 25M SERIES CONTINUOUS MINER © VUVR / 03 5.21

Operation ____________________________________________________

C CAUTION

1. View A - Remove the three 1” capscrews and lock washers where the arms meet the CLA hub.

2. View A - Remove the six 1” capscrews and lock washers located in the center of the CLA hub. The CLA should now be free and able to be removed.

3. View B - Remove the four CLA alignment keys from the exposed gathering head gear case turntable. Store the keys in a safe place.

4. View C - On installation of the CLA, mark the outer bolt hole on the CLA that is directly adjacent to a key cut-out. Place a 1” wooden dowel in the outer bolt hole of the gear case turntable that is directly adjacent to a key cut-out. Place the four keys into their cut-outs on the gear case turntable.

5. View D - Place the CLA on the gear case turntable so that the dowel extends through the marked CLA hole. Adjust as necessary to fit the turntable keys into the CLA cut-outs.

6. View D - Remove the wooden dowel and install the nine lock washers and capscrews. If hog rings are used, they should be installed so that their sharp points prevent the capscrew from loosening per View E. 7. After CLA installation, inspect the positions of the CLAs to insure that the arms will not collide during rotation.

Lower the conveyor tail until it is level with the floor. Lower the gathering head to the floor. Raise and block up the cutter head assembly. Remove and lock-out electrical power to the miner.

Never work under any raised assembly without proper blocking.

DANGER

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© DBT AMERICA 2005

CLA installation / removal See figure—16

__________________________________________________ Operation gathering head motor installation / removal

© DBT AMERICA 2005

C

1. View A - Remove the side cover secured by two capscrews and lock washers. The end of the motor will be exposed.

2. View B - Remove the 2” pipe plug on the end of the motor. Using a screwdriver remove the retaining ring that secures the shaft end plug inside the motor housing.

3. View B -Pull the drive shaft out using a slide hammer with a 3/8”-16 adapter. Store the drive shaft, shaft end plug and the retaining ring in a safe place. Replace the pipe plug in the end of the motor.

4. View D - Disconnect and plug the water connections.

5. View E - Remove the four 3/4” socket head capscrews that secure the motor to the gear case adapter plate. The motor can now be pulled out to get to the junction box. Note the seal between the motor and the gear case.

6. View C -Disconnect the electrical cables in the junction box. Mark the cable motor leads so they can be reconnected correctly. Remove the stuffing box clamp and pull the cable out of the motor.

7. To install a motor - reverse the above removal procedure. Use a new seal between the motor and the gear case.

8. A newly installed motor must be run independent of the other motor to insure proper rotation. This can be done by isolating the other motor in the controller case.

Verify electrical power to the miner is disconnected and lockedout.

CAUTION

foot shaft installation / removal

1. View A -Slowly advance the conveyor chain until a connecting link appears at the gathering head foot shaft area.

2. Loosen the conveyor chain tension as much as possible. ( See Conveyor Chain Adjustment Procedure.)

3. View A - Remove the conveyor chain connecting link.

4. View B -Remove the eight 3/4” capscrews and lock washers securing the footshaft cover to the gathering head.

5. View C -Remove the four 1/2” capscrews from each of the two collars and remove the collars from the footshaft.

6. View D -Slide the two couplings from the ends of the footshaft toward the center sprocket on the footshaft.

7. View E - The footshaft can now be removed.

8. To install the footshaft - reverse the above removal procedure.

9. Be sure to readjust the conveyor chain tension.

Never work under any raised assembly without proper blocking.

DANGER

C Verify power to the miner is disconnected and lock-out.

CAUTION

______________________________________________________________ DBT – 25M SERIES CONTINUOUS MINER © VUVR / 03 5.23

Operation ____________________________________________________

C CAUTION

1. Completely drain the gear case lubricant by removing the two 3/4” plugs located on the underside of the gear case. Replace the drain plugs.

2. Reconnect electrical power and lower the gathering head assembly to the floor.

3. Remove the CLA ( Follow that procedure.)

4. Remove the drive motor. ( Follow that procedure. ) 5. Remove the footshaft. (Follow that procedure.)

6. View A - Remove capscrews and the upper and lower deck covers.

7. View B -Disconnect the four lubrication hoses from the gear case.

Tag the hoses so they can be reconnected properly. Plug both ends to keep dirt out.

8. View C - Remove the twelve capscrews that secure the gear case pot and mounting wedges to its mounting plate.

9. The gear case can now be removed.

10. To install a gear case -Reverse the removal procedure. Use a new gear case-to-motor seal.

11. Fill the gear case. Attach a rose gun to the lower port located next to the gathering head side cover and fill the gear case to the proper level with gear lubricant. The gear case is full when steady oil flow is observed from the breather plug in the top port. Check for leaks.

Lower the conveyor tail until it is level with the floor. Raise and block up the cutter head assembly. Raise and block up the gathering head assembly. Remove and lock-out electrical power to the miner.

Never work under any raised assembly without proper blocking.

DANGER

The cutter head assembly should still be blocked up.

NOTICE

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© DBT AMERICA 2005

gear case installation / removal

__________________________________________________ Operation lift cylinder installation / removal See figure—23

C

© DBT AMERICA 2005

CAUTION

DANGER

1. View A - Remove two capscrews and the Piston Pin Retaining Bar. 2. View A -Use the slide hammer with a 5/8”-11 adaptor to pull the Piston Pin from the clevis bushings.

3. Lower the gathering head control lever at the valve bank. The weight of the lift cylinder piston should cause the piston end to come free of its clevis.

4. Move the gathering head lift cylinder control lever up and down to release any pressure from the lift cylinder.

5. View C - Remove the hydraulic hose from the lift cylinder’s hydraulic fitting. Plug the hose end to keep it clean.

6. View D -Remove the two capscrews that secure the Pin Retaining Plate to the tractor frame. Remove the Pin Retaining Plate.

7. View D - Use the slide hammer with a 5/8”-11 adapter to pull the rod end pin from the frame cleves bushing.

8. The lift cylinder can now be removed.

9. To install the lift cylinder - reverse removal procedure.

Lower the conveyor tail until it is level with the floor. Raise and block up the cutter head assembly. Raise and block up the gathering head assembly. Remove and lock-out electrical power to the miner.

Never work under any raised assembly without proper blocking.

Stand clear of the blocked cutter head and gathering head assemblies.

Be prepared to support the cylinder when it becomes free.

WARNING

______________________________________________________________ DBT – 25M SERIES CONTINUOUS MINER © VUVR / 03 5.25

Operation ____________________________________________________ tractor frame ass’y See figure—1

The maintenance procedures for the tractor frame assemblies are basically the same for all of the Dash Series miners.

The installed tram case includes the tram motor, the tram primary planetary gear, the tram reach gear set, the tram secondary planetary gear, and the tram sprocket. Removal of the tram case is a major undertaking involving the removal of crawler track pads from the tram case. Depending upon the maintenance required removal / installation procedures are given for each major component.

1. VIEW A - Remove the tram rub rail after pulling the two tram rub rail pins.

2. VIEW B - Remove the four hex head capscrews and lock washers that hold the input shaft access cover to the motor frame. Remove the input shaft access cover and o-ring.

3. VIEW B - Remove the retaining ring, shaft plug & o-ring and pull out the motor input shaft. Replace the input shaft access cover.

4. VIEW C - Disconnect the cooling water hoses from the motor. Plug the hoses and fittings to keep them clean.

5. VIEW D - Remove the four capscrews that hold the tram motor bracket to the tram case. Remove the tram motor bracket.

6. VIEW D -Slide the tram motor out from the tram case until the electrical connection and hand hole cover are accessible. Remove the eight capscrews that hold the hand hole cover to the motor frame. Remove the hand hole cover and o-ring.

7. VIEW D - Mark the wire connections and disconnect the power cables. Remove the two capscrews that hold the stuffing boxes half moon clamp to the junction box. Slide the stuffing box out of the junction box. On the Dash Zero remove the scrubber duct mounting bracket also.

8. VIEW E -Slide the tram motor out from the tram case onto blocking.

Take care not to damage the motor adapter plate seal.

9. To install the tram motor - reverse the above removal procedure.

Note: Slide the input shaft through the tram motor (VIEW B) and into the tram planetary primary gear -The input shaft end without the threaded hole should be inserted first. It may take some adjusting to get the splined end of the shaft to fit into the gear spline. Be sure to install a new motor-to-adapter seal.

C CAUTION

LOWER THE GATHERING HEAD AND CUTTER HEAD TO THE FLOOR. POSITION THE CONVEYOR TAIL SECTION LEVEL WITH THE FLOOR. REMOVE AND LOCK OUT ELECTRICAL POW ER TO THE MINER. DO NOT RECONNECT ELECTRICAL POWER TO THE MINER WHILE THE TRAM MOTOR POWER CABLE IS DISCONNECTED.

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© DBT AMERICA 2005

For detail disassembly and assembly and to identify parts of the tram gear case refer to the assembly drawing in the parts book for that miner.

__________________________________________________ Operation

© DBT AMERICA 2005

tram primary planetary gear Installation / removal see figure—3

C CAUTION

1. VIEW A - Remove the tram motor. ( Follow that procedure ) The tram primary planetary gear is located behind the tram motor.

2. VIEW B - Remove the sixteen capscrews that secures the motor adapter plate and the primary gear ring to the tram case.

3. Remove the motor adapter plate from the gear case.

4. Carefully slide the primary planetary carrier assembly out of the primary gear ring and remove the assembly from the tram case.

5. Carefully slide the primary gear ring out of the tram case.

6. Installation of the primary planetary gear set - Reverse the above procedure using the following installation steps.

7. VIEW B - Insert alignment dowels inserted into four (4) of the sixteen (16) capscrew holes in the tram case.

8. VIEW B -Mark the mounting holes of the primary planetary gear ring that correspond to the holes in which the alignment dowels were placed.

9. VIEW B - Carefully insert the primary planetary gear assembly into the gear ring. Be sure that the extension of the sun gear faces out from the center of the miner and that the internal gear teeth of the primary carrier are seated securely onto the tram drive pinion gear. Orient the adapter plate with the adapter dowels along the bottom edge.

10. VIEW B - Install and tighten the sixteen 3/4” capscrews to 230 lb.-ft. Remove the alignment dowels as you proceed.

Lower the gathering head and the cutter head to the floor. Lower the conveyor tail section. Remove and lock-out electrical power to the miner.

Recommended to replace input seal.

IMPORTANT

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tram secondary planetary gear Installation / removal see figure—4

C CAUTION

1. VIEW A - Remove the tram rub rail after pulling the two pins.

2. VIEW B - Remove the 3/4” plug from the bottom of the secondary planetary gear cove and drain the lubricate from the gear case.

Replace the plug.

3. VIEW C - Remove the 16 capscrews that hold the secondary planetary gear cover to the tram case.

4. Remove the secondary planetary gear thrust washer from the planetary gear cover.

5. VIEW D -Slide the secondary planetary gear ring off the secondary planetary gear assembly.

6. VIEW D -Install eight 3/4” - 10x2 1/2” hex head capscrews into the sprocket bearing carrier to hold it on the tram case.

7. VIEW E - Pull the secondary tram gear shaft from the gear and sprocket.

8. VIEW F -Carefully slide the secondary planetary assembly out of the sprocket bearing carrier.

9. VIEW G - Installing the secondary planetary assembly is basically the reverse of the above procedure, except for the following.

10. Slide the secondary tram drive shaft with the thread hole end to the outside into the tram drive sprocket and reach gear set. The shaft may require some adjustment to introduce the splined end into the reach gear.

11. Insert four alignment dowels into the holes in the sprocket bearing carrier.

12. To facilitate ring gear insertion, mark the mounting holes of the secondary planetary ring gear that corresponds to the holes in which the alignment dowels were placed.

13. Carefully slide the secondary planetary ring gear onto the four alignment dowels so that the dowels appear through the marked holes. The planetary should slide smoothly into the ring gear teeth.

14. Place a new thrust washer into the secondary planetary cover.

The side of the thrust washer with the inscribed circles should face away from the drive shaft.

15. To facilitate the gear cover replacement, mark the mounting holes of the secondary planetary gear cover that corresponds to the holes in which the alignment dowels are placed. NOTE: The flat edge of the cover located adjacent to the 3/4” lubrication fitting is the top of the cover.

16. Slide the secondary planetary gear case cover onto the alignment dowels so that the dowels appear through the marked holes.

17. Using the 5/8” torque wrench, install and torque all sixteen capscrews to 220 ft.-lb., removing the alignment dowels as you proceed.

18. Fill the secondary planetary gear case to the proper level with the recommended lubricant. Allow the lubricant level to stabilize and recheck it several times before operation.

Lower the gathering head and the cutter head to the floor. Lower the conveyor tail section. Be prepared to support the heavy weight of the secondary planetary ring gear when removing it from the secondary planetary assembly. Be prepared to support the heavy weight of the secondary planetary gear assembly when removing it from the sprocket bearing carrier in the tram case.

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Operation ____________________________________________________

__________________________________________________ Operation

© DBT AMERICA 2005

tram case installation / removal See figure—5 & 6

1. VIEW A - Place blocking under the cutter head assembly and raise the front of the miner and use the stabilizer jack to raise the rear of the miner. Place blocking in multiple locations under both crawler tracks. When the miner is lowered, the weight of the miner rests on the tram track blocking. Leave the blocking under the cutter head; the crawlers will be raised off their blocking later.

2. VIEW B - Remove the tram rub rail after removing the two tram rub rail pins.

3. VIEW B - Open the front rub rail after removing the capscrew holding it in place.

4. VIEW C - Use a grease gun to extend the take-up jack to remove the pusher plate pressure and remove the idler adjustment shims, 5. VIEW C - Open the pressure release valve on the take-up jack to allow the cylinder to contract. This will loosen the tension on the crawler chain.

6. VIEW D -Disconnect the tram crawler pads near the track entry opening by removing the two roll pins that hold the crawler pins in the crawler pads.

7. VIEW D - Attach heavy wires to the end of the crawler track link that passes through the tram case and over the tram sprocket.

8. If the tram drive is operational reconnect electrical power to the miner.

9. VIEW E -Slowly operate the tram motor forward to rotate the sprocket so that the end of the tram track that passes through the case and rolls off the sprocket.

10. VIEW E -Pull the tram track from the front of the miner ( near the idler ) so that the free end of the tram track is pulled clear of the tram case exit opening.

11. VIEW F -Remove the two 1-1/4”x 3-3/4” lg. Superbolts from the sprocket side of the tram case and the two 1-1/4”x 3-3/4” Superbolts from the motor side of the tram case. Follow the SUPERBOLT installation / removal procedures.

12. VIEW F - Remove the two 1-1/4”x 5” Superbolts from the sprocket side of the tram case and the two 1-1/4”x5” Superbolts from the motor side of the tram case. Remove the two capscrews from the sprocket side of the tram case.

13. Follow the TRAM MOTOR removal procedure to disconnect the tram motor power cable and cooling water hoses.

14. VIEW G -Slide the tram case out from the tractor frame onto blocking. Pull the tram track guide wires out of the tram case exit opening and secure the wires to the tractor frame.

15. To install the tram case - reverse the above procedure.

16. VIEW H - Check the tram track tension when the crawlers are off the floor. The track sag should be between 2-1/2” and 3-1/2”. If the tram track is not at the proper tension follow the adjustment procedure in TRAM TRACK.

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Operation ____________________________________________________ Never work under any raised assembly without proper blocking.

DANGER

CAUTION

stabilizing cylinder installation / removal See figure—7

DANGER

Remove and lock-out electrical power to the miner. Stand clear of the miner w hen using the tram motor to remove the tram track from the sprocket. The assembled tram case is very heavy. Be prepared to support the tram case before removing it from the tractor frame.

1. VIEW A - Place blocking under the conveyor tail section. Place blocking under the cutter head assembly. Lower the gathering head onto blocking. Lower the conveyor tail section onto blocking.

2. VIEW A - Pressure down the cutter head to raise the front of the miner. Pressure down the stabilizer to raise the rear of the miner.

Place blocking in multiple locations under both tracks. Add blocking under the tractor frame.

3. VIEW A -Raise the cutter head and the stabilizer until the weight of the miner is on the blocked up tracks and tractor frame.

4. Remove the blocking from under the stabilizer shoe.

5. VIEW B -Reference for horizontal mounted stabilizer cylinder on Dash One, Dash Two, and Dash Three miners. VIEW C Reference for vertical mounted stabilizer on Dash Zero miners.

6. VIEW B / C - With the stabilizer shoe resting on the ground, remove the capscrews securing pins at the cylinders rod end clevis.

7. VIEW B / C - Remove the rod end pin using a hammer and punch.

8. Connect electrical power to the miner.

9. Contract the stabilizer cylinder. The rod end bearing of the cylinder should remove itself from its clevis.

10. Raise and lower the stabilizer cylinder lever to release any pressure from the stabilizer shoe lift circuit.

11. Disconnect the hydraulic hoses from the stabilizer cylinder. Mark the hoses and plug them to keep them clean.

12. Remove and cap the hydraulic fittings from the cylinder.

13. VIEW B / C - Remove the cotter pins or capscrews used to secure the cylinder pin at the tractor frame clevis.

14. VIEW B / C - Remove the cylinder pin at the tractor frame using a hammer and punch.

15. To install a stabilizer cylinder - reverse the above procedure.

16. VIEW D - If both stabilizer cylinders have been removed, The stabilizer shoe can be removed by removing the two pivot pins at the tractor frame.

Never work under any raised assembly without proper blocking.

C CAUTION

Remove and lock-out electrical power to the miner. Be prepared to support the heavy stabilizer cylinder.

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© DBT AMERICA 2005

C

__________________________________________________ Operation tram sprocket assembly installation / removal See figure—8

1. VIEW A - Place blocking under the cutter head assembly and raise the front of the miner and use the stabilizer jack to raise the rear of the miner. Place blocking under both crawler tracks. Lower the miner onto the crawlers. Leave the blocking under the cutter head; the crawlers will be raised off their blocking later.

© DBT AMERICA 2005

2. VIEW B - Remove the tram rub rail after removing the two tram rub rail pins.

3. VIEW B - Open the front rub rail after removing the capscrew holding it in place.

4. VIEW C - Use a grease gun to extend the take-up jack to remove the pusher plate pressure and remove the idler adjustment shims.

5. VIEW C - Open the pressure release valve on the take-up jack to allow the cylinder to contract. This will loosen the tension on the crawler chain.

6. VIEW D -Disconnect the tram crawler pads near the track entry opening by removing the two roll pins that hold the crawler pins in the crawler pads.

7. VIEW D - Attach heavy wires to the end of the crawler track link that passes through the tram case and over the tram sprocket.

8. If the tram drive is operational reconnect electrical power to the miner.

9. VIEW E - Slowly operate the tram motor forward to rotate the sprocket so that the end of the tram track that passes through the case rolls off the sprocket.

10. VIEW E - Pull the tram track from the front of the miner (near the idler) so that the free end of the tram track is pulled clear of the tram case exit opening.

11. VIEW F - Remove the tram secondary planetary gear - follow that procedure.

12. VIEW G - Remove the outboard sprocket bearing carrier using puller holes provided.

13. Using a scoop or other pulling equipment pull the sprocket assembly from the case. The rear bearings and seals should come out with the sprocket.

14. Removal is complete.

15. To install the tram sprocket, reverse the above procedure.

16. VIEW H - Check the tram track tension while the crawlers are off the floor. The track sag should be between 2-1/2” and 3-1/2”. If the tram track is not at the proper tension follow the adjustment procedure in TRAM TRACK.

IMPORTANT

The Tram Sprocket Assembly is provided with new bearings seals and O-rings.

Never work under any raised assembly without proper blocking.

DANGER

C CAUTION

Remove and lock-out electrical power to the miner. Stand clear of the miner when using the tram motor to remove the tram track from the sprocket. Be prepared to support the weight of the sprocket.

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Operation ____________________________________________________ tram track adjustment 1. Raise the tractor frame off the blocking by lowering the stabilizer See figure—9 and gathering head and cutter head assemblies.

2. VIEW A - Lower the conveyor tail section on to blocking.

3. VIEW A - Raise the gathering head and cutter head and place a small stack of blocking under these two assemblies.

4. VIEW A - Lower the cutter head onto the blocking so that the front of the miner lifts off the floor.

5. VIEW A - Extend the stabilizer completely so that the rear end of the miner lifts off the floor.

6. VIEW A - Place blocking under the tractor frame in multiple locations. The blocking must not interfere with the tram track.

7. VIEW A - Raise the stabilizer and the cutter head and lower the tractor frame securely on to blocking.

8. VIEW B - Remove the capscrew and lock washer that secures the front rub rail to the tractor frame and open the front rub rail cover.

9. VIEW C - Evaluate the tram track for proper tension. The tram track is at the proper tension when it hangs approximately 2 1/2” to 3 1/2” from the bottom wear shoes when the tractor frame is blocked off the floor. Check both sides.

10. VIEW D - IF THE TRAM TRACK IS TOO TIGHT, re-adjust the idler position using the following steps:

and remove pusher plate pressure on the idler shims.

¢ Remove one or more idler adjustment shims from the idler slide channel.

¢ Open the pressure release valve for the front idler take-up

¢

IMPORTANT

jack and allow the jack to contract. The pusher plate will slide backwards until it is stopped by the remaining idler shims.

Evaluate the resulting track tension and repeat these steps until the track reaches proper tension.

If the tram track is too loose, re-adjust the idler position using the following steps:

¢ Pump grease into the idler take-up jack to extend the cylinder, move the idler assembly forward, and tighten the tram track until it is at the correct tension. The tram track is at the proper tension when it hangs 2 1/2” to 3 1/2” from the bottom wear shoes when the tractor frame is blocked off the floor.

¢ Insert shims into the idler slide channel until the space between the tractor frame and the pusher plate is filled.

¢ Check that the shims are correctly seated on the idler slide channel’s inside surface by looking at the channel’s inside surface from the opposite side of the miner, through the space between the gathering head and the idler assembly.

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¢ Pump grease into the take-up jack to extend the cylinder

__________________________________________________ Operation ¢ Open the pressure release valve for the front idler takeup jack and allow the cylinder to contract. The idler adjustment shims will keep the idler stationary and the track tensioned.

¢ Evaluate the resulting track tension and repeat these steps until the track reaches proper tension.

IMPORTANT

If the tram track tension is still too loose when the entire 5” shim set if inserted into the idler slide channel, re-adjust the idler position after removing a tram track link using the following steps:

¢ Pump grease into the take-up jack to extend the cylinder and remove pusher plate pressure on the idler shims.

¢ Remove all of the idler adjustment shims from the idler slide channel.

© DBT AMERICA 2005

¢ Open the pressure release valve for the front idler takeup jack and allow the jack to contract. The pusher plate and idler assembly will slide backwards.

1. VIEW E - Locate a tram track link near the idler. Using the hammer and punch, remove the four roll pins of the two tram track pins that secure the tram track link to the track.

2. Remove the tram track pins to disconnect the link from the track. Remove the disconnected link.

3. Store the tram track link, one of the tram track pins, and two of the roll pins in a safe place.

4. Having removed one link reconnect the tram track.

11. Repeat the previous procedures.

12. VIEW D -When the tram track has been adjusted to the proper tension, remove the grease gun from the idler take-up jack grease fitting.

13. VIEW B -Close the front rub rail cover and replace capscrew and lock washer to secure the front rub rail to the tractor frame.

14. Connect the electrical power to the miner.

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Operation ____________________________________________________

NOTICE

C CAUTION

Shims must be inserted completely into the idler slide channel. A shim that is not correctly seated on the idler slide channel’s inside surface provides uneven support that can cause idler slant. A slanted idler can cause uneven wear and stress on the tram track and can cause improper operation of, or damage to, the tram system. The tram track tension should now be reduced and separation of the tram track will be easier.

Remove and lock-out electrical power to the miner. Stand clear of the miner when raising it off the support blocking. Carefully remove the support blocking from under the miner.

Never work under any raised assembly without proper blocking.

tram track front idler installation / removal See figure—10

1. VIEW A - Raise the gathering head and cutter head assemblies to their highest points and place blocking underneath. Lower the assemblies onto the blocking.

2. VIEW B - Remove the capscrew and lock washer that secure the front rub rail to the tractor frame. Open the front rub rail cover.

3. VIEW C - Locate the idler take-up jack grease fitting and attach the grease gun to the fitting. Pump grease into the take-up jack to extend the cylinder and remove pusher plate pressure on the idler adjustment shims.

4. VIEW C - Remove all of the idler adjustment shims from the idler slide channel and store the shims in a safe place.

5. VIEW D -Open the pressure release valve for the front idler take-up jack and allow the jack to contract. The pusher plate and idler assembly will slide backwards.

6. VIEW E - Locate a tram track link near the tram front idler. Using a hammer and punch, remove the two roll pins that secure the tram pin between the links. Store the roll pins in a safe place.

7. VIEW E - Using a hammer and punch, remove the tram track pin to disconnect the links and separate the track. Store the track pin in a safe place.

8. VIEW F - Slide the front idler assembly out of the idler slide channel.

9. To install the tram track front idler, reverse the above procedure.

Never work under any raised assembly without proper blocking.

DANGER

NOTICE

The gathering head and cutter head must be blocked high enough to allow the idler assembly to be removed from the tractor frame’s idler slide channel.

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© DBT AMERICA 2005

DANGER

__________________________________________________ Operation front idler take-up jack assembly installation / removal

C CAUTION

© DBT AMERICA 2005

hydraulic pump installation / removal See figure—12

1. VIEW A - Remove the capscrew and lock washer that secure the front rub rail to the tractor frame and open the front rub rail cover.

2. VIEW B - Pull the flip pin from the half link to release the take-up jack bracket from the tractor frame.

3. VIEW C -Lower the end of the bracket until it clears the half link and pull the bracket straight out to remove it from the tractor frame.

4. To install the front idler take-up jack assembly - reverse the above procedure.

Lower the gathering head and the cutter head to the floor. Lower the conveyor tail section. Remove and lock-out electrical power to the miner.

1. VIEW A—Remove or open the rub rail to the rear of the tram rub rail on the left side (scrubber exhaust side) after pulling the two rub rail pins.

2. VIEW B—Disconnect the hoses from the pump and plug then to keep dirt and dust out.

3. VIEW C—Remove the hose fittings from the pump and store in a clean location.

4. VIEW D—Remove the capcrews (usually more than two each) that secure the hydraulic pump to the electric motor.

5. To install the hydraulic pump - reverse the above procedure.

The following procedure involves disconnecting hydraulic hoses.

They can be under high pressure.

DANGER

NOTICE

C CAUTION

Take special care to prevent coal dust and mine dirt from getting into the hydraulic system when removing any hydraulic component.

Lower the gathering head and the cutter head to the floor. Lower the conveyor tail section. Remove and lock-out electrical power to the miner.

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Operation ____________________________________________________ 1. VIEW A -Remove or open the rub rail to the rear of the tram rub rail on the left side (scrubber exhaust side) after pulling the two rub rail pins.

2. VIEW B -Remove the hydraulic pump - follow that procedure.

3. VIEW C -Remove the capscrews (usually more than two each) that mount the pump stand to the frame.

4. VIEW D -Disconnect the two cooling water hoses from the fittings on the pump motor. Remove the fittings. Plug the hose ends and motors inlets to keep them clean. NOTE: The motor may need to be partially slid out to access the hoses and junction box.

5. VIEW D -Remove the four capscrews that hold the junction box cover and o-ring in place. This will permit access to the wiring connections.

6. VIEW E -Mark the three wires, strip off the insulation tape and disconnect the three power cable lugs from the three motor lugs.

7. VIEW F -Remove the capscrews holding the half moon clamp to the junction box. Slide the stuffing box out of the junction box.

8. VIEW G -Take care as the motor is slid out from the tractor frame on to blocking.

9. To install the pump motor - reverse the above procedure. Be sure to jog the motor on and off to determine correct rotation.

The following procedure involves disconnecting hydraulic hoses.

They can be under high pressure.

DANGER

NOTICE

C CAUTION

Take special care to prevent coal dust and mine dirt from getting into the hydraulic system when removing any hydraulic component.

Lower the gathering head and the cutter head to the floor. Lower the conveyor tail section. Remove and lock-out electrical power to the miner. Remember the pump motor is very heavy.

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© DBT AMERICA 2005

hydraulic pump motor installation / removal See figure—13

__________________________________________________ Operation conveyor assembly installation / removal See figures 38 & 39

1. VIEW A -Position the conveyor tail section level with the floor and straight. Advance the conveyor chain until a connecting link moves onto the tail section slide pan.

© DBT AMERICA 2005

2. VIEW B - Using the procedure outlined in CHAIN TENSION, loosen the conveyor chain as much as possible.

3. VIEW C - Remove the two retaining rings and the connecting link.

4. VIEW D - Connect a wire rope to the bottom side of the conveyor chain. Note, this rope will assist in threading the chain through the new conveyor assembly.

5. Connect electrical power to the miner.

6. Raise the conveyor tail section and remove the blocking.

7. VIEW E - Move a shuttle car or scoop directly behind the miner and under the conveyor tail section. Lower the conveyor tail section and secure it to the vehicle.

8. Follow the procedure outlined in LIFT CYLINDER, to detach the rod ends of the lift cylinders from the tail section.

9. VIEW F -Locate the right conveyor pivot pin at the front of the conveyor assembly. Remove the grease hose.

10. VIEW G -Remove the two capscrews that secure the retaining plate to the conveyor.

11. VIEW G - Using the slide hammer with a 1”-8 adapter pull the conveyor pin.

12. Repeat Steps 9, 10 and 11 to remove the left conveyor pivot pin.

13. VIEW H - The conveyor assembly is now free and can be removed.

Slowly tram the vehicle and conveyor assembly away from the miner. Make sure that the conveyor chain and the guide rope smoothly slide out of the conveyor’s return slide channel.

14. Installation of the new conveyor assembly is basically the reverse of the above removal procedure.

15. VIEW I - While moving the new conveyor assembly forward into position, use the guide ropes to pull the conveyor chain through the return slide channel and up the bed of the new conveyor assembly.

16. After complete installation, follow the procedure in CHAIN TENSION to adjust the chain tension and check out operation of the new conveyor assembly.

C CAUTION

Lower the gathering head and the cutter head to the floor. Block up the conveyor tail section. Remove and lock-out electrical power to the miner.

Never work under any raised assembly without proper blocking.

DANGER

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Operation ____________________________________________________

C CAUTION

1. Position the conveyor tail section straight behind the miner.

2. VIEW A - Remove the rod end pin. The rod end of the cylinder should now be disconnected.

3. Connect electric power to the miner.

4. Completely retract the swing cylinder. The rod end bearing of the cylinder should retract from the clevis.

5. 2 6. Move the swing cylinder control valve lever up and down to release any cylinder pressure.

7. VIEW A -Mark and then disconnect the hydraulic hoses from the swing cylinder’s fittings. Plug the hose ends to keep them clean.

Remove the hydraulic fittings from the cylinder and store in a clean place.

8. VIEW A -Remove the piston end retainer pin. A hammer and punch may be needed to remove both the capscrew and the retaining pin. Removal is now complete.

9. To install the swing cylinder - reverse the above procedure.

Lower gathering head and cutter head to the floor. Then lower the conveyor tail section level with the floor and block it up. Remove and lock-out electrical power to the miner. Remove and lock-out electrical power to the miner.

Never work under any raised assembly without proper blocking.

The swing cylinder is very heavy be ready to support it.

DANGER

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swing cylinder installation / removal See figure—40

__________________________________________________ Operation swivel pin installation / removal See figure—41

1. The conveyor chain must be broken apart for access to the swivel pins. VIEW A Advance the conveyor chain until a connecting link moves onto the conveyor tail section slide pan. Swing the tail section straight..

2. Using the procedure in CHAIN TENSION, loosen the conveyor chain.

3. VIEW B - Remove the retaining pin from the chain connecting link and remove the connecting link. The conveyor chain should now be separated and there is access to the swivel pin.

4. VIEW C - Remove the six capscrews from the upper swivel pin.

5. VIEW D - Remove the center setscrew from the upper swivel pin.

6. VIEW D -Use the slide hammer with a 5/8”-11 adapter and remove the upper swivel pin.

7. VIEW E - Follow the same procedure to remove the lower swivel pin.

8. VIEW F - Reach into the conveyor chain return channel and retrieve both upper and lower swivel pin retainers. Removal is complete.

9. To install the swivel pin - reverse the above procedure.

© DBT AMERICA 2005

C CAUTION

Lower the gathering head and cutter head to the floor. Lower the conveyor tail section level with the floor and block it up. Remove and lock-out electrical power to the miner.

Never work under any raised assembly without proper blocking.

DANGER

______________________________________________________________ DBT – 25M SERIES CONTINUOUS MINER © VUVR / 03 5.39

Operation ____________________________________________________ tail roller installation / removal See figure—42

1. VIEW A - Advance the conveyor chain until a connecting link moves onto to the conveyor tail section slide pan.

2. VIEW B - Using the procedure outlined in CHAIN TENSION, loosen the conveyor chain as much as possible.

3. VIEW C - Remove the retaining rings from the connecting link and remove the connecting link. The conveyor chain should now be separated.

4. Move the chain out of the way of the tail roller.

5. VIEW D - Remove the two capscrews that secure the tail roller to the slide pan. The tail roller assembly can now be removed.

6. To install the tail roller assembly - reverse the above procedure.

C CAUTION

LOWER THE GATHERING HEAD AND THE CUTTER HEAD TO THE FLOOR. LOWER THE CONVEYOR TAIL SECTION LEVEL WITH THE FLOOR AND BLOCK IT UP. KEEP THE BLOCKING CLEAR OF THE TAIL ROLLER. REMOVE AND LOCK-OUT ELECTRICAL POWER TO THE MINER. NEVER WORK UNDER ANY RAISED ASSEMBLY WITHOUT PROPER BLOCKING.

tail shim adjustment See figure—43

As the conveyor wears the tail section may sag relative to the conveyor front section. The conveyor has been designed to allow correction of the sag by adding shims.

1. Position the conveyor tail section straight and raise it so the rear end of the tail section is slightly higher than the front end.

2. VIEW A - Place blocking between the tractor frame and the bottom of the conveyor front section leaving a 2” gap.

3. VIEW B - Loosen the seven capscrews that secure the shims between the shim retainer and the conveyor lower pivot plate.

4. Connect electrical power to the miner.

5. VIEW C & VIEW D - Lower the conveyor until the conveyor front section rests on the tractor frame blocking which removes the 2” gap. The slotted shims should fall out.

6. VIEW E - Replace and add shims to align the conveyor tail section with the front section. Tighten the shim retainer.

7. Connect electrical power to the miner. Remove the blocking and check the adjustment.

C CAUTION

LOWER THE GATHERING HEAD AND THE CUTTER HEAD TO THE FLOOR. BLOCK UP THE CONVEYOR TAIL SECTION. REMOVE AND LOCK-OUT ELECTRICAL POWER TO THE MINER. NEVER WORK UNDER ANY RAISED ASSEMBLY WITHOUT PROPER BLOCKING. WATCH OUT FOR FALLING SHIMS.

DANGER

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DANGER

__________________________________________________ Operation lift cylinder installation / removal See figure—44

For lift cylinders side mounted.- see VIEW A For lift cylinders mounted under the conveyor - see VIEW E

© DBT AMERICA 2005

1. Move the conveyor lift cylinder control valve up and down to release any pressure in the cylinder.

2. Remove the over-center valve. The over-center valve is a cartridge valve mounted on the cylinder.

3. Disconnect the cylinder’s rod end: VIEW B - At the upper clevis, remove the capscrew that passes through the bearing pin and remove the bearing pin. VIEW F - At the upper clevis, remove the cotter pin and the upper pin.

4. Remove and plug the two hydraulic hoses from the lift cylinder.

5. For bottom clevis mounting: VIEW C - Remove the two capscrews, locking plate and the lower pin. VIEW G - Remove the cotter pin and lower pin.

6. For bottom pedestal mounting, see VIEW D - Remove the two lift jack retainer capscrews and the retainer. Note the capscrew nuts will fall free under the miner’s tractor frame; be prepared to retrieve them. Slide the cylinder’s square mounting out of the miner frame.

7. The lift cylinder can now be removed.

8. To install the lift cylinder - reverse the above procedure. Do not remove the over-center valve from the replacement cylinder.

Connect power to the miner to hydraulically extend the cylinder to connect the rod end.

C CAUTION

Lower the gathering head and the cutter head to the floor. Raise the conveyor tail section to its highest point. Place blocking between the conveyor and the tractor frame. Block up the conveyor tail section and remove and lock-out electrical power to the miner.

Never work under any raised assembly without proper blocking.

DANGER

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Operation ____________________________________________________ chain installation removal See figure—45

1. VIEW A -Advance the conveyor chain until a connecting link moves onto the conveyor tail section slide pan. Swing the tail section straight from the miner.

C CAUTION

chain tension adjustment See figure—46

Lower the gathering head and the cutter head to the floor. Lower the conveyor tail section fully. Remove and lock-out electrical power to the miner

1. Position the conveyor tail section level with the floor and straight.

For Screw Take-up: 2. VIEW A - On the side of the conveyor loosen ( but do not remove ) the two bolts that secure the split block to the take-up rod. Repeat this step on the other side.

3. VIEW B - Using a 3/4 “ allen wrench inserted in the take-up rod’s crank socket rotate clockwise to tighten or counterclockwise to loosen the chain. Alternately rotate left and right take-up rods until proper chain tension is reached.

4. VIEW A - When the proper tension is reached, tighten the split blocks to the take-up rods which were loosen in Step 1.

For Shim / Grease Take-up: 1. VIEW C - Pump grease into the take-up jack to extend the cylinder rod and remove pressure on the adjustment shims Repeat this step on the other side.

2. VIEW C - Alternately, left and right, add shims to increase chain tension or remove shims to decrease chain tension. An equal number of shims must be used on each side of the conveyor.

3. VIEW C - Once proper chain tension is achieved open the grease take-up valve and allow pressure to bleed from the cylinder.

Repeat for the other side.

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2. VIEW B - Using the procedure outlined in CHAIN TENSION, loosen the conveyor chain as much as possible.

3. VIEW C -Remove the retaining pins from the connecting link and remove the connecting link. The conveyor chain should now be separated.

4. VIEW D - Connect a towing vehicle to the old chain on the conveyor bed.

5. Connect the new chain to the end of the lower chain and allow the new chain to extend behind the miner on the floor.

6. VIEW E - Pull the old chain out of the miner. The new chain will follow the old through the conveyor return channel, around the footshaft sprocket, and out onto the conveyor tail section.

7. VIEW C -Connect the ends of the new chain with the connecting link and retaining rings.

8. Follow the procedure outlined in CHAIN TENSION to tension and check out the installation of the new chain.

__________________________________________________ Operation Checking For Proper Adjustment: 4. Connect electrical power to the miner.

5. Slowly raise the conveyor tail section and remove the blocking.

6. Start the conveyor / gathering head and observe the chain for proper tension. The conveyor chain should rise about 2” or less above the gathering head’s footshaft sprocket as the chain emerges from under the conveyor pan. Check that there is no contact between the CLAs and the chain flights.

7. View D - Slowly swing the conveyor tail section from left to right behind the miner and check the chain tension. The chain tension decreases when the tail section moves away from center.

C

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CAUTION

Lower the gathering head and the cutter head to the floor. Block up the conveyor tail section. Remove and lock-out electrical power to the miner.

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Operation ____________________________________________________ scrubber system See figure—47

The Dash Series Miners have an optional dust scrubber system. The scrubber systems are designed for each of the different size miners.

However, the basic operation is the same: A fan motor is mounted on the miner connected by duct work to intakes close to the cutter drum. The fan creates a vacuum in the duct work which pulls the dusty air from the face. The air passes through a filter which is being sprayed by water to “scrub” the dust from the air. The air next passes through a mist eliminator to remove the water from the air. After the dry air passes through the fan it is exhausted to the rear of the miner. The dirty water from the screen filter runs down into a sump where the water is pumped out onto the conveyor.

The scrubber system must perform as designed. The maintenance of the scrubber system is very important.

Maintenance - At least once per production shift: 1. Clean filter screen 2. Flush out inlet duck work using access covers 3. Clean mist eliminator and sump Extremely dusty conditions will require more frequent cleaning.

Keep the fan motor in good running condition. Grease the fan motor every eighty shifts with high temperature lubricant.

The scrubber system performance specifications are given in the parts catalog furnished with each miner.

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The scrubber system helps clear the face so the miner operator can better see. The system is part of the ventilation system; it is used with both blowing and exhaust methods of face ventilation. Refer to the mine ventilation plans for proper scrubber application.

__________________________________________________ Operation scrubber cleaning See figure—48

C

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CAUTION

fan motor assembly See figure 49

C CAUTION

1. VIEW A - Insert a water hose in both the right and left scrubber air intakes at the front of the miner. Thoroughly flush each scrubber intake.

2. VIEW A - Remove the clean out covers and flush with water to remove any accumulated debris. Replace the covers.

3. VIEW B - Open the scrubber rub rail and remove mist eliminator cover.

4. VIEW C - Slide the filter screen out of its frame. Thoroughly rinse the filter screen and set it aside.

5. VIEW D - Slide the mist eliminator assembly out of its frame.

Thoroughly rinse the mist eliminator assembly and clean all the catch viens to maintain proper operation. Set it aside.

6. VIEW E - Remove the sump screen and clean out any accumulated debris. Thoroughly flush out the sump area.

7. Replace the scrubber parts - make sure the mist eliminator’s air flow arrow points toward the exhaust fan.

8. Replace the covers and close the rub rail. Cleaning is complete.

Lower the gathering head and the cutter head to the floor. Lower the conveyor assembly until it is level. Remove and lock-out electrical power to the miner.

1. VIEW A - Pull the rub rail pin and open the two rub rails at the scrubber and fan location at the left rear side of the miner.

2. VIEW B - Remove the rub rail hinge post.

3. VIEW C - Remove the fan motor’s junction box cover and o-ring.

4. VIEW D - Mark the motor leads and disconnect them.

5. VIEW E - Disconnect the stuffing box from the junction box and slide the stuffing box and three power cable leads out of the junction box. Replace the junction box cover.

6. Place blocking to support the fan motor assembly.

7. VIEW F - Remove the twelve capscrews that hold the fan motor assembly to the fan motor housing.

8. VIEW G - The scrubber fan motor assembly can be now be removed.

9. To install the fan motor assembly - reverse the above procedure.

Be sure to check for proper operation and motor rotation.

LOWER THE GATHERING HEAD AND THE CUTTER HEAD TO THE FLOOR. LOWER THE CONVEYOR TAIL SECTION. REMOVE AND LOCK-OUT ELECTRICAL POWER TO THE MINER. TAPE THE MOTOR CABLE LEADS IN CASE THERE W ILL BE ELECTRIC POW ER ON THE MINER.

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Operation ____________________________________________________ power schematic See figures 50, 51, 52, 56, 57 & 58

NOTICE

The Dash Series continuous miners all have the same basic electrical systems. Radio remote control is the standard method of operation.

The Electrical Schematic used in this manual to describe the various circuits is typical for a Dash Series miner; however, each individual miner may be different; always use the schematic in the miner’s parts catalog when troubleshooting.

In addition to the magnetic or fault trip, CB-1 also has a shunt trip.

When the shunt trip coil is energized it trips the breaker. This is used for radio E-Stop. CB-2 has an auxiliary contact, which, is connected in the control circuit and requires CB-2 to be closed as well as CB-1 to operate any of the motors.

NOTICE

Instead of a shunt trip coil tripping the main circuit breaker, some miners use a relay, OE, controlled by the radio E-Stop which has a normally closed contact in the ground wire monitoring circuit and trips the out-by circuit breaker.

Motor Overloads All of the motors have thermal overloads relays. They are designated OL-2, OL-4, OL6, OL-8, OL-10, OL-11, OL-12, and OL-13. They are bimetallic type, ambient compensated, monitoring motor currents in all three phases. The cutter motors units, OL-2 and OL-4 are driven by current transformers, CTs. Using CTs allow smaller current size overload relays to be used. The thermal overload relays have normally closed contacts wired in the control circuit, which open on a overload and stop the motor(s). The contacts will automatically reset after the thermal overload cools down. If another overload occurs right away then the overload relay will trip faster and the time to reset will be longer.

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Three phase power is connected to the miner through the Main Circuit Breaker (CB-1). When the main circuit breaker is open all power is off.

CB-1 has a magnetic trip unit to provide short circuit protection. This is too high to protect the smaller power cables so an Auxiliary Circuit Breaker (CB-2) with a lower magnetic trip setting is used. As an option, CB-1’s and CB-2’s operating handles are mechanically connected; they are operated together by a hydraulic cylinder remotely controlled.

However, each circuit breakers can “trip” independently.

__________________________________________________ Operation The cutter motors and the gathering head / conveyor motors are subject to starting under load, jam ups, and stalls.

Instantaneous overloads are used to detect those conditions and stop the motors. They are designated OL-1, OL-3, OL5, and OL-7.

While called “instantaneous” overloads the current sensing relays have an adjustable start-up delay after which they operate as soon as the motor current exceeds the preset level. The instantaneous overloads have normally open contacts in the motors’ control circuit which close when controlled voltage is applied. The instantaneous overloads protect the motors from stall currents and also help teach the miner operator how far he can “push” the miner for best production.

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Motor Control The two DC tram motors each have an SCR drive with solid state reversing. The schematic shows a circuit breaker, CB-T, for over current protection. Some miners may have fuses instead of the circuit breaker.

All of the Dash Series miners have a power transformer to reduce the three phase voltage to the SCR drives.

See figure—67 All of the motor contactors are vacuum type except for the scrubber fan motor, contactor E, which is a standard contactor. The pump motor contactor, F, also connects power to the tram. The gathering head / conveyor motors have forward and reverse contactors, CF and CR.

Cutter Motor Feedback The miner operator has control over the tram speed when the cutter motors are not running. The Dash Series miners have a feedback circuit from the cutter motors to the tram motors so that when the cutter motors are running the maximum forward tram speed is determined by the load on the cutter motors. This is accomplished by monitoring the phase current for one of the cutter motors and feeding this current level to the tram control circuit. The amount of phase current on a cutter motor is a measure of the load on the motor. When the current is low then the cutting work is low like during a place clean up and when the current is high then the cutting work is high like sumping into the face.

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Operation ____________________________________________________ By preventing a too fast sump speed the cutter motors will not stall and the crawlers will not break traction and spin. This feedback signal is from current transformer CT-3. Some miners may also have an external Feed Back switch, as shown, to allow easy adjustment of the feedback signal to accommodate various mine conditions, See CUTTER MOTOR FEEDBACK ADJUSTMENT.

control schematic See figure—53

Radio / Manual The Dash Series miners are radio remote control. Manual operation is not allowed for production operation unless the miner has an operator’s pit and canopy. Manual operation is for troubleshooting and maintenance under roof support.

Switch SW1 sections 1-2 and 5-6 selects 120v power to be connected to either, the manual push buttons or to the radio receiver. Section 7-8 of SW1 connects +24v power from the radio receiver power supply when in “radio”. SW1 removes manual control from the tram interface when radio control is selected.

SW2 connects motor control to the manual push buttons and isolates control from the radio receiver as shown. In the radio position SW2 isolates the push buttons and connects motor control to the radio receiver The Light Switch has three positions: manual, off, and radio. In the radio position the miner operator can turn the head lights on and off from the radio transmitter by controlling the HR relay.

tram dead man See figure—54

If there is an operator’s pit, the tram “deadman” is a foot operated control switch, which, must be held closed. This switch is on all the Dash Series miners and it is still called the foot switch even though it is a hand-operated push button on the operator’s control panel for miners without an operator’s pit.

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The operating controls are available either in radio remote control or in manual control. The control mode is selected by using three switches.

__________________________________________________ Operation Methane Monitor The methane monitor circuit will alert the miner operator via a signal light if methane gas is detected. If the methane level becomes high, the MMR contacts will open and shut down the miner, including area & headlights. There are several suppliers of methane monitors; refer to the parts book for complete wiring and to the monitor manufacturer’s manual for service information.

Low Oil Level The hydraulic tank float switch will energize the LOR relay and turn on the LOL signal light if the oil level becomes too low.

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e-stop bypass See figure—55

E - Stop Bypass The E-Stop Bypass circuit allows the operator, when using radio remote control, to bypass the emergency stop palm switch located on the left side of the miner for about 30 seconds. This is useful in cases where the miner has become jammed against a rib causing the normally closed E-Stop switch to be stuck open. The ESB relay contacts bypass the emergency stop push button.

Battery Back-up The radio receiver power supply has an optional battery back-up which provides control power to operate the solenoids for fire suppression and power to operate the shunt trip coil of the main circuit breaker. The battery back-up in conjunction with a hydraulic accumulator will allow control of those functions in the case of a power outage.

Scrubber Fan The manual start push button for the scrubber fan motor contactor, E, does not have a holding circuit. Therefore, when in manual control the fan motor and the scrubber spray will only operate as long as the push button is held. There is no manual stop push button.

For miners with an operator’s pit and canopy, there is a holding circuit for the scrubber fan motor contactor. The fan motor stops, after a short time delay, when the cutter motors are stopped.

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Operation ____________________________________________________ cutter motor feedback adjustment See figure—59

The tram motor speed voltages are limited in the forward direction when the cutter motors are running. How much the tram speed is limited is controlled by the load on the cutter motors. When the load is light as in a clean-up operation the tram speed is less limited that when there is high cutter motor loading as in a sumping operation.

The cutter motor loading is monitored by using a current transformer, CT3, in a phase lead.

This cutter motor feedback is connected to the tram interface to control the tram motor speed voltages. The “clean-up” and “sump” tram voltages are factory set. It may be necessary to adjust these voltages to suit the actual mining conditions.

DBT America has a current generator, which can be used to simulate the secondary current in the feedback current transformer, CT3. The current generator needs to be connected to 120 vac. This can be tapped at terminal numbers 14 and 79 on the tram interface terminal strip.

Remove the feedback wires number 196 and 197 from the tram interface terminal strip and connect the output of the current generator (flat cable) to the tram interface terminals 196 and 197. Be sure the power switch is off and the adjustable dial is set at zero.

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1. Open the tram case and access the traction case.

2. CURRENT GENERATOR

__________________________________________________ Operation 3. VOLT-OHM METER To check the left tram reference voltage > Connect VOM to tram interface terminal 41 pos. and D42 neg.

To check the right tram reference voltage > Connect VOM to tram interface terminal 51 pos. and D52 neg.

See figures—60, & 61

To check left armature voltage > Connect VOM to left SCR drive terminals A1 pos. and A2 neg.

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To check right armature voltage > Connect VOM to right SCR drive terminals A1 pos. and A2 neg.

4. Before setting the clean-up and sump tram reference voltages, made sure the maximum high tram reference voltage is at 2.5 VDC to 3.0 VDC. This voltage is a fixed internal design and is not field adjustable.

5. Notes: · C The left and right tram voltages must be adjusted separately.

C The pump motor must be running for all tests / adjustments.

C Always adjust clean-up voltage first.

C If the miner does not track properly after the voltages are correctly adjusted do not readjust the voltages. Look for excessive looseness of a crawler track, binding in the traction drive train, or even missing cutter bits or bit holders.

6. Setting the tram clean-up speed – C Apply 1.0 amp from the current generator to terminals #196 and #197 on the C tram interface.

C Move the tram control lever to full on forward.

C A VOM armature voltage reading of 200 to 225 VDC should be on the SCR drive terminals A1 - A2. Note - The reference voltage will be approximately 1.25VDC. C Adjust the clean-up voltage using the adjustment screws marked “C” on the tram interface. Set the left and right tram voltages the same.

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Operation ____________________________________________________ 7. Setting the sump speed – C Apply 4.5 amp from the current generator to terminals #196 and #197 on the

C tram interface.

C Move the tram control lever to full on forward.

C A VOM armature voltage reading of 90 to 100 VDC should be on the SCR C drive terminals A1 - A2.

radio remote control See figures—62, 70 & 71

8. Reconnect the cutter motor feedback wires to the tram interface terminals #196 and #197. Reconnect tram control wires to the tram interface terminals and #51.

System Overview The radio remote control system consists of a battery powered portable transmitter, which, sends UHF radio signals to the miner. The encoded control signals, from the transmitter, are decoded by the radio receiver unit located in the main controller case. The transmitter has a built-in antenna while the receiver, located in the explosion proof main controller, has a external antenna.

See figure—69

Receiver , Power Supply, and Module Traction Case The receiver responds to the control signals from the transmitter and activates the machine functions. The radio receiver power supply provides 110 VDC for the solenoids to control the hydraulic valves and 24 VDC for the radio traction module which provides tram direction and speed radio signals to the tram interface. Receiver outputs also control the 120 vac machine circuits.

An optional battery back-up to the power supply will provide power to operate the fire suppression solenoid and the E-Stop in case of a power outage.

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NOTICE

The reference voltage will be approximately 0.55 VDC. · Adjust the sump voltage using the adjustment screws marked “S” on the tram interface. Set the left and right tram voltages the same.

__________________________________________________ Operation See figure—63

Diagnostic Display The radio system has a diagnostic display on the miner in an explosion proof enclosure, which, can be seen at the right rear of the miner. This display comes in very handy for troubleshooting. Refer to the separate radio manual for complete use of the diagnostic display.

See figures—64 & 65

Transmitter The radio transmitter has a rechargeable battery, which has a recharge socket for connection to the out-by battery charger. The complete transmitter unit is changed out each shift. The transmitter panel has switches or “keys” for all of the miner functions.

Battery Charger

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See figure—66 The complete system includes a battery charger which is used to recharge the transmitter battery. This unit is usually located above ground. Four transmitter units can be recharged at the same time. A built-in radio receiver and screen will allow the transmitter to be tested before use underground.

PERMISSIBILITY The Dash Series Miners for use in the United States are designed and built to be MSHA (Mine Safety and Health Administration) “Permissible”, that is, the electrical system uses MSHA certified explosion proof enclosures and MSHA approved intrinsically safe circuits.

All of the electrical circuit components are located within explosion proof enclosures except - the radio remote control transmitter, the radio receiving antenna, the manual tram control switches, the low oil level float switch, and the methane monitor.

A permissible explosion proof enclosure will prevent an explosion inside the enclosure from causing ignition of a methane-air atmosphere or a coal dust layer outside the enclosure.

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Operation ____________________________________________________ The electrical circuit components not located within an explosion proof enclosure are intrinsically safe circuits.

A permissible intrinsically safe circuit (ISC) is incapable of producing a spark or thermal effect, under the approval criteria, which would cause an ignition of a methane-air atmosphere or a coal dust layer.

Insuring the miner is “PERMISSIBLE” and safe is the most important maintenance job.

Operating equipment must be maintained by a “Qualified Person” as defined in Part 75, Title 30, of the Federal Code of Regulations.

TROUBLESHOOTING

DANGER

DBT America’s electrical drawings supplied with each miner’s parts book include a circuit schematic along with a wiring diagram. These two drawings types compliment each other. Use the schematic to understand how the circuit works while using the wiring diagram to locate the wired devices and components.

Dual Systems Take advantage of the miner’s “dual” systems - two cutter head motors, two conveyor / gathering head motors, and two tram motors.

Remember the two cutter head motors and the two gathering head motors share their common loads. The “hot” motor may not be the problem but is simply doing more than its share of the work. The left and right tram drives and motors are independent when the tracks are off of the ground. But when tramming there is a certain amount of sharing since they are moving the same load.

Take and note ammeter readings and voltmeter readings when there are no problems for comparison later when there is a problem.

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Only qualified technicians should troubleshoot the electrical systems. Touching or shorting energized components can cause serious injury or death.

__________________________________________________ Operation Of course the dual control modes, manual and radio remote, will allow you to quickly close in on a problem area. For example if you can raise the conveyor tail assembly manually but not by radio then the problem is not the conveyor lift cylinder or the main hydraulic valve. The problem is either in the radio system or in the hydraulic pilot control such as the solenoid control valve.

Diagnostic Display Use the radio system diagnostic display at the right rear of the miner to check out the operation of the radio system and review stored fault messages

Component Change Out

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The tram drive system units and the radio system units are not field serviceable; they must be exchanged and returned for check out and repair.

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Operation ____________________________________________________

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6

Technical data

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_____________________________________________________________

______________________________________________ Technical data This section contains drawings and illustrations of items referenced in the previous section.

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References can be established between Section 5 and Section 6.

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Technical data ________________________________________________

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tractor frame assemblies— figure-1

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tractor frame—tractor motor figure 2

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tram preliminary planetary gear figure-3

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tram secondary planetary gear Figure 4

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tram case—page 1 of 2 Figure—5

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tram case—page 2 of 2 Figure—6

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stabilizing cylinder Figure—7

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tram sprocket—figure—8

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tram track adjustment figure—9

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tram track from idler—figure—10

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front idler take-up jack figure—11

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hydraulic pump figure—12

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hydraulic pump motor figure—13

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gathering head—figure—14

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gathering head assembly figure - 15

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gathering head CLA installation / removal Figure—16

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Technical data ________________________________________________

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gathering head motor installation /removal—figure—17

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gathering head foot shaft installation / removal—figure—18

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foot shaft assembly—figure—19

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gathering head gear case Installation / removal—figure—20

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Technical data ________________________________________________

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gathering head gear case assembly Figure—21

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gathering head gear case assembly Figure—22

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gathering head lift cylinder Installation / removal Figure—23

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cutter head assemblies figure—24

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cutter head boom assemblies Figure—25

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Cutter head dash-0, 1, 2 boom pivot pin Figure 26

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Technical data ________________________________________________

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Cutter head dash-3 boom pivot pin Figure—27

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cutter head dash-2, 3 drum drive torque Limiting clutch Figure—28

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Technical data ________________________________________________

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cutter head dash-2, 3 drum drive motor Figure 29

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cutter head dash-0, 1 drum drive motor Figure—30

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Technical data ________________________________________________

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Cutter head dash-0, 1, 2 shear cylinder Figure—32

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Cutter head dash-3 shear cylinder Figure—33

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cutter boom dash-0 cutter drums Figure—34

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cutter boom dash-1 cutter drums Figure—35

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cutter boom dash-2 cutter drums Figure—36

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cutter boom dash-3 cutter drums Figure—37

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Conveyor—Figure 38

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conveyor—figure 39

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Swing cylinder—figure—40

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swivel pin—figure—41

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tail roller—figure—42

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tail shim—figure—43

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© DBT AMERICA 2005

Technical data ________________________________________________

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_________________________________________________ Our service

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service addresses

If you need to order spare parts, or if technical problems occur, please contact our after-sales service personnel or contact us directly.

DBT America (Corporate Headquarters & manufacturing Facility) 2045 West Pike Street Houston, PA 15342-1010 Telephone (724) 743-1200 FAX (724) 743-1201

© DBT AMERICA 2005

DBT America (Warehouse Facility) 2301 West Pike Street Houston, PA 15342 Telephone (866) 825-4606 (after hours number) FAX (724) 743-1521 DBT America (Rebuild and Service Facility) Berry Road Washington, PA 15301 Telephone (724) 743-1200 FAX (724) 743-1201 DBT America (Manufacturing Facility) Pulaski, VA Telephone (540) 980-4530 FAX (540) 980-6211 Internet: http://www.dbt.com

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Forced Potato Simpson Remote Control System (DBT 25M Miner Version)

Operator’s Manual Issue: FA1901.B

Forced Potato Mining Electronics

Contents Contents ...............................................................................................2 (1) Preface ............................................................................................4 (2) Introduction......................................................................................5 (3) Safety Notice ...................................................................................6 (4) System Information .........................................................................7 (5) Explanation of Terms ......................................................................8 (6) Overview of Remote Equipment .....................................................9 (7) System Control Modes ..................................................................12 Manual Mode...............................................................................12 Remote Mode ..............................................................................13 (8) Remote Control Console...............................................................14 TITO Remote Console Diagnostic Messages .............................15 Charging the Remote Control Console (TITO)............................16 Cleaning the Remote Control Console (TITO) ............................19 (9) Using the Remote Control.............................................................21 Remote Console – Power On......................................................22 Remote Console – Power Off......................................................22 Remote Console – Emergency Stop ...........................................22 Remote Console – Fire Suppression ..........................................23 Remote Console – Pump Motor Control .....................................24 Remote Console – Cutter Motors Control ...................................25 Remote Console – Conveyor Motors Control .............................26 Remote Console – Fan Motor Control ........................................27 Remote Console – Cutter Boom Raise/Lower ............................28 Remote Console – Gathering Pan Raise/Lower .........................28 Remote Console – Stabilizer Jack Raise/Lower .........................29 Remote Console – Conveyor Boom Control ...............................30 Remote Console – Water Sprays Control ...................................31 Remote Console – Head Lights Control......................................31 Remote Console – Tram Enable .................................................32 Remote Console – Tram Track Control ......................................32 Remote Console – Tram Speed Control .....................................33 (10) Advanced Remote Features .......................................................34 Remote Console – Machine E-Stop Bypass ...............................34 Remote Console – Breaker On and Off ......................................36 Remote Console – Auxiliary Outputs ..........................................38

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Forced Potato Mining Electronics (11) Automatic and Special Features .................................................39 Automatic Scrubber Fan Control .................................................39 Fan Before Cutter Option ............................................................40 Pennsylvania Scrubber Fan Requirements.................................40 Methane Monitor Override Option ...............................................41 (12) Main Diagnostic Screen ..............................................................42 (13) System Menu ..............................................................................43 To Enter the System Menu..........................................................43 To Return to REMOTE MODE ....................................................43 Moving Around in the System Menu ...........................................44 System Menu Pages and Options...............................................45 (14) Setting the Time and Date ..........................................................46 (15) Checking Module Temperatures .................................................47 Viewing Module Temperatures....................................................47 How to Reset Temperature Monitors ..........................................48 (16) Testing Machine Solenoids .........................................................49 (17) User Setup Options .....................................................................50 (18) Engineering Setup Options .........................................................52 Restore Default Settings .............................................................61 (19) Fault Log .....................................................................................62 To Enter the Fault Log.................................................................62 To Move Around the Fault Log....................................................62 Seeing More Information About a Fault ......................................63 Clearing the Fault Log .................................................................64 (20) System Fault Messages..............................................................65 (21) Control System Pin Outs.............................................................68 Simpson Receiver Control Unit Connector X1 – 35 Pin Burndy Female ...........68 Simpson Receiver Control Unit Connector X2 – 19 Pin Burndy Female ...........69 Simpson Receiver Control Unit Connector X3 – V35 Burndy (34 Pin Female) ...70 Simpson Battery Backup Power Supply Connector X5 – 8 Pin Burndy Female .71 Simpson Battery Backup Power Supply Connector X6 – 8 Pin Burndy Male .....71 Simpson Display Unit Terminal Connections J3, J4....................................71 Simpson Traction Unit Connector X10 – GAPL26 26 Pin Male ......................72

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(1) Preface This document is intended as an operator’s reference to the Simpson Remote Control System (DBT 25M Miner Version). This version of the Simpson RCS (Remote Control System) is integrated into the electrical system of DBT 25M Continuous Miners and is used to provide radio remote control and monitoring of the machine.

Forced Potato Incorporated 640 Bizzell Drive Lexington KY 40510 Telephone: +1 859 252 4439 Fax: +1 859 252 4641 Web: www.forcedpotato.com © Forced Potato Inc.

Other than is permitted by law, no part of this document may be reproduced, stored in a retrieval system or transmitted in any form or process without prior written consent of Forced Potato Incorporated.

Every effort has been made to ensure the accuracy and correctness of the information presented within this document. However, Forced Potato does not provide guarantee of its correctness or accuracy.

Other than is required by law, no warranty of any kind is expressed or implied.

Copies of this manual, and other documentation pertaining to Forced Potato control system products, may be obtained by contacting Forced Potato directly.

For all matters involving servicing or purchase of Simpson RCS (DBT 25M Miner Version) control system components, please contact your DBT representative or local DBT service center.

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(2) Introduction The Simpson Remote Control System (DBT 25M Miner Version) is a dependable and high-speed radio remote control and monitoring system developed for DBT 25M series continuous miners.

The system is installed in the electrical system of a 25M continuous miner and allows an operator to remotely control machine operation from a safe distance using a radio remote control console.

This manual provides basic information and user instructions for the system. This control system was first fitted to 25M machines in 1998.

Since that time the system has undergone a number of software revisions to improve performance and to provide additional automation features. Each new revision of software is accompanied by a different part number of receiver control unit.

This manual only pertains to the following model of receiver control unit:

DBT Receiver Part Number: 305242 Forced Potato Part Number: L0FA1901 Software Revision: DBT 25M Revision 4.23 If this manual does not correspond to your model of receiver control unit, please contact Forced Potato immediately to obtain a copy of the correct publication.

Please contact your local DBT America representative or service center to obtain service or replacement parts for the control system.

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(3) Safety Notice The advent of remote control has afforded the operator a notable improvement in personal safety. However, the potential for injury or fatality still exists when operating heavy machinery remotely.

Thus, it is expressly important that the operator observe safe work practice when operating a remote control mining machine. This will be defined by mine and company management and should encompass any relevant state and federal regulations and/or guidelines where applicable.

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(4) System Information System Name Software Name Last S/W Rev.* Receiver Part Number

Simpson RCS (DBT 25M Miner Version) DBT 25M Simpson DBT 25M Revision: 4.23 Forced Potato P/N: L0FA1901 DBT P/N: 305242

For exact details on machine wiring configuration please consult the electrical schematic that pertains to your particular miner.

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(5) Explanation of Terms Simpson RCS (DBT 25M Miner Version)

Name given to the remote control system and all its components.

Receiver Control Unit

Main control unit of the control system that includes the radio data receiver used to receive and decode commands from the remote control handset

Remote Control Handset

Handheld controller that an operator would typically use to control the machine at a distance.

Also known as the “Remote Control Console”, “Remote Box” or “Transmitter”

Remote Mode

Mode of operation where the control system is in control of the machine and can be operated at a distance using the remote control handset.

Manual Mode

Mode of operation where “hardwired” switches, buttons and hydraulic levers on the miner are used to control the machine. In this mode all power is usually removed from the Simpson control system.

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(6) Overview of Remote Equipment “TITO” (Remote Control Console)

“BRICK” (Remote Control Console)

“LARGE BRICK” (Remote Control Console)

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“Receiver” (Integrated radio control receiver and machine control unit)

“Standard Power Supply” (no battery backup)

“Battery Backup Power Supply” (automatic battery backup)

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“Traction Unit” (controls machine tramming)

“Miner Display” (Miner Diagnostic Display)

“Antenna” (Standard Radio Data Antenna)

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(7) System Control Modes The Simpson RCS (DBT 25M Miner Version) is designed to operate in one of two modes:

(1) Machined-based Manual Control Mode (Manual Mode) (2) Radio Remote Control Mode (Remote Mode) Typically, the 25M continuous miner features a pair of remote/manual selector switches that the operator may use to switch between the two control modes at any time.

Manual Mode Normally, when the remote/manual selector switches on the miner are in the MANUAL position, all power is removed from the remote control system. In this case, the control system diagnostic display will be blank.

In MANUAL MODE machine control is achieved using hard-wired control buttons and hydraulic levers. Control buttons mounted on the front panel of the operator’s electrical enclosure are used to start and stop all machine motors. When the pump is running, manual levers mounted on the main hydraulic valve bank are used to operate hydraulic functions on the machine.

The Simpson RCS (DBT 25M Miner Version) is isolated in Manual Mode and normally has no control or effect on manual control functions or operations.

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Remote Mode When the remote/manual selector switches on the 25M miner are in the REMOTE position, the system will assume the REMOTE MODE of operation.

In REMOTE MODE, the Simpson RCS (DBT 25M Miner Version) is in control of machine motors and hydraulic functions. The operator uses a remote control handset to operate the machine at a distance. This is the typical mode of operation and is normally used when the machine is used in a production situation.

Currently, there are several different models of remote control handset that can be used to operate the system in REMOTE MODE. The TITO model handset (DBT P/N: 312982) is the latest model of remote control console. The machine can be operated in the same fashion with earlier model handsets also.

In REMOTE MODE, the diagnostic display will be active and should appear as follows:

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(8) Remote Control Console A remote control console (or handset) is used by the operator to remotely control the miner at a distance in REMOTE MODE. The Simpson RCS (DBT 25M Miner Version) can be controlled with several different models of remote control handset. Forced Potato recommends use of the latest model handsets – known as TITO. The TITO model handsets offer improved battery life, additional safety features and enhanced diagnostics. TITO handsets also comply with the latest MSHA recommendations for continuous miner remote control safety (as outlined in MSHA Program Information Bulletin PIB P03-3).

Available handsets that can be used with the Simpson RCS (DBT 25M Miner Version) include:

DBT P/N

FP P/N

Description

312982 322394

L0KN2601 L0KN5301

295490 313808

L06K0602 L06K0701

295502 295472

L0KC0101 L0KG0101

TITO Remote Handset TITO Remote Handset (Reversed Function Version) BRICK Remote Handset BRICK Remote Handset (Reversed Function Version) Large BRICK Remote Handset BRICK Remote Handset* (Caplamp Battery Version)

* Not approved for use in underground coal mines Control switches on each model of remote are generally identical (except for reverse function versions where hydraulic function directions are reversed). This manual will explain machine operation based on the TITO L0KN26 model handset. Please contact Forced Potato or DBT if you require more information on an earlier model of handset.

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TITO Remote Console Diagnostic Messages TITO model handset feature a built-in diagnostic screen on the radio remote console that provides the operator with useful diagnostic messages. Note that these messages are only available on TITO model remote handsets.

Earlier model handsets do not feature a built-in diagnostic display.

Message UHF1, UHF2, UHF3, UHF4

Meaning Operating on Frequency 1,2,3 and 4

ON

Power is ON

ON ! (Flashing)

Power is ON and a switch on the console is currently pressed.

OFF

Powering down whilst issuing PUMP OFF command.

STOP

Radio Stop Activated

TILT

The RC’s angle of inclination is beyond 45° relative to horizontal. The STOP command is issued continuously until the unit is righted.

(Must be enabled using setup mode) The internal battery is low with and expected remaining operating time of approximately 30 minutes.

Indicating possible service requirements, a fault condition has been detected.

LOW (Flashing)

SERV

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Charging the Remote Control Console (TITO) The TITO remote console contains an internal battery that allows up to 20 hours of continuous operation. The internal battery can be recharged using the Battery Charger. Recharge times for the unit are typically 1-4 hours; depending on the remaining charge in the battery.

(1) (2) (3) (4) (5) (6)

Plug one of the 4 Charging Cables into the Transmitter.

Red and Green Lights will flash for a few moments.

Charger will begin charging.

While charging is in progress, the red light will be on When charging is complete the green light will come on During charging, the screen shows how long each transmitter has been on charge.

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Be Careful Plugging in the Remote Console

(1) (2) (3) (4)

Look at the socket on the transmitter and the charging plug Ensure that the socket and plug are free from dirt and coal.

Line up the plug so that it slides gently into the socket Push gently until you feel or hear the plug “click” into the socket.

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Be Careful Unplugging the Remote Console

(1) (2) (3) (4)

Hold the outside tube of the plug firmly.

The tube should be slightly loose.

Pull backwards on the tube so it slides outwards from the transmitter.

The Plug should release itself from the transmitter.

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Cleaning the Remote Control Console (TITO) The TITO remote console is designed for long-term use in harsh underground mining environments. As such, the unit is totally selfcontained and requires very little routine maintenance. To extend the service life of the control switches and ensure that switches remain free of mud and debris, regular cleaning of the switch plate is recommended.

Typically the cleaning procedure should be observed once every 2 weeks or as often as required.

Step (1) – TITO Disassembly • • • • •

Remove the M3 bolts.

Remove the switch guard.

Remove the switch caps.

Remove the comfort knobs by loosening the grub screw.

Remove the engraved plate.

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Step (2) – TITO Cleaning • • •

•

Expunge heavy debris from the switch assembly with a Soft Bristle Cleaning Brush.

Wash the transmitter with warm soapy water.

Inspect the switch seals for signs of deterioration. Seals exhibiting wear require the equipment to be scheduled for factory service.

Note: these seals are the primary seal, a secondary seal within the switch itself and an internal neoprene seal operate as a barrier to moisture ingress.

Dry the transmitter with light compressed air or cloth.

Important Do not use caustic solvents or displacement solutions as this may cause premature seal failure.

Do not use metal implements to dig out coal, mud or soapstone that may be found in the charge receptacle.

Step (3) – TITO Reassembly • •

• • • • •

Ensure all switch seals are tight. If a seal appears loose, tighten the seal to the recommended torque of 2.5Nm. Ensure all switch plate M2 bolts are tight. If an M2 bolt appears loose, tighten the bolt to the recommended torque of 1.5Nm. Do NOT over tighten these bolts as this may break the enclosure seal.

Install the engraved plate.

Install the comfort knobs as depicted. Tighten the grub screw to the recommended torque of 2.5Nm. Install the switch caps Install the switch guard. Tighten the switch guard M3 bolts to the recommended torque of 2.5Nm. After reassembly, test the unit on the Remote Control Battery Charger

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(9) Using the Remote Control

Single Key Functions Functions activated by a single key press.

Two Key Functions Functions marked in “[]” brackets require the [SHIFT] key also be used to operate that function.

Motor starts are generally Two Key Functions for added safety.

Pump Motor Start Two Key Function. Pump Motor must be started before other motors, tramming or hydraulics can be controlled.

Hydraulics Single Key Functions control hydraulic cylinders on the Miner.

Tramming Transmitter provides 3 tram speeds. Speed selected by pressing [TRAM 2-3] whilst tramming levers are engaged and the machine is tramming.

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Remote Console – Power On (1) Press and hold the ON key forward for 1 second.

(2) The console display should read HOLD. (3) Release the key and the display should show ON.

"

Remote Console – Power Off (1) Move the ON/OFF key to the OFF position.

(2) The console display will show the OFF message for a moment.

(3) The console will then turn itself off.

#

Remote Console – Emergency Stop (1) The Radio Emergency Stop will quickly shutdown all motors and functions on the miner.

(2) At any time, press the STOP key down towards the top of the console panel.

(3) The console will send the stop command and then turn itself off.

(4) The STOP key must be reset – by rotating the button clockwise – before the handset can be turned on again.

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Remote Console – Fire Suppression The control system uses a solenoid output to drive a fire suppression system on the continuous miner. The fire suppression can be activated at any time from the remote control console. If the machine is fitted with the battery backup version of power supply, the fire suppression can also be activated in BATTERY STANDY MODE. The system remains in BATTERY STANDBY MODE at least 10 minutes after the loss of mains power to the machine.

(1) The Fire Suppression System can be engaged at any time.

(2) Press the [SHIFT] key and the [FIRE] key together.

(3) Continue to assert the [SHIFT] key and the [FIRE] key for a full 2 seconds.

(4) After 2 seconds, the fire suppression system will activate. At this time, the [SHIFT] and [FIRE] keys can be released.

"&

#

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Remote Console – Pump Motor Control Starting the Pump Motor (1) Ensure that the console is on.

(2) Press [SHIFT] and wait ¼ second.

(3) Press PUMP [ON] while [SHIFT] is also pressed.

(4) Keep the keys asserted for a few moments.

(5) After a few moments the pump motor will start.

(7) Release PUMP [ON] first. This is important. If [SHIFT] is released first the pump is shutdown.

(8) Then release [SHIFT].

(9) Pump should continue to run normally.

"&

"

Stopping the Pump Motor (1) Pump is running normally.

(2) Press and hold PUMP OFF. (3) The Pump Motor should shut down immediately.

(4) Release PUMP OFF.

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Remote Console – Cutter Motors Control Starting the Cutter Motors (1) Ensure that the pump motor is first running normally.

(2) Press [SHIFT] and wait ¼ second.

(3) Press CUTTER [ON] while [SHIFT] is also pressed.

(4) Keep the keys asserted for a few moments.

(5) After a few moments the cutter motors will start.

(7) Release CUTTER [ON] first. This is important. If [SHIFT] is released first the cutters are shutdown.

(8) Then release [SHIFT].

(9) Cutter motors should continue to run normally.

"

&

#

Stopping the Cutter Motors (1) Cutters are running normally.

(2) Press and hold CUTTER OFF. (3) The Cutter Motors should shut down immediately.

(4) Release CUTTER OFF.

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Remote Console – Conveyor Motors Control Starting the Conveyor Motors in Forward (1) Ensure that the pump motor is first running normally.

(2) Press [SHIFT] and wait ¼ second.

(3) Press CONV [ON] while [SHIFT] is also pressed.

(4) After a few moments the conveyor will start in forward.

(5) Release CONV [ON] first. Then release [SHIFT].

(6) Cutter motors should continue to run normally.

" &

"

Stopping the Conveyor Motors

"

(1) Conveyor is running in forward (2) Press and hold CONV OFF. (3) The Conveyor Motors should shut down immediately.

Running the Conveyor Motors in Reverse (Momentary Only) (1) Ensure that the pump motor is first running normally.

(2) Press [SHIFT] and wait ¼ second.

(3) Press [CONV REV] while [SHIFT] is also pressed.

(4) After a few moments the conveyor will start in reverse.

(5) The Conveyor will remain running in reverse until the [CONV REV] key or the [SHIFT] key is released.

" &

"

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Remote Console – Fan Motor Control Starting the Fan Motor (1) Ensure that the pump motor is first running normally.

(2) Press [SHIFT] and wait ¼ second.

(3) Press FAN [ON] while [SHIFT] is also pressed.

(4) Keep the keys asserted for a few moments.

(5) After a few moments the cutter motors will start.

(7) Release FAN [ON] first. This is important. If [SHIFT] is released first the fan is shutdown.

(8) Then release [SHIFT].

(9) Fan motor should continue to run normally.

"

&

#

Stopping the Fan Motor (1) Cutters are running normally.

(2) Press and hold FAN OFF. (3) The Fan Motor should shut down immediately.

(4) Release FAN OFF.

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Remote Console – Cutter Boom Raise/Lower The pump motor must be running in order to raise and lower the cutter boom.

Press SHEAR UP to move the Cutter Boom up. Shear Up Solenoid remains energized until key is released (unless height limiting is in force).

Press SHEAR DOWN to move the Cutter Boom down. Shear Down Solenoid remains energized until key is released.

Remote Console – Gathering Pan Raise/Lower The pump motor must be running to allow the gathering pan to be raised and lowered.

Press PAN UP to lift the gathering pan.

The Pan Up Solenoid remains energized until key is released.

Press PAN FLOAT to “float” the pan down.

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Remote Console – Stabilizer Jack Raise/Lower Remote control of the stabilizer jack requires that the pump motor be running.

Press STAB UP to lift the stabilizer jack.

The stabilizer jack solenoid will remain energized until the key is released.

Press STAB DWN to lower the stabilizer jack.

The down solenoid for the stabilizer remains on until the key is released.

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Remote Console – Conveyor Boom Control

The conveyor raise and lower and swing can only be controlled once the pump motor is started and running.

Press the CONVEYOR LEFT/RIGHT to the left to swing the conveyor tail to the left. The solenoid controlling the left conveyor swing will remain energized until the key is released.

Press the CONVEYOR LEFT/RIGHT to the right to swing the conveyor tail to the right. The conveyor right solenoid will remain on until the key is released.

Press the CONVEYOR DWN key to lower the conveyor boom. The solenoid for the conveyor lower function remains on until the key is released.

Press the CONVEYOR UP key to raise the conveyor boom. The conveyor up solenoid will stay on until the key is released.

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Remote Console – Water Sprays Control The control system has the possibility of turning cutter water sprays on and off from a key on the remote console.

However, this function is normally not available due to the wiring configuration of most miner electrical systems.

Check with DBT or mine staff if remote control of water sprays is a necessary requirement for your particular mining operation.

Press and release the WATER key to turn on or off the water sprays. Water sprays are typically turned on automatically when cutter motors are started.

Remote Console – Head Lights Control Head lights can be turned on and off from the remote console at any time that the system is in REMOTE MODE and the remote console is on, Press the [SHIFT] and [LIGHTS] keys together. The lights will turn on.

To turn off the lights press the [SHIFT] and [LIGHTS] keys together again.

" &

"

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Remote Console – Tram Enable Normally the pump motor must be running in order to control machine tramming.

To enable machine tramming the TRAM 2-3 key must be pressed and released. This enables the tram function. Once enabled, the tram levers can be used to drive left and right tramming tracks forwards and backwards. If the tram levers are released for a continuous period of 5 seconds, the tram becomes disabled again. To re-enable the tram function, the TRAM 2-3 key must be pressed and released again.

Remote Console – Tram Track Control Tram tracks on the machine can be moved forwards and backwards using the tram levers on the remote control console. Control of machine tramming is only possible once the pump motor is running and the tramming has been enabled (see above).

Press the LEFT FWD tram key to turn the left tramming track forwards.

Press the LEFT REV tram key to turn the left tramming track backwards.

Press the RIGHT FWD tram key to turn the right tramming track forwards.

Press the RIGHT REV tram key to turn the right tramming track backwards.

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Remote Console – Tram Speed Control The system allows the tramming to be driven in three discrete speeds (SPEED 1, SPEED 2 and SPEED 3).

SPEED 1 is the default tramming speed and is the slowest tramming speed.

By pressing the TRAM LEVERS and [TRAM 2-3] keys together the operator may move to SPEED 2 from SPEED 1. Once in SPEED 2, the operator can toggle between SPEED 2 and SPEED 3 using the TRAM LEVERS and [TRAM 2-3] keys together.

The following tramming configurations are enforced by the control system for safety reasons: • • •

Split Track Tramming is limited to SPEED 1 Single Track Tramming is normally limited to SPEED 1 It is possible to speed up a single track from SPEED 1 to SPEED2 providing that tramming is started in SPEED1

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(10) Advanced Remote Features Remote Console – Machine E-Stop Bypass A typical DBT 25M continuous miner is fitted with a “mushroom-style” emergency stop button on the left side of the machine. This button is normally used to shut down the machine in an emergency. In difficult mining conditions, it is possible for the left side of the machine to become jammed against the wall (rib) of the mine roadway. In these cases, the emergency stop button can be jammed in the “on” position by the wall, preventing the pump motor to be started on the machine.

To allow the machine to be started and moved away from the wall in such a scenario, the control system provides a special emergency stop bypass feature that can be activated from the remote control console. When activated, the bypass function affords the operator a 30-second window where the emergency stop button is bypassed and the pump motor can be started. During this window the operator is able to tram the machine away from the wall, allowing the emergency stop button on the machine to reset.

To activate the E-stop Bypass, press and hold the [SHIFT] and [BYPASS] keys together for a continuous 5 seconds.

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While the keys are held, the diagnostic display on the miner will show a “countdown timer”. The timer counts the 5-second period that the keys must be held in order for the bypass function to become enabled.

One the 5-second delay has passed, the system will enter the ESTOP BYPASS mode. The [SHIFT] and [BYPASS] keys can then be released. The screen will then show that the bypass is active and feature another countdown timer. In this case the timer counts down the 30 second window for which the bypass will remain active.

Once the 30-second window has expired, the bypass will again be disabled. The bypass mode can be activated again by pressing and holding the [SHIFT] and [BYPASS] keys again for 5 seconds.

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Remote Console – Breaker On and Off The control system allows the main circuit breaker on the miner to be turned on and off using the radio remote control console. This normally requires that a battery backup version of power supply be installed on the machine.

To turn off the breaker: Press and hold the [SHIFT] and [C.B. OFF] keys together for a 2 seconds.

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After 2 seconds, the breaker off solenoid will energise (turning off the machine circuit breaker)

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To turn on the breaker: It is essential that a battery backup version of the control system power supply be installed for this function to be available.

Typically, a hydraulic valve provides the mechanical force for the breaker mechanism. To allow this valve to be operated after loss of power a hydraulic accumulator is charged by the pump motor during normal “powered” operation of the machine. If the hydraulic accumulator is discharged then it will not be possible for the breaker to be turned on from the remote control transmitter.

Press and hold the [SHIFT] and [C.B. ON] keys together for a 2 seconds.

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After 2 seconds, the breaker on solenoid will energise (turning on the machine circuit breaker)

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Remote Console – Auxiliary Outputs The control system provides two independent auxiliary outputs that can be controlled from the remote control console and used for a number of different applications.

The outputs are controlled as a 2-key function on the remote console:

[SHIFT] and [AUX-1] Or [SHIFT] and [AUX-2]

These outputs can be configured to operate with or without interlocking from the pump motor. The outputs can also be configured to be latching or non-latching (momentary).

Please consult with mine management as to the application and control configuration of the outputs on your machine.

Note: The AUX-2 output may not be available on machines where the methane monitor override is supported. On these machines, the [AUX-2] function is used to activate the methane override system (See Section 11).

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(11) Automatic and Special Features The Simpson RCS (DBT 25M Miner Version) is fitted with a number of special and automatic functions. These special features either improve machine productivity or provide for compliance with special safety or statutory requirements.

! !

The control system provides for user configuration of different functions. It is important that operators are aware of which features are setup on the machine that they are using. Please contact mine management for more details as to the exact configuration of the machine you are using.

Automatic Scrubber Fan Control When enabled (See Section 18), the automatic scrubber fan option turns on the scrubber fan 3 seconds after the start of the cutter motors and turns the fan off 10 seconds after the cutters have been shut down.

Even if the automatic scrubber fan is enabled, the operator may still start and stop the fan at any time using the remote control console.

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Fan Before Cutter Option In certain cases, local statutory authorities or difficult mining conditions may require that the scrubber fan be started before the cutter motors are started.

To support these mining situations, the control system has a “Fan Before Cutter” option that can be enabled.

When this option is enabled (See Section 17), the control system will not allow the cutter motors to be started until the fan motor has been running for a full 3 seconds.

Pennsylvania Scrubber Fan Requirements In the state of Pennsylvania, it is typically a statutory requirement that the scrubber fan feature the following automatic operations: (1) Scrubber fan is started at least 3 seconds prior to cutter motors are started.

(2) Scrubber fan remains on at least 10 seconds after cutter motors are shut down.

To satisfy these automatic control requirements, two different setup options must be enabled in the Simpson RCS (DBT 25M Miner Version) setup. These options should be configured as follows:

Recommended Scrubber Fan Setup for State of Pennsylvania Statutory Requirements Setup Option Recommended Setting AUTOMATIC FAN FAN BEFORE CUTT

ENABLED ENABLED

See Section 17 and Section 18 for instructions on how to access and modify these setup options.

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Methane Monitor Override Option Normally, the methane monitor system on the miner will disable the pump, tramming and all other electrical circuits if the methane sensor is faulty. This can pose a problem for mine staff if the machine is inaccessible or under a section of roof that has not be properly secured and supported.

The Methane Monitor Override Option has been designed to allow the operator to start the pump motor and tram the machine if the methane monitor is reporting a fault condition.

This option is only available on machines that feature the General Monitors S800 Methane Monitor and have been fitted with additional wiring. Please contact mine management or DBT for information about the availability of this feature on your continuous miner.

This option can be turned on and off in the non-password protected section of the system setup menu (See Section 17).

The override must be activated by the operator using the radio remote control handset.

To activate the methane monitor override: Ensure that the methane monitor is in fault condition. This will be reported by the control system diagnostic display.

Press and hold the [SHIFT] and [AUX-2] keys together for a 5 seconds.

After holding the keys for 5 seconds, the system should enter the methane override mode for 120 seconds. During this time, the pump may be started and the machine can be trammed in SPEED 1 only.

Hydraulic functions can also be controlled whilst the override mode is active. It is not possible to start any other motors – including the cutter – in this mode.

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(12) Main Diagnostic Screen The main diagnostic screen is displayed during normal remote control operation of the continuous miner. The screen presents real-time diagnostic and performance information.

ACTIVE MODE

Current operating mode either REMOTE or MANUAL. In MANUAL machine will not respond to the transmitter

CARRIER STATUS

Tells you how the radio transmitter is performing.

First Black DOT – Remote is Communicating OK. Second Black DOT - A key on the remote is pressed.

EVENT MESSAGES

Any warning or fault messages.

ACTIVE COMMAND

Machine function that is currently on.

ACTIVE CHANNEL

Radio channel used by the miner.

Up to 4 channels are available: UHF01, UHF02, UHF03 and UHF04.

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(13) System Menu The control system provides a number of information, diagnostic and setup screens that are grouped together in the System Menu. The System Menu is accessed by using the diagnostic display module and a remote control handset. Different keys on the remote handset are used to select, view and navigate between different screens in the menu.

To Enter the System Menu At any time, press the [SHIFT] key and the [MENU] key together on the remote console. The system will then switch from REMOTE MODE to SYSTEM MENU MODE. Note that all functions and motors will be shut down and disabled when the system menu is selected.

To Return to REMOTE MODE You can leave the menu system and return to the REMOTE MODE at any time by pressing [SHIFT] and [REMOTE] keys together on the remote control handset.

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Moving Around in the System Menu The remote control console is used to move around in the system menu and select different options and perform different diagnostic tasks.

Changing pages: !

Press CONV LEFT to go to the previous page. Press CONV RIGHT to go to the next page.

Moving the Cursor: !

Use CONV UP and CONV DOWN to move the cursor to the desired option.

Selecting an Option: !

When the cursor is next to the desired option, press [SHIFT] and [MENU] to select that option.

To exit the System Menu: !

Select the REMOTE MODE option or

!

Press [SHIFT] and [REMOTE] at any time.

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System Menu Pages and Options The System Menu is composed of 13 main options. These options are arranged across 7 different pages with two options per page.

REMOTE MODE – Return to normal machine operation.

EVENT MONITOR – Fault Log. DIGITAL MONITOR – Monitor Digital Inputs ANALOG MONITOR – Monitor Analog Inputs TEMP. MONITOR – Monitor Unit Temperatures SLAVE MONITOR – Monitor Communications between units and status of units SOL. SELF TEST – Test for short and open solenoids.

SOL. USER TEST – Turn on groups of solenoids to test output voltages to coils.

CONSOLE TEST – Test transmitter keys MOTOR HOURMETERS – Logged operating hours for motors REMOTE SETUP – Machine Setup Options (Password) TIME /DATE SETUP – Set Time and Date NOPASSWORD SETUP – Machine Setup Options (Not Password Protected)

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(14) Setting the Time and Date The control system features a real-time clock that keeps track of the time of day and the date, even when power is removed from the receiver control unit.

To set the time and date, select the TIME / DATE SETUP option from the System Menu (See Section 13).

Once in the TIME/DATE SETUP screen, use the CONV LEFT and CONV RIGHT keys to move to the portion of the date or time that you wish to modify.

When that portion is flashing (selected) you may modify the value by using the CONV UP and CONV DOWN keys on the remote console.

Note that international date format is used by the control system: DAY : MONTH : YEAR rd

For example, the date 23 : 06 : 1998, indicates June 23 , 1998.

Once the correct date and time is entered, press [SHIFT] and [MENU] to return to the system menu and save the date and time.

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(15) Checking Module Temperatures Internal temperature sensors are fitted to the following components: ! ! !

Receiver Control Unit (Relay Board and Solenoid Driver Board) Traction Control Unit Power Supply (Battery Backup Version Only)

These sensors are useful for tracking the temperature of the machine and the control system modules. An option is provided in the System Menu to view these temperatures.

Viewing Module Temperatures To view temperatures, select the TEMP. MONITOR option from the System Menu (See Section 13). When selected, the temperature monitoring screen will appear for the first control system module.

Each screen shows the current temperature of the module, the maximum recorded temperature of the module and the module’s minimum recorded temperature.

There are a total of 4 monitor screens (one for each module and two for the two sensors in the receiver control unit). You many navigate between the screens using the CONV LEFT and CONV RIGHT keys.

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How to Reset Temperature Monitors The maximum and minimum temperatures recorded for each module are stored in permanent memory. It may be useful at times to reset these values in order to establish the minimum and maximum temperatures that were experienced over a known period of time.

To Reset the Temperature Monitor: Move to the monitor of the module whose temperature monitors you wish to reset.

Press and hold the [SHIFT] key. The screen will display a 5-second count down timer.

At the end of the 5-second delay, the maximum and minimum temperatures for that module will be reset to the current temperature that is being monitored.

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(16) Testing Machine Solenoids The control system provides an easy-to-use Solenoid Self Test facility that allows simple troubleshooting of faulty solenoid coils. When selected, the test analyses each solenoid coil and determines if the coil is short circuit or open circuit. Select the SOL. SELF TEST option from the System Menu (See Section 13). When this option is selected, the self-test begins automatically.

The system looks at one solenoid at a time. If the system finds that the coil is normal, it displays SOLENOID OK and then moves on to the next solenoid.

If the system believes that a solenoid coil is open circuit, it will pause the test at that solenoid and display SOLENOID OPEN. The number 3 key (LEFT TRAM REVERSE) must be pressed to continue the test.

If the system finds a solenoid coil that is short circuit, it pauses the test and displays the SOLENOID SHORT message for the solenoid. The number 3 key (LEFT TRAM REVERSE) must be pressed to continue the test.

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(17) User Setup Options The control system provides two groups of machine configuration options: ! !

User Setup Options (No Password Required) Engineering Setup Options (Password Protected)

To access the User Setup Options, simply select the NOPASSWORD SETUP option from the System Menu (See Section 13).

When selected, each setup option is displayed on its own page. Use the CONV LEFT and CONV RIGHT keys to move between different options. The CONV UP and CONV DOWN keys can be used to modify the value of the option that is currently displayed.

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1 - Methane Monitor Override Default Value Minimum Value Maximum Value

DISABLED DISABLED ENABLED

This option allows the Methane Monitor Override facility to be enabled or disabled (See Section 11).

2 - Fan Before Cutter Option Default Value Minimum Value Maximum Value

DISABLED DISABLED ENABLED

When this option is set to ENABLED, the control system will not allow cutter motors to be started unless the scrubber fan is first started and run for a full 3 second period (See Section 11).

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(18) Engineering Setup Options The control system provides two groups of machine configuration options: ! !

User Setup Options (No Password Required) Engineering Setup Options (Password Protected)

To access the Engineering Setup Options a password must be entered. Contact mine management to obtain the password.

First select the REMOTE SETUP option from the System Menu.

Enter the password using the CONV LEFT / RIGHT key to move the cursor and the CONV UP/DOWN key to change the character at the cursor position.

Once the correct password has been entered, press the [SHIFT] key only and the system will enter the Remote Setup (Engineering Setup).

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Forced Potato Mining Electronics Once the Remote Setup has been entered, each setup option is displayed on its own page. Use the CONV LEFT and CONV RIGHT keys to move between different options. The CONV UP and CONV DOWN keys can be used to modify the value of the option that is currently displayed.

1 – Radio Timeout Default Value Minimum Value Maximum Value

1.0 Seconds 0.5 Seconds 2.0 Seconds

This parameter determines how long the control system will wait after the loss of a radio control signal before shutting down the pump and all other motors and functions.

2 – Prestart Timeout Default Value Minimum Value Maximum Value

0.2 Seconds 0.2 Seconds 2.0 Seconds

Determines how long the [SHIFT] and [MOTOR] keys on the remote console must be asserted together before the motor is started.

3 – Pull In Timeout Default Value Minimum Value Maximum Value

1.0 Seconds 0.5 Seconds 2.0 Seconds

Amount of time before a frozen contactor is detected on motor shutdown or before an open contactor is recorded on motor start.

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4 – Pull Out Timeout (Run Timeout) Default Value Minimum Value Maximum Value

0.1 Second 0.01 Second 1.0 Second

Time that the control system will wait after the loss of feedback from a motor contactor before an open contactor fault is recorded for that contactor.

5 – Cutter Timeout Default Value Minimum Value Maximum Value

1.5 Seconds 1.0 Seconds 2.0 Seconds

Time allowed by the control system for both cutter contactors to close and provide feedback to the control system that they are closed.

6 – Battery Timeout Default Value Minimum Value Maximum Value

10 Minutes 10 Minutes 30 Minutes

When the control system loses main power, the battery backup power supply will provide power in BATTERY STANDBY MODE. The duration that the system will remain in this mode – without turning itself off - is determined by the Battery Timeout parameter.

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7 – Speed Key Timeout Default Value Minimum Value Maximum Value

5.0 Seconds 2.0 Seconds 5.0 Seconds

When tramming at higher speeds, the control system will retain the higher speed while the tramming keys are released momentarily. The amount of time that the system will retain the speed in the absence of tramming operation is determined by the Speed Timeout parameter.

8 – Pan Assistance Default Value Minimum Value Maximum Value

ENABLED DISABLED ENABLED

This option must be ENABLED for machines that are fitted with the PAN ASSIST hydraulic system. When the option is enabled, the control system will continue to drive the Pan Float solenoid after the operator releases the PAN FLOAT key and until the PAN UP key is pressed.

9 – Automatic Scrubber Fan Control Default Value Minimum Value Maximum Value

ENABLED DISABLED ENABLED

When this option is enabled, the control system automatically starts the scrubber fan 3 seconds after the cutter motors are started and automatically turns off the fan 10 seconds after the cutters are shut down (See Section 11).

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10 – E-Stop Relay Trip on Frozen Contactor Default Value Minimum Value Maximum Value

ENABLED DISABLED ENABLED

When this option is enabled, the control system will trip the machine e-stop relay when a frozen condition is detected in a motor contactor or an internal motor control relay.

11 – Left Tram Forward Speed 1 Default Value Minimum Value Maximum Value

25 % 0% SPEED 2

12 – Left Tram Forward Speed 2 Default Value Minimum Value Maximum Value

40 % SPEED 1 SPEED 3

13 – Left Tram Forward Speed 3 Default Value Minimum Value Maximum Value

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14 – Right Tram Forward Speed 1 Default Value Minimum Value Maximum Value

25 % 0% SPEED 2

15 – Right Tram Forward Speed 2 Default Value Minimum Value Maximum Value

40 % SPEED 1 SPEED 3

16 – Right Tram Forward Speed 3 Default Value Minimum Value Maximum Value

100 % SPEED 2 100 %

17 – Left Tram Reverse Speed 1 Default Value Minimum Value Maximum Value

25 % 0% SPEED 2

18 – Left Tram Reverse Speed 2 Default Value Minimum Value Maximum Value

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19 – Left Tram Reverse Speed 3 Default Value Minimum Value Maximum Value

100 % SPEED 2 100 %

20 – Right Tram Reverse Speed 1 Default Value Minimum Value Maximum Value

25 % 0% SPEED 2

21 – Right Tram Reverse Speed 2 Default Value Minimum Value Maximum Value

40 % SPEED 1 SPEED 3

22 – Right Tram Reverse Speed 3 Default Value Minimum Value Maximum Value

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23 – Overload Monitor Default Value Minimum Value Maximum Value

ENABLED DISABLED ENABLED

This option allows the overload relay monitoring feature of the control system to be turned on (enabled) or off (disabled).

24 – Ratchet Start Default Value Minimum Value Maximum Value

DISABLED ENABLED DISABLED

The control system provides two independent cutter contactor relay outputs. When this option is enabled, the control system alternates which output is started first on successive cutter motor start sequences.

25 – Ratchet Timeout Default Value Minimum Value Maximum Value

0.6 Seconds 0.5 Seconds 1 Second

The Ratchet Timeout parameter determines the length of the delay between the starting of the first and second cutter contactor outputs from the receiver.

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26 – Pump Interlock AUX 1 Output Default Value Minimum Value Maximum Value

ENABLED DISABLED ENABLED

This parameter allows the user to specify if the pump must be running in order for the Auxiliary Output #1 to be available. If ENABLED, the operator must first start the pump motor before the Auxiliary Output #1 can be used.

27 – Latching AUX 1 Output Default Value Minimum Value Maximum Value

DISABLED DISABLED ENABLED

Allows the user to specify if the Auxiliary Output #1 is to operate in a "Latching" or "Non-Latching" fashion. If this option is ENABLED, the Auxiliary Output #1 will remain on after keys are released and the output can be switched off by re-asserting the keys.

28 – Pump Interlock AUX 2 Output Default Value Minimum Value Maximum Value

ENABLED DISABLED ENABLED

This parameter allows the user to specify if the pump must be running in order for the Auxiliary Output #2 to be available. If ENABLED, the operator must first start the pump motor before the Auxiliary Output #2 can be used.

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29 – Latching AUX 2 Output Default Value Minimum Value Maximum Value

DISABLED DISABLED ENABLED

Allows the user to specify if the Auxiliary Output #2 is to operate in a "Latching" or "Non-Latching" fashion. If this option is ENABLED, the Auxiliary Output #2 will remain on after keys are released and the output can be switched off by re-asserting the keys.

Restore Default Settings In cases where an overwhelming number of setup options have been changed, or possibly tampered with, it is sometimes useful to revert to factory default settings. This can be achieved with the DEFAULT SETTINGS option.

Note that this option also restores the non-password-protected setup parameters to their default values.

To restore default settings, first access the DEFAULT SETTINGS page, the Remote Setup, and then assert [SHIFT] for 5 seconds.

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(19) Fault Log The system fault log (Event Monitor) stores the most recent fault conditions detected by the control system. Up to 32 faults are stored in permanent memory at any time.

To Enter the Fault Log Enter the System Menu (See Section 13) and select the EVENT MONITOR option. This will put the fault log on the screen.

To Move Around the Fault Log Use the CONV LEFT and CONV RIGHT keys to look at different fault messages in the Fault Log. To return to the System Menu press [SHIFT] and [MENU] keys together.

To return to normal REMOTE MODE operation, press [SHIFT] and [REMOTE] keys together.

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Seeing More Information About a Fault In some cases you may be unfamiliar with a particular fault message and need to see a more verbose description of the message.

Go to the fault message in the log that you wish to know more about.

With the fault message displayed, press and hold the [SHIFT] key.

After a delay of 2 seconds, the screen will present a text description of the fault message. The text will remain in place until the [SHIFT] key is released.

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Clearing the Fault Log It is sometimes useful to clear all faults from the log in order to troubleshoot a problem on the machine.

To empty the fault log of all fault entries, ensure that the system is currently in the Event Monitor (Fault Log).

Press the [SHIFT] key and the LEFT TRAM REVERSE (3) key together at the same time.

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The fault log will be cleared of all fault entries.

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(20) System Fault Messages Summary Message

Verbose Message

System Response

110V OUTPUT SHORT

A SHORT CIRCUIT ON THE 110V SUPPLY FROM THE BATTERY BACKUP WAS DETECTED THE FEEDBACK ON THE EXTERNAL CONVEYOR CONTACTOR WAS ILLEGALLY ACTIVE

1.

2.

Event Logged.

Solenoids will not operate.

1.

2.

THE FEEDBACK ON THE INTERNAL CONVEYOR RELAY WAS ILLEGALLY ACTIVE

1.

2.

Event Logged.

All motors and solenoids are disabled.

The machine’s pilot circuit is opened to remove mains power.

Event Logged.

All motors and solenoids are disabled.

The machine’s pilot circuit is opened to remove mains power.

Event Logged.

Conveyor motors only are shutdown.

CONV – FROZEN EXT.

CONV – FROZEN INT.

3.

3.

CONV – OPEN EXT.

CONV – OPEN INT.

CUTT – FROZEN EXT.

CUTT – FROZEN INT.

THE FEEDBACK ON THE EXTERNAL CONVEYOR CONTACTOR DID NOT ACTIVATE AS EXPECTED THE FEEDBACK ON THE INTERNAL CONVEYOR RELAY DID NOT ACTIVATE AS EXPECTED

1.

2.

THE FEEDBACK ON THE EXTERNAL CUTTER CONTACTOR WAS ILLEGALLY ACTIVE

1.

2.

THE FEEDBACK ON THE INTERNAL CUTTER RELAY WAS ILLEGALLY ACTIVE

1.

2.

1.

2.

3.

3.

CUTT – OPEN EXT.

CUTT – OPEN INT.

DEADMAN SW. OPEN

FAN - FROZEN INT.

THE FEEDBACK ON THE EXTERNAL CUTTER CONTACTOR DID NOT ACTIVATE AS EXPECTED THE FEEDBACK ON THE INTERNAL CUTTER RELAY DID NOT ACTIVATE AS EXPECTED THE FEEDBACK ON THE INTERNAL DEADMAN OUTPUT DID NOT ACTIVATE AS EXPECTED THE FEEDBACK ON THE INTERNAL FAN RELAY WAS ILLEGALLY ACTIVE

1.

2.

1.

2.

Event Logged Cutter motors only are shutdown

1.

Event Logged

1.

2.

Event Logged.

All motors and solenoids are disabled.

The machine’s pilot circuit is opened to remove mains power.

Event Logged Fan motor only is shutdown.

3.

FAN - OPEN INT.

THE FEEDBACK ON THE INTERNAL FAN RELAY DID NOT ACTIVATE AS EXPECTED

Event Logged Conveyor motors only are shutdown.

Event Logged.

All motors and solenoids are disabled.

The machine’s pilot circuit is opened to remove mains power.

Event Logged.

All motors and solenoids are disabled.

The machine’s pilot circuit is opened to remove mains power.

Event Logged Cutter motors only are shutdown.

1.

2.

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Verbose Message

System Response

LCAT – FROZEN INT.

THE FEEDBACK ON THE INTERNAL LEFT CAT OUTPUT WAS ILLEGALLYACTIVE

1.

2.

THE FEEDBACK ON THE INTERNAL LEFT CAT OUTPUT DID NOT ACTIVATE AS EXPECTED THE MANUAL STOP SWITCH FOR THE CONVEYOR IS ACTIVE. MOTOR SHUTDOWN THE MANUAL STOP SWITCH FOR THE CUTTERS IS ACTIVE. MOTOR SHUTDOWN THE MANUAL STOP SWITCH FOR THE PUMP IS ACTIVE. MOTOR SHUTDOWN

1.

Event Logged.

All motors and solenoids are disabled.

The machine’s pilot circuit is opened to remove mains power.

Event Logged

1.

2.

Event Logged Conveyor Motors are stopped

1.

2.

Event Logged Cutter Motors are stopped

1.

2.

THERE IS MORE THAN ONE TRANSMITTER OPERATING IN THE AREA.

1.

2.

Event Logged All motors & solenoids are shutdown Event Logged All motors & solenoids are shutdown Remote operation is suspended for 30 seconds.

Event Logged.

All motors and solenoids are disabled.

The machine’s pilot circuit is opened to remove mains power.

Event Logged.

All motors and solenoids are disabled.

The machine’s pilot circuit is opened to remove mains power.

Event Logged All motors and solenoids are shutdown Event Logged All motors and solenoids are shutdown Event Logged All motors and solenoids are shutdown The pilot circuit is opened to remove mains power from the machine.

Event Logged.

All motors and solenoids are disabled.

The machine’s pilot circuit is opened to remove mains power.

Event Logged

3.

LCAT – OPEN INT.

MAN CONV STOP ON

MAN CUTT STOP ON

MAN PUMP STOP ON

NEW TX DETECTED!

3.

PUMP – FROZEN EXT.

THE FEEDBACK ON THE EXTERNAL PUMP CONTACTOR WAS ILLEGALLY ACTIVE

PUMP – FROZEN INT.

THE FEEDBACK ON THE INTERNAL PUMP RELAY WAS ILLEGALLY ACTIVE

1.

2.

3.

1.

2.

3.

PUMP – OPEN EXT.

THE FEEDBACK ON THE EXTERNAL PUMP CONTACTOR DID NOT ACTIVATE AS EXPECTED

1.

2.

PUMP – OPEN INT.

THE FEEDBACK ON THE INTERNAL PUMP RELAY DID NOT ACTIVATE AS EXPECTED

1.

2.

RADIO STOP

THE RADIO STOP KEY HAS BEEN ACTIVATED ON THE TRANSMITTER

1.

2.

3.

RCAT – FROZEN INT.

THE FEEDBACK ON THE INTERNAL RIGHT CAT OUTPUT WAS ILLEGALLY ACTIVE

1.

2.

3.

RCAT – OPEN INT.

THE FEEDBACK ON THE INTERNAL RIGHT CAT OUTPUT DID NOT ACTIVATE AS EXPECTED

1.

Simpson RCS (DBT 25M Miner Version) – Operator’s Manual Issue: FA1901.B

Page 66 of 72

Forced Potato Mining Electronics Summary Message

Verbose Message

System Response

RF CARRIER LOST

THE TRANSMITTER SIGNAL WAS LOST WHILE THE PUMP WAS RUNNING.

1.

2.

TX – LOW BATTERY

THE TRANSMITTER’S BATTERY NEEDS TO BE RECHARGED SOON.

1.

2.

PUMP OR TRAM OLOAD

PUMP OR TRAM THERMAL OVERLOADS RELAY CONTACTS APPEAR TO BE TRIPPED.

1.

2.

CUTTER OVERLOAD

INSTANEOUS OR THERMAL CUTTER OVERLOAD RELAY CONTACTS APPEAR TO BE TRIPPED. INSTANEOUS OR THERMAL CONVEYOR OVERLOAD RELAY CONTACTS APPEAR TO BE TRIPPED. FAN OVERLOAD RELAY CONTACTS APPEAR TO BE TRIPPED S800 METHANE MONITOR HAS REPORTED AN INTERNAL MALFUNCTION COMMUNICATIONS WITH S800 METHANE MONITOR LOST INTERRUPTION OF CLEAN 24VDC POWER SUPPLY

1.

2.

CONVEYOR OVERLOAD

FAN OVERLOAD

METH MON FAULT

METHMON COMMS FAIL WATCHDOG POWER FAIL

Event Logged All motors and solenoids are shutdown Event Logged Headlights on the machine flash 3 times every 30 seconds.

Event Logged All motors and solenoids are shutdown.

Event Logged Cutter motors only are shutdown.

1.

2.

Event Logged.

Conveyor motors are shutdown only.

1.

2.

Event Logged.

Fan motor is shutdown only.

1.

Event Logged

1.

Event Logged

1.

2.

Event is not logged Control system may not run correctly Possible short-circuit of 24 VDC bus or problem with power supply module.

3.

Simpson RCS (DBT 25M Miner Version) – Operator’s Manual Issue: FA1901.B

Page 67 of 72

Forced Potato Mining Electronics

(21) Control System Pin Outs Simpson Receiver Control Unit Connector X1 – 35 Pin Burndy Female Pin No.

Signal Name

X1-A X1-B X1-C X1-D X1-E X1-F X1-G X1-H X1-J X1-L X1-M X1-L X1-M X1-N X1-P X1-R X1-S X1-T

Output Relay 1 – Pump Run Output Output Relay 2 – Water Spray Output Output Relay 3 – AUX #1 Relay Output Output Relay 4 – E-Stop Bypass Output Relays Input (1 - 8) Output Relay 5 – AUX #2 Relay Output Output Relay 6 – Spare Output Relay 7 – Lights Output Output Relay 8 – Spare Output Relay 9 – Cutter A Run Output Output Relay 10 – Fan Run Output Output Relay 9 – Cutter A Run Output Output Relay 10 – Fan Run Output Output Relay 11 – Conveyor Forward Run Output Output Relay 12 – Conveyor Reverse Run Output Relays Input (9 - 16) Output Relay 13 – Cutter B Run Output Digital Input 15 – Pump Contactor Feedback

X1-U

Digital Input 16 – Cutter Contactor Feedback

X1-V

Digital Input 17 – Fan Contactor Feedback

X1-W X1-X

X1-Z X1-a X1-b X1-c X1-d X1-e X1-f X1-g X1-h

Neutral Digital Input 18 - Conveyor Forward Contactor Feedback Digital Input 19 – Conveyor Reverse Contactor Feedback Output Relay 19 – Not Fitted Output Relay 20 – Not Fitted Relays Input (17 - 24) Output Relay 21 – Not Fitted Output Relay 22 – Not Fitted Output Relay 23 – Not Fitted Output Relay 24 – Not Fitted Neutral Emergency Stop Circuit Emergency Stop Input

X1-I

Emergency Stop Output (N/O Contact)

X1-Y

Simpson RCS (DBT 25M Miner Version) – Operator’s Manual Issue: FA1901.B

Signal Type 110 VAC Output 110 VAC Output 110 VAC Output 110 VAC Output 110 VAC Input 110 VAC Output 110 VAC Output 110 VAC Output 110 VAC Output 110 VAC Output 110 VAC Output 110 VAC Output 110 VAC Output 110 VAC Output 110 VAC Output 110 VAC Input 110 VAC Output 110 VAC Digital Input 110 VAC Digital Input 110 VAC Digital Input Neutral 110 VAC 110 VAC Digital Input 110 VAC Digital Input 110 VAC Output 110 VAC Output 110 VAC Input 110 VAC Output 110 VAC Output 110 VAC Output 110 VAC Output Neutral 110 VAC E Stop110 VAC Input E Stop 110 VAC Output

Page 68 of 72

Forced Potato Mining Electronics Simpson Receiver Control Unit Connector X2 – 19 Pin Burndy Female Pin No.

Signal Name

Signal Type

X2-A

Aux. Supply Output 24V+

24V Output

X2-B

Aux. Supply Output 0V

0V Output

X2-C

Supply Input 24V+

24V Input

X2-D

Supply Input 0V

0V Input

X2-E

Data Logging (Methane) RS485 - A

External Communications

X2-F

Data Logging (Methane) RS485 - B

External Communications

X2-G

Data Logging (Methane) RS485 - Common

External Communications

X2-H

External Slaves RS485 - A

External Communications

X2-J

External Slaves RS485 - B

External Communications

X2-K

External Slaves RS485 - Common

External Communications

X2-L

RS232-TX

External Communications

X2-M

RS232-RX

External Communications

X2-N

RS232-COMMON

External Communications

X2-P

24V Input - Spare

24V Digital Input

X2-R

24V Input - Spare

24V Digital Input

X2-S

24V Input - Spare

24V Digital Input

X2-T

24V Input - Spare

24V Digital Input

Simpson RCS (DBT 25M Miner Version) – Operator’s Manual Issue: FA1901.B

Page 69 of 72

Forced Potato Mining Electronics Simpson Receiver Control Unit Connector X3 – V35 Burndy (34 Pin Female) Pin No.

Signal Name

Signal Type

X3-A X3-B X3-C X3-D X3-E X3-F X3-H X3-J X3-K X3-L X3-M X3-N X3-P X3-R X3-S X3-T X3-U X3-V X3-W X3-X X3-Y X3-Z X3-AA X3-BB X3-CC X3-DD X3-EE X3-FF X3-HH X3-JJ X3-KK X3-LL X3-MM X3-NN

Solenoid 1 - Gathering Head Up Solenoid 3 - Shear Up 110+ VDC for Solenoid Drivers Solenoid 4 - Shear Down Solenoid 2 – Gathering Head Down Solenoid 5 – Conveyor Up 0V for 110 VDC Solenoid Drivers Solenoid 6 – Conveyor Down 0V for 110 VDC Solenoid Drivers Solenoid 7 – Conveyor Left Digital Input 1 – Spare Input Solenoid 8 – Conveyor Right Digital Input 2 – Spare Input Solenoid 9 – Stabilizer Up Digital Input 3 – Spare Input Solenoid 10 – Stabilizer Down Digital Input 4 – Manual Pump Stop Monitor Solenoid 11 – Fire Suppression Digital Input 5 – Manual Cutter Stop Monitor Solenoid 12 - Breaker OFF Digital Input 6 – Manual Conveyor Stop Monitor Solenoid 13 – Breaker ON Digital Input 7 – Manual Supply Status Input Solenoid 14 – Cutter Water Spray Digital Input 8 – Radio/Manual Mode Select Input Solenoid 15 – Scrubber Water Digital Input 9 – Spare Input Solenoid 16 – Methane Override Enable Digital Input 10 – Spare Input Digital Input 11 – Fan Overload Monitor Neutral Digital Inputs Digital Input 12 – Pump Overload Monitor Digital Input 13 – Conveyor Overload Monitor Digital Input 14 – Cutter Overload Monitor

Solenoid 0VDC O/P Solenoid 0VDC O/P 110 VDC + Input Solenoid 0VDC O/P Solenoid 0VDC O/P Solenoid 0VDC O/P 0V – Input Solenoid 0VDC O/P 0V – Input Solenoid 0VDC O/P 110VAC Digital Input Solenoid 0VDC O/P 110VAC Digital Input Solenoid 0VDC O/P 110VAC Digital Input Solenoid 0VDC O/P 110VAC Digital Input Solenoid 0VDC O/P 110VAC Digital Input Solenoid 0VDC O/P 110VAC Digital Input Solenoid 0VDC O/P 110VAC Digital Input Solenoid 0VDC O/P 110VAC Digital Input Solenoid 0VDC O/P 110VAC Digital Input Solenoid 0VDC O/P 110VAC Digital Input Solenoid 0VDC O/P Neutral 110VAC I/P 110VAC Digital Input 110VAC Digital Input 110VAC Digital Input

Simpson RCS (DBT 25M Miner Version) – Operator’s Manual Issue: FA1901.B

Page 70 of 72

Forced Potato Mining Electronics Simpson Battery Backup Power Supply Connector X5 – 8 Pin Burndy Female Pin No. X5-A X5-B X5-C X5-D X5-E X5-F X5-G X5-H

Signal Name Door Switch Input Door Switch Output Main Supply O/P 24V+ Main Supply O/P 0V N/C RS485-A RS485-B RS485-COM

Signal Type Link Link 24V+ Output 0V Output Coms Coms Coms

Simpson Battery Backup Power Supply Connector X6 – 8 Pin Burndy Male Pin No.

Signal Name

X6-A X6-B

110V AC Neutral Earth

X6-C X6-D X6-E X6-F X6-G X6-H

110V AC Line N/C 0V DC 110V DC + N/C N/C

Signal Type Supply Input Supply Earth Connection Supply Input Output 110 VDC Output 110 VDC

Simpson Display Unit Terminal Connections J3, J4 Pin No. 24V+ 0V A B COM

Signal Name Auxiliary Supply I/P 24V+ Auxiliary Supply I/P 0V Display RS485 - A Display RS485 - B Display RS485 - Common

Simpson RCS (DBT 25M Miner Version) – Operator’s Manual Issue: FA1901.B

Signal Type 24V Input 0V Input External Communications External Communications External Communications

Page 71 of 72

Forced Potato Mining Electronics Simpson Traction Unit Connector X10 – GAPL26 26 Pin Male Pin No.

Signal Name

X10-Z

RH Proportional Output

X10-BB

LH Proportional Output

X10-N

RHFWD

X10-J

RHREV

X10-D

LHFWD

X10-M

LHREV

X10-H

Deadman

X10-C

Spare

X10-X X10-V X10-L

0VFP 0VFP External Supply (GND)

X10-F

External Supply (GND)

X10-B

External Supply (GND)

X10-CC

System Supply (24 VDC GND)

X10-K

External Supply (GND)

X10-E

External Supply (GND)

X10-A

External Supply (GND)

X10-DD X10-U X10-Y X10-AA

Data Com Data A Data B +VIN

X10-T

External Supply (13 VDC)

X10-R

External Supply (13 VDC)

Simpson RCS (DBT 25M Miner Version) – Operator’s Manual Issue: FA1901.B

Signal Type 0-10 Volts prop.

Output 0-10 Volts prop.

Output +13 Volts on/off output +13 Volts on/off output +13 Volts on/off output +13 Volts on/off output +13 Volts on/off output +13 Volts on/off output 12 volts ground 12 volts ground +13 volts ground (External) +13 volts ground (External) +13 volts ground (External) +24 volts ground (System) +13 volts ground (External) +13 volts ground (External) +13 volts ground (External) RS-485 Common RS-485 Signal A RS-485 Signal B +24 volts supply (System) +13 Volts supply (External) +13 Volts supply (External)

Page 72 of 72

Forced Potato TITO Remote Console (DBT Miner Version)

Operator’s Manual Issue KN2601.B

Forced Potato Mining Electronics

Contents Contents ...............................................................................................2 Preface .................................................................................................3 Introduction ...........................................................................................4 Notice ............................................................................................4 Safety Notice ........................................................................................5 What’s New...........................................................................................6 Remote Control Battery Charger ..........................................................8 Remote Control Diagnostics...............................................................11 Notice ..........................................................................................12 User Setup..........................................................................................13 Password Entry ...........................................................................13 Options ........................................................................................14 1. Radio Channel .......................................................................15 2. Radio Timeout .......................................................................15 3. Tilt Switch ..............................................................................16 4. ID Number .............................................................................16 5. Saving Changes ....................................................................17 Maintenance .......................................................................................18 Inspection Frequency ..................................................................18 Factory Service Frequency .........................................................18 Tools............................................................................................19 Disassembly ................................................................................20 Cleaning ......................................................................................21 Reassembly.................................................................................22

Type L0KN26 – Operator’s Manual

Page 2 of 24

Forced Potato Mining Electronics

Preface This document is intended to provide reference to the Type KN Remote Console. This version of the TITO remote console has been developed for operation of DBT continuous miners.

Forced Potato Inc. 640 Bizzell Drive Lexington, KY 40510 Telephone: +859 252 4439 Fax: +859 252 4641 Web: www.forcedpotato.com © Forced Potato Inc. Other than is permitted by law, no part of this document may be reproduced, stored in a retrieval system or transmitted in any form or process without prior written consent of Forced Potato Inc. Every effort has been made to ensure the accuracy and correctness of the information presented within this document. However, Forced Potato does not provide guarantee of its correctness or accuracy.

Other than is required by law, no warranty of any kind is expressed or implied.

Copies of this manual, and other documentation pertaining to Forced Potato control system products, may be obtained by contacting Forced Potato directly.

For all matters involving servicing or purchase of Forced Potato control system components used with machinery manufactured by DBT, please contact your DBT representative or local DBT service center.

Type L0KN26 – Operator’s Manual

Page 3 of 24

Forced Potato Mining Electronics

Introduction The Type L0KN Remote Console (RC) is a self-contained battery powered remote control that has been specifically designed to provide a safer, more efficient means of operating mining machinery.

Notice This manual includes information specific to the following part: Part# L0KN2601

Description DBT UHF

If this manual does not correspond to your equipment’s part number, please contact Forced Potato Inc. immediately to obtain a copy of the correct publication.

To obtain service of your TITO L0KN26 model remote control handset please contact your local DBT representative or service center.

Type L0KN26 – Operator’s Manual

Page 4 of 24

Forced Potato Mining Electronics

Safety Notice The advent of remote control has afforded the operator a notable improvement in personal safety. However, the potential for injury or fatality still exists when operating heavy machinery remotely.

Thus, it is expressly important that the operator observe safe work practice when operating a remote control mining machine. This will be defined by mine management and should encompass MSHA recommendations where applicable.

Type L0KN26 – Operator’s Manual

Page 5 of 24

Forced Potato Mining Electronics

What’s New The Type KN Remote Console has been designed to meet the requirements of AS4240 / MDG5001. These requirements compel a number of design variations over existing equipment manufactured by Forced Potato Inc.

•

Size Whilst a similar physical layout has been retained to support transparent integration, the overall size has grown to support control spacing standards as specified by AS4240.

•

Visual Diagnostics A highly efficient LED display has been integrated to facilitate operating diagnostics. Information such as operating frequency, power and general operating status is available at all times.

Type L0KN26 – Operator’s Manual

Page 6 of 24

Forced Potato Mining Electronics •

Battery To improve operational readiness, a larger battery pack has been incorporated which affords a minimum 20 hours of continuous remote control operation.

•

Tilt Monitoring Dual tilt switches have been installed to allow detection of the angle of inclination relative to the horizontal plane. This feature can be enabled or disabled via the User Setup Options on the Remote Control Battery Charger. By default, this option is disabled.

•

Safety The most important design addition is single electrical fault tolerance. By incorporating dual-pole switch architecture and a new approach to switch sampling, a high level of fault tolerance has been achieved.

The KN26 TITO remote console also features a push-button stop button. This push-button makes the device compliant with MSHA P03-3 recommendations.

•

Ergonomics In an effort to improve operator comfort, stylish comfort knobs have been added to the most commonly used functions – traction and shear. These are entirely optional and can be removed if required.

Type L0KN26 – Operator’s Manual

Page 7 of 24

Forced Potato Mining Electronics

Remote Control Battery Charger Connect the Remote Control Battery Charger to your mains power outlet. During initial power-up, the firmware release information is displayed for 10 seconds.

After this period, the charger will then display the main screen which details the charge status.

Type L0KN26 – Operator’s Manual

Page 8 of 24

Forced Potato Mining Electronics Diagnostics The Remote Control Battery Charger permits the operator to verify that all switches are operating as expected. Similarly, it provides a secondary means of determining the operating frequency.

Power Up Turn the RC on by asserting and holding the ON [SHIFT] key for twoseconds. This startup requirement has been introduced to reduce the likelihood of incidental activation.

After the two-second period has expired, the RC will show the operating frequency via the LED display. The available operating frequencies for the L0KN2601 (DBT UHF) are as follows: Indicated Frequency UHF1 UHF2 UHF3 UHF4

Actual Frequency 458.500MHz 458.525MHz 458.550MHz 458.575MHz

Type L0KN26 – Operator’s Manual

Page 9 of 24

Forced Potato Mining Electronics The Remote Control Battery Charger continually scans all 4 channels in an attempt to recognize a supported RC. On average, the Remote Control Battery Charger requires approximately 4 seconds to acquire a signal.

Upon detecting a valid signal, an identification screen is displayed for three seconds to allow classification of the type and frequency of the operating RC.

After this period has expired, the diagnostic screen is displayed.

Operators should be satisfied that all key functions operate as expected prior to taking the equipment underground. Similarly, operators should verify that the operating frequency corresponds to that displayed on the RC – See the Frequency Table on the previous page.

Type L0KN26 – Operator’s Manual

Page 10 of 24

Forced Potato Mining Electronics

Remote Control Diagnostics The RC supports a number of inbuilt diagnostics to aid operation. The following table details each of these messages and their implication.

Message UHF1, UHF2, UHF3, UHF4 ON

Meaning Operating on Frequency 1,2,3 or 4

ON ! (Flashing)

Power is ON and a command is being sent to the machine.

OFF

Powering down whilst issuing PUMP OFF command.

STOP

Radio Stop Activated

TILT

The RC’s angle of inclination is beyond 45° relative to horizontal. The STOP command is issued continuously until the unit is righted.

The internal battery is low with and expected remaining operating time of approximately 30 minutes.

Indicating possible service requirements, a fault condition has been detected.

LOW (Flashing) SERV

Power is ON

Type L0KN26 – Operator’s Manual

Page 11 of 24

Forced Potato Mining Electronics

Notice The SERV message is displayed when a fault condition has been detected. There are a number of problems that can generate this fault and most of these would typically require the unit to be submitted for factory service.

However, this condition can be triggered if the operator asserts switches prior to turning the unit ON. If switches other than those allocated to User Setup are asserted prior to power up, it is assumed that these switches are faulty, consequently resulting in automatic power down.

Type L0KN26 – Operator’s Manual

Page 12 of 24

Forced Potato Mining Electronics

User Setup The RC supports a number of user programmable options that can be adjusted via the Remote Control Battery Charger. To engage User Setup and with the RC turned off, assert the following keys, in sequence, for two seconds: Assert Assert Assert

CONVEYOR ► SHEAR UP ON [SHIFT]

The RC will display SET on its LED display to indicate that User Setup has been selected.

Password Entry When the Remote Control Battery Charger has acquired the signal, the following password entry screen is displayed:

The password FORCED must be entered before access to User Setup is granted.

Type L0KN26 – Operator’s Manual

Page 13 of 24

Forced Potato Mining Electronics To enter characters, use the following keys: To change a character: Assert CONVEYOR UP or CONVEYOR DOWN To change cursor position: Assert CONVEYOR ► or CONVEYOR ◄ To check the password: Assert ON [SHIFT] After entering the password, assert ON [SHIFT] to gain access to the System Menu.

Options There are five menu options available to the end user. To navigate the system menu, see the following:

To change the menu option: Assert CONVEYOR ► or CONVEYOR◄ To engage or leave the menu option: Assert ON [SHIFT] To change the option value: Assert CONVEYOR UP or CONVEYOR DOWN

Type L0KN26 – Operator’s Manual

Page 14 of 24

Forced Potato Mining Electronics

1. Radio Channel

There are 4 selectable channels available to the end-user. This allows the mine to support multiple machines.

2. Radio Timeout

The RC supports a timeout that automatically powers the unit down if there is no switch activity after a defined period of time. A selectable range of between 2 and 60 minutes can be chosen.

Type L0KN26 – Operator’s Manual

Page 15 of 24

Forced Potato Mining Electronics

3. Tilt Switch

To support AS4240 requirements, dual tilt switches which detect the angle of inclination have been installed. If this option is enabled, the RC will automatically issue the Radio Stop command until the unit is righted upon detecting tilt motion beyond 45° relative to horizontal. (The LED display will show TILT as a diagnostic response.) After being righted, power is automatically removed.

Importantly, a 250ms timer acts to filter our mild impacts to compensate for the effects of inertia. This is an essential requirement when Tilt Monitoring is enabled.

4. ID Number

Each Remote Console is programmed with its respective serial number upon leaving the factory. This feature is not accessible to the end user and is password protected.

Type L0KN26 – Operator’s Manual

Page 16 of 24

Forced Potato Mining Electronics

5. Saving Changes

To save changes to the setup, you must select the EXIT & SAVE option and assert ON [SHIFT]. To abort changes to the setup, you can simply turn the RC OFF.

Type L0KN26 – Operator’s Manual

Page 17 of 24

Forced Potato Mining Electronics

Maintenance The maintenance required for Remote Consoles is basically limited to assembly, cleaning & inspection. Coal dust and other particulate deposits foul switch operation and can eventually lead to premature seal failure if not regularly expunged.

Inspection Frequency The following routines should be undertaken daily.

•

Determine if cleaning and disassembly is necessary. Onsite conditions should be used to determine the regularity of this procedure. If cleaning is required, see the following pages.

Typically, cleaning on a weekly basis is sufficient.

•

Perform a functional test on the Remote Control Battery Charger.

Factory Service Frequency Factory Service of this equipment is required 12-months from the date of dispatch with an allowance of 1-month for logistics.

Type L0KN26 – Operator’s Manual

Page 18 of 24

Forced Potato Mining Electronics

Tools Forced Potato Inc. recommends that the Maintenance Accessory Kit be acquired (or similar) to aid systematic maintenance. A maintenance kit is available which includes the following parts: Allen Hex Set

Allen ⅝″ Socket

Multi-Bit Precision Torque Driver

Field Part Replacements

Type L0KN26 – Operator’s Manual

Page 19 of 24

Forced Potato Mining Electronics

Disassembly • • • • •

Remove the M3 bolts.

Remove the switch guard.

Remove the switch caps.

Remove the comfort knobs by loosening the grub screw.

Remove the engraved plate.

Type L0KN26 – Operator’s Manual

Page 20 of 24

Forced Potato Mining Electronics

Cleaning • • •

•

Expunge heavy debris from the switch assembly with a Soft Bristle Cleaning Brush.

Wash the transmitter with warm soapy water.

Inspect the switch seals for signs of deterioration. Seals exhibiting wear require the equipment to be scheduled for factory service.

Note: these seals are the primary seal, a secondary seal within the switch itself and an internal neoprene seal operate as a barrier to moisture ingress.

Dry the transmitter with light compressed air or cloth.

Important Do not use caustic solvents or displacement solutions as this may cause premature seal failure.

Do not use metal implements to dig out coal, mud or soapstone that may be found in the charge receptacle.

Type L0KN26 – Operator’s Manual

Page 21 of 24

Forced Potato Mining Electronics

Reassembly • •

• • • •

Ensure all switch seals are tight. If a seal appears loose, tighten the seal to the recommended torque of 2.5Nm. Ensure all switch plate M2 bolts are tight. If an M2 bolt appears loose, tighten the bolt to the recommended torque of 1.5Nm. Do NOT over tighten these bolts as this may break the enclosure seal.

Install the engraved plate.

Install the comfort knobs as depicted. Tighten the grub screw to the recommended torque of 2.5Nm. Install the switch caps Install the switch guard. Tighten the switch guard M3 bolts to the recommended torque of 2.5Nm.

After reassembly, test the unit on the Remote Control Battery Charger to verify operation.

Type L0KN26 – Operator’s Manual

Page 22 of 24

Forced Potato Mining Electronics

B

O

Battery · 7

Options · 14

C

P

Cleaning · 21

Password Entry · 13 Power Up · 9 Preface · 3

D Diagnostics · 9 Disassembly · 20

E Ergonomics · 7

I Introduction · 4

R Radio Channel · 15 Radio Timeout · 15 Reassembly · 22 Remote Control Battery Charger · 8 Remote Control Diagnostics · 11

S Safety · 7 Safety Notice · 5 Size · 6

M Maintenance · 18

N

T Tilt Monitoring · 7 Tilt Switch · 16, 17 Tools · 19

Notes on “SERV” · 12 Notice · 4

Type L0KN26 – Operator’s Manual

Page 23 of 24

Forced Potato Mining Electronics

U

W

User Setup · 13

What’s New · 6

V Visual Diagnostics · 6

Type L0KN26 – Operator’s Manual

Page 24 of 24