Cat Continuous Miner 30M3 Energy West Operation & Maintenance Manual - PDF DOWNLOAD

BI377591

© Bucyrus All Rights Reserved

BUCYRUS R

Technical Manual

BI377591

BUCYRUS

3-17-2008 Model 30M3 CONTINUOUS MINER Serial Number 300995

Energy West

BI377591

,N34

/20VAC COM 2 1 — 120VAC UNE

120 VAC ti

"" f 12 VAC fl RS VAC

MATERIAL:

FOR INFORMATION THIS DRAYANG IS THE PROPERTY OF DOT AMERICA INC. NO REPRODUCTION OR USE OF THIS DRAVAND MAY SE DONE %MOUT THE WRITTEN CONSENT OF DOT AMERICA INC.

PiEiGHT

LB

MT P/N UNITS RAW DIMENSIONS SO FT/LIN FT MATERIAL

00 NEW RELEASE

s/N: 300995

AY N °RABB BY 01/02/00 CHECKED BY 01 /02/01 Ft£NEBBO BYovozive

SCALE TITLE:

1:1 PRO.= MODEL HO.: FIRST USED:

ELECTRICAL SCHEMATICS, ENGERY WEST, POWER, 995VAC, 60HZ

605894 SRALAR TO:

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MATERiAL:

FOR INFORMATION

9

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DATE

MC WO 1, Ms NAME lot 300005

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NODS. Nao

UN* 3

WOE:

ELECTRICAL SCHEMATICS, ENERGY 0EST CONTROL, 095VAC, 60HZ

Kam 605894 2

MIEa2or 3

BI377591 12

11

10

8

7

6

4

5

1

2

3 NOTES:

1. THE INTRINSICALLY SAFE CIRCUITS PARED INTO THE MAIN CONTROL CASE HAW BEEN 'TESTED BY THE MINE, SAFETY, AND HEALTH ADMINISTRATION (MSHA) TO PROW THAT THEY CANNOT CREATE AN ARC OF SUFFIE7ENT TEMPERATURE TO IGNITE GAS. ANY SUBSTITUTION OR ELIMINATION CF PARTS WILL VOID THE MACHINE AND CREATE A HAZARDOUS CONDITION. 2. WIRES 24, 25, 45, 46, 259, 260, (INTRINSICALLY SAFE WIRING) AND. 600 VOLT IIARE(UGHT OWE), DOT SHALL BE WIRED WITH P/N 394089, BUNDLE SEPARATELY THESE MIRES IN ORDER 10 KEEP THEM SEPARATE FROM NON-IS. CONTROL MIRES. WIRES 2. 2A, 157 TO THE IICU FACEPLATE SHALI. BE WIRED • 3.

NTH 818AwG (11H1).1, ALL WIRING FROM THE mCU FACEPLATE TO THE NEAREST DEVICE OR TERMINAL BOARD SHALL BE WIRED WITH 816 AWG, 8EK vARE, DOT P/N 123955 UNLESS OTHERWISE NOTED (EX. CHO. A 4, WIRES 2. 2A. 20, 2C, 2D, 2G5, 155, 157. 802, KM. 605 SHALL BE MIRED WITH 06 ARC (WHT), DOT P/N 296540.* ALL OTHER 120 VAC AND DC CONTROL WIRES SHALL BE MIRED NTH #16 A1140 (OLN) DOT P/N 296871. *5. WIRES X2, Y2, 702, 704, 705 SHALL BE WIRED YAM 812 ARG (1ImT), DOT PA 296823.* MIRES X1, IT, 701. 703, 706 SHALL BE WIRED WITH /12 ARC (BLK), DBT P/N 296618.

AU. CURRENT TRANSFORMERS (C1s) MUST BC LOCATED AND 6.

TYE-WRAPPED I NECESSARY TO TO AVOM THE IMOD BEING DAMAGED TO 'AERATION OR COMING IN CONTACT WITH EXPOSED TERMINALS. AU. CABLE JACNETS SHALL PROTRUDE THROUGH THE GLAND 7. i pzutTvrptiG pox A MINIMILIM_DISTANCE OF 1/4'..

THIS NoTAnow SHALL BE wwED USNG xAREs /12 ANC (CANT ) WIRE DBT P/N 394077 PER MSHA APPROVAL. ALL OTHER GROUND WIRES SHALL BE #16 AMYL (CNN) DOT P/N 128960. GROUND MIRES SHALL WARE 10 MACHINE FRAME.

TO MAIN CONTROL CASE 1-EIL11 2•-V4H 5 3-CA 170

(NOT IN CONTROL CASE — LOCATED LEFT REAR OF MINER)

Maw ROTARY galas (illt)

poosic MIRY Si1tD1 (1.41

LEFT E—STOP -{}-1(TB1)

5(TB2) -170(782)-0

INvilkoj

e

n.MOMENTARY WITH SPRING RETURN

CONTROL CASE MAIN ROTARY SWITCH NY

00NTROL CASE E-STOP 1(189

—CT 1 41—

a

LIGHTING ROTARY SW

POSITION STOPS IN SWITCH AS SHOWN

6 LA 802(M CB 6)

NM)

A

170(182)—{}._,..p----189(192)

(7,

801(MCEI

254(102) 69(T62)

*702(MCE14)

4 6 6 6 6 • 6 1 CO N- .- 04 Pr) ‘I- in (0

8 8U 8 U 8 8e ..2....m

701(M033)

R

9

9, 4l_,_4__t__/...A...

U

SHAFT ENO OF SWITCH ALL ON

FAN OFF FAN W/GUTTER

AREA LIGHTS

HEAD LIGHTS

OFF/ETRAIA CHK

ALL OFF

NOTE: MOUNT LS1 ROTARY SWITCH SUCH THAT COPPER TERMINALS 1, 5, 9, 13, (7, 21) ARE POINTING DOWNWARD ELSE LIGHTING OPERATION WILL NOT FOLLOW NAMEPLATE

FOR INFORMATION

_

_

-

THIS DRAWING IS THE PROPERTY OF DOT AMERICA INC. NO REPRODUCTION OR USE OF THIS DRAWING MAY BE DONE 600002017012 00 NEW RELEASE WITHOUT THE MITTEN CONSENT OF Day AMERICA INC. El HUMBER REV DESCRIPTION

12

-

-

-

-

msom rAc Aommer DATE DATE NAME sjf1:300995

MATERIAL:

DBT P/N MATERIAL -

-

WEIGHT L BS UNITS

RAW DIMENSIONS SO FT/LIN FT -

-

NA ME _DATE DRA.Am ty out2Ams r MOWS C. CHECKED BY 01/02/NI Woo' REviciwo 5Yolio2tML F. "II" cm A ra DOT AMERICA 11/11/03 r'' DOC #2835 REV '

a

ATTENTION

B3 -.

7kor PROJEC .

MODEL NO,: 11057 USED:

SCALE

1:1 30.4 --

TITLE:

WRING DIAGRAMS, 30M, ENERGY WEST (CONTROL CASE FACE W) WAR* 605895 smILAR 10;

I

SHEET 3 OF 4

1

0

BI377591 11

12

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8 #18-1C TFE HOOK UP 173955 {34(TB6)

R21 3(1813 43(PCI r- 0*twe'

35(186)

a l a

Pt

I 31(CPS) 30(Ces) WW1 21186 27 186 26 185

P27 et 12111110p11117 1(7013 A2111314) VALAIS! al.?

DI B-14 312 CHAN f OtAN I 1,5„ X.S.

i .i.

•

10

1913

81(785)

11313 1813

RI6

Ip

121(7810)

,n 60(T84)

225183} —0 234 (T83 .4 226(183 14

N

122 12 124 126 12

R17 R4

• tS

TB10 1810 TBIO TBIO TBIO 1810

156(F3) 41157(F4)

Pp

0

R1

R12

3(1813)79

'Melt 044"

R6

R8

61 6( 50\184 52 TB4 54 184 56 TB4 —0 R4

IG

N

.-4-701A(Te4) 706(T84)

0 4.4 V

3(1813)

N V

it

R1 217(183) —o

64(184)

0 r ryi

R3

N 13(7813

1320810

235 183 2281183 22E783 231 183 2 T1113 23 763 232 TO 3 227 T83

RIB

TO METHANE MONITOR READOUT/CONTROL UNIT

CARE

T x 3BLU CTS

DC POKER SUPPLY (GND) GNU A.20814)- L2/14j "DPS' kom-113(F2) 1(1613)- LI (241.^-17(F1)

4BLX

IIHT/81,K I 7(DPS) MPL:4 22(187) 154(184 jfigl[0111 156(R8-5) * irtig3 23(187) A155084) 1113141311 157(R13-64 ' 4 R20 16(DPS) III

ee

COM1 RX RTS

254A(ESR ) 4(1014) r 255058T)

SHOULD GET 120VAC PRESENT ONLY wHEN FAULT EXISTS

255(ISBT)

3-3 F3-3

-305(1913) TB4 ) 23 T8 ) 235 183) LD 2+511 Lo 252 LD Lo RD 245 RD 247 246 RD 253 RD

MACHINE CONTROL UNIT MODEL MCU-944 - LEGEND HARE TERM. MARE TERM. CARE TERM. NO. NO. DESCRIPTION DESCRIPTION NO. NO. NO. NO, DESCRIPTION NOT 110 R7-I PUMP CURRENT +i 223 81 -1 FIRE SUPPRESSION nEHOO 3 R2I-1 POKER ( TE TRIP RI -2 BR ON OUTPUT 12VD% CENTER TRIP EN Ilt1674,1ENWTD Auxug L Wii ciiat% RNPIT.V 25.1. WI WEN 1§1:011 13-973 45 till UM o DUS AY E 01 1-4 AC NFU R7.- ilif iig/ LII) Vila k++ CUTTER HEAD uP SOLENOO FIZiu Pu7 + GATHER HEAD DOwn (FLOAT) SOLER 106 R7 6 AN ROW OR 61 1 31 R22-1 BATTERY POWER ACTIVE - N/u in 104,firc Frij ..:) , F. Lig44 FOR 120VAC L) FOR DANK R1/R2 101 R8-1 11 /1 -8 SP R 114Pu 1 -8 P I 3 2UINR .WAMTAN R8:3 AA AN IN UT ifr-4 %OUT 4I N CPMON TivE -4 AR AN IN LIT_ -5 + R111 it CODMLIEI IGH 111 AM PENDENT POWER/DATA t I- 111 11 Rui + " D /11:4' gg : YDTEN • gND 14i COW -_ k:;.BR[ 1ANi &b., Rati--$3 8 141 Li I TRAM GNA60 „1 INPUT FORw 14I -L g fi -10 AR R INPUT a-10 114-8LIFT REWR cowrie!.

169 R3-1 MN 32 815:1 !IAA SYS Tx + Mbl) 77 MIC AttraT "BACK OF SWING PANEL" t litl TALI 3 11 1AAUV -4 PUmP SI T ... Niel I li i E i 1I R -0 CONYEYOR START - N/u _ AL C IA n 1 1 Fl ux -IT CUTTER START - N/U 121 RI -1 71F p ti 3 LIIIILBSPI911,3 132 11 -i Y 4- 4 EUPi 4-+. i 1 811i DI i" 1 RI -5 SPLAY C04.4 0 ill FiropuT ii I • ' q DA A ATI AA iii 9 10-:i 1, Si ICI ,t,.. 1 et Mt ktk 3,4+ 56 R4-10 V YTE WP M& 8 I -4 1 0 F MOTOR R D R -1 7 R11-1 CAN S AA WNW aToOpP 1,4 411.1 B:11 A` t R 1 5 till Evi: PRI 1 COMMON ii: I _ -4 T USE _2 111:g 1 .j OU 1 l'r ;, 2 p i DATA R19,-1 S8190 MOH OPTION METH III:9 ti f iTtfkil 1 Li8O u R t R R11-5 ON -107 COIN 3 R1' 19-5 NOT CONN 254 § -2 falfrirArEtAlitILE BY 53 PORT - COAA 820-1 -3 UN IBY s4 1 N titi i ri1 t8 69 tit -4 F W S4 I - cx AB r' A BL t LI OYES- 18164° Cr 4i VAC • 1 COMMON (RS/R11/R12) DESCRIPTION

TRAY MONT INTERFACE 1167146

1g HE1 z -5 In

eo

P3-I RIGHT CONE CONNOR DO 133-2 MD D2-2) P3-2 PONT ORNE 156/5RSE CONTRACT (10 03-2) INCIR FOINmAD COKIMET (TO 03-1) P3-4 KM CONE 1423w. (TO 02-1) P3-5 Len SINE C014NON (10 03-1 NM 02-7) P3-5 LEFT OARS MEM WORACT (TO 03-2) P2-1 120 INC LINE P3-7 Lin own MOM.. CONTRACT (TO 03 -1) P2-2 P2-3 120 vAC WNW. P3-5 LEFT OWE scow. (10 03-1) P3-C CUTTER LOTtER 02-4 P3-10 CUTTER iNsE P2-5 TRW 1:164R6 P3-11 PUMP MOTOR P2.1 P3-12 120 vAC LINE

&iuAiioRctt

PI-1

P1-3 KANO CONON Pi -4

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'16 AVM BLK (EXCEPT FOR MCU FACEPLATE CARING)

P3-S

£116 AWG MHT (EXCEPT f__ FOR I.O LATE VARING)

tor RIR HEN-4-itAi••

1iI / lir] ilti I vim wigp 1 R R-

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c

NOTES:

P1-I 412 ,4Ectou4

M

11E1 i

TO METHANE SENSOR

1GREEN RED ORANGE BLUE BLACK

1(1813) 4)th

2(18

"SWING PANEL"

MARE TERM. NO. NO. 111-1 217 R1-2 R1-3 R1-4 2254 R1-5 226 111-6 3 R2-1

R5

R7 184 184 184 TB4 184 184

0

224TB ( 6) 79085)-

(N/u) *R19

rxTva ,3):

SET AS TCHS --, -...101 AS SHOWN (RECORD oisoauc, + IKElli [112114121 I- 2224 COR. N. ENERG2) ...1 77(RO-2) GHEIS CANNOT —/ ....-..

3(1813) AA4PER TOGETHER

R9 N 77(CFM120)

=KM

_ Vs, Cs CANNOT JLAIPER TOGETHER 3(1013) —4(19iML / ig A11A2L1 L2IKALT1ILT21PT SET RESPONSE /Ts. AS SHOWN 000) Noold) 14)°,00 /Et 'Orm120"

!CM* 5(182) O

33(T86) 36(186) 15(187 12(787) 13ft TO DISPLAY - 13067; BOX 14(TB7) - 16(1'87) J11(1137) 8(187) 19R TO SENSOR 9(197) 10(787) 185(T06) (N/u) BE 181088)1 gg 182(186)

SEND R22

R

815 2230E16

11 41424)--32086)

r-

ttig

P4STALL BLUE SHEATH ON .31CSE CABLE ASSY O1.A00CTOR58..

igniTig

E. 88

Ifl4cF441

11111111 MOW-[Bgi

1. THE INTRINSICALLY SAFE CIRCUITS CARED INTO THE MAW

BY THE MINE, SAFETY, AND CONTROL CASE HAVE BEEN TESTED HEALTH ADMINISTRATOR (MENA) 70 PROVE THAT THEY CANNOT CREATE AN ARC OF SUFFICIENT TEMPERATURE 10 iC/ATE GAS. ANY SUBSTITUTION OR ELIAINATION OF PARTS WILL v00 THE MACHINE AND CREATE A HAZARDOUS CONDITION. ',IT. 2. TARES 24. 25, 45, 46, 259. 260 (INTRINSICALLY SAFE WRING) SHALL SE MIRED MOTH #16 AMC. 800 VOLT wat(LIGNI kW. DST P/N 394089. BUNDLE SEPARATELY THESE "ARES IN A BLUE SHEATH IN CODER 11) PROTECT THEM AND KEEP THEM SEPARATE FROM NON-IS. CONTROL CARES. • 3. VARES Z 2A, 157 TO THE 1ACU FACEPLATE SHALL BE CARED WITH #160/0 (11A1).• ALL WRING FROM THE mCu FACEPLATE 10 THE NEAREST OEM OR 018 AR% MK MIRE, DOT TERMINAL BOARD SHALL BE CARED P/N 173955 UNLESS OTHERWISE NOTED (EX. GAD).

A 4. SIRES 2. 2A, 26. 2C, 20. 2GS, 155. 157. 802, 804. 805 118 ARO OAT), DST P/N 298840.

SHALL OE WED MIRED NTH ALL OTHER 120 VAC ACID DC CONTROL MARES SHALL #I6 ARC (04.K) DOT PAI 296871.

AwG *5 *RES NIL 12, 7M 704, 705 SHALL BE WM WITH (CANT), T), COT P/N 2068231* OATH #12 ARO (EILK).

AIRED X1, Y1, 701.

703.

706 SHALL BE MARES DOT P/N 296818.

6. ALL CURRENT TRANSFORMERS (CTe) MUST OE LOCATED AND TYE-VAAPPED IF NECESSARY TO TO A1100 INC TOM BEING DAMAGED 10 VIBRATION OR COMING IN CONTACT MATH EXPOSED TERMINALS. 7. ALL CABLE JACKETS SHALL PROTRUDE THROUGH THE GLAND ASSY STUFFING Box A MINIMUM DISTANCE OF 1/4-.

GROUND WIRES 17TH THIS HOTADON SHALL BE MED USING #I2 ARO (GRN) ORE DOT P/N 304077 PER iiSHA APPROVAL, ALL OTHER GROUND MIRES SHALL BE /16 AND ((CNN DOT P/N 128060. GROUND WOES SHALL MIRE 10 MACHINE FRAME.

-

FOR INFORMATION

ALL DIMENSIONS ARE IN MILLIMETERS nits DRAWING IS THE PROPERTY OF E181 AMERICA INC. JNLESS NOTED OTHERWISE R° REPRODUCTION DR usE °F. D" "YAmERICA DtINENAC, 1°X" (X) NEW RELEASE wITHOuT THE WRITTEN CONSENT OF DOT Et C17°12 Balm REV DESCRIPTION 12 11 1 9 8 1

10

MATERIAL:

WEIGHT LBS

CHEM.

V

DBT P/N UNITS REME/4CD BY 01/02A1B f CLOFAES RAW DIMENSIONS MATERIAL SO FT /1.1A1 FT ckitA .D131 AMERICA 11/14/03 DATE NAME S/14: 300995 Fnivi DDC 02835 REV 7 4 6 5 -1 I FAc *away DATE

1

NAME DATE 01/02/0e F CLONES

DRAWN BY

ATTENTION ‘sP PROJECTOR mODD. NO.: FIRST USED:

3

SCALE TITLE: WIRING DIAGRAMS, 30M, ENERGY 1:1 WEST (SWING PANEL W/MCU944) tottVatill3 30U 6 0589 5 SHEET 2 OF 4 SIMILAR TO; I 1

BI377591 12 10 RADIO RECEIVER BOX

TO PE

ANT TRANSMITTER I rlSEE NOTE 2

1-BLK 27 2-V.H 3-RE 3/ 4 33 5 6 -et 7-4411 ALI() 36 8.RED/BLKI

(LEFT HEADLIGHT)

TO LEFT HEADLIGHT

1-GRNI26 2- ED 3-REO/WHTI...

GHT HEAD LIGH TS) TO RIGHT HEADLIGHTS (RI • / • • • •• • 703 NI 705 HO ORN

TO LEFT AREALIGHT

703 2 -1411 3-ORN 705

1-8LK* 2-**

3-GR i

TRAM PENDANT

TO RIGHT AREALiGHT

TO PUMP MOTOR

TO LEFT EMERGENCY STOP

I -BLKId03

1-BLK 1 2-WH 5 3 -GRN 170 (WRAP CIRN CORD WIR EDTAPE)

7

1-RED(256 2-GRIA255

2-WI 3-

I-RE TI 2-II/14 512 3-BLK 13 4-YEL a-GRN1128 6-GRN1121

JUMPERS or14-1C DEL 1Kv 253870 JUMPERS 12-1C DEL 2 Kv 169237 12 VAC 500 VA

yr

1L1( T5)

1i1

112

JUMPERS .1/0-1C DEL 2 Kv 169238

1L3

211

21.2

TAM)* x1(129)

1L2(15)

9211118141 120

V

VAC WOO VA

1 -131.14

'21M2 3-131141613

3 4

4.-ttu 5-ORNI130 6-409P41121

5

641U

230

131 0-4144 28 10 -ORG 29 11 -81.U/134. 232 12-84.4/wri 233 8-RED/BL

2L3 JUMPERS ifr /2./Q-IC DEL 2 Kv 172942

13-RED/101 14 -GRN/W•I 15-8LU/1191 2D 16-131.K/REO

32

TI

Ef,

— 11.2(CF)

20 COMMON OLu/VmT

rir..11.2(11)

52(101)

EV1500V OvJ "75" 50 VA

CO

54(181)

A DS C CHO 0 CHU E CH0 F 040 G CSR H CU

106010

IA101(TB8)

271

OV 150V

JumPERSjI6-ic 173960

SOLENOID BLOCK

0 r- 0

950V/120v/12V 1L1 (Cr) 10(T1)

70 SCRUBBER MOTOR

I i

SEE NOTE 2

6T1 6T2 613 100(188)

2t

`CT6"

154(104) 155(184) (FOR MACH VOLTAGE INPUT ONLY)

102(188)

"CT,"

REAR WALL

PLUG IN THIS SIDE

101(108)

*101(108) 111

L CU

ALL UNUSED CABLES MUST BE PLUGGED MATH 192760

213

11.2 4

217 SOMMER SPRAYS wit 225 DUST SPRAYS O 226 CH FLOAT GRN 227 CH RAISE ORN 234 CH RAISE Btu 235 CH LOWER 11411/94.K 230 CONY SWING RIGHT REVOLK 231 CONY svANG LEFT OrNALK 228 CONY UP DRII/81.K 229 CONY DOWN 81.u/OLK 212 Rua JACK DOW 84K/II41T 233 STA8 JACK UP RED/WHT SPARE GRN/MIT SPARE

J CO K 550 I. 5511

"CT2"

70 DISPLAY BOX LEFT WALL

LEFT WALL

Tel (911AR (1813 (11i13

(R11-1 R3-2

(16AR)(CSR n (R11-2)

(LO (RD

(1813)

111

11eXlit

(MAR (1014 (1814 0.0

ILI

112

1L2

RIGHT WALL

i0-at

(R10-1)

3 4 -BLU -0RC 1 90

8-BLU/8LK 15 10-YEL/81.K 16 22 12-BLK/RE 23

(705)

. ,. .

(L SI

(Lsi 57(09

R12-2 -4

16- /RED 17-Box/Stu

3! — A •

I

443(184)

4B(

\JF211__EaLlya/ L

465(101)11

1290-99 - L G/E I LL 92 21- XL

110(184) 104(184)

(

101(184)

STi

312

"ci3-

TB3

I

313 n

571 512 513

C!@

412 413

SS

(P)

CF)

511

PC

©?,©?,©

.C15*

10 HYDR, OIL LEVEL SW. SEE NOTE 2

8

JUMPERS 92/0-1 DEL 2 Kv 72942C

512 513

CT3

)

-13,1 2-WH 79 3-GRN...

)

HYDR LOw LEVEL 81 c cit•

(TPI) (T11) TT)

ma)

NOTES: BOTTOM WALL

F3 F4 MM)

QOM '(185 8)) 15 WA) r3DT) itSOT) PL RED)) PL 6RN))( .0 L IILK)) PL 144i1)),

A.

(P8-i) (R7-2 (R7-3 (R7-4 (R7-5 (R7-6 (R7-I

)

1pi.

CT4" C

(114-7 R4-9 R4-9 (R4-10 (R3-6 (R3-6 TS TS

10 01

101(184)

223=

411

22 3:R 9LEE D/ /99 ORG G::: 24-BLU/ORG -

n

P) (111) 0408) (11314) £m)

.1,

le-RED/83. 'sib

0

6I(Cr)

- 4E(Cr)

(1AC87)

Al- 4) P1-S R2-10) (R2-4) R2-6) 02-7) (R2-6) (R2-0) (R2-8) R1-161TPI) R2 ( TPi)

: igti t n:D DGAL m:RE IE IBL 6 1112K 1143 1161515297-1E _o am

JUMPERS /2-1C DEL 2Kv 169237

1E1

X (LW (LSI

(RI-2)

Jig

o-

g

(MC87)

(p (T814 088 (ER (TT (1814 (T63

C

IL3

4

1488) (t

4 JUMPERS F2/0-1C DEL 2 Kv 172942

©

EON NMI

(ACE12)

(40

O

JUMPERS 12-1C DEL 2 Kv 159237

Da *O. h-h

0. )44.1„W,

ARAMS 12-1C DEL 2 Kv 169237

T5

C._

162 ( m C8 )

_.-{C-ESTOP

ce)

JuHPERS 114-1C DEL 1Kv 253879

C14) IRO C13 C14 1+

(1122-5)

022-0

RIB-1) R15-2 1 R15-3 R15-4 R15-5 RIP-1 ?1118-2 0918-5

8

TYPICAL SIZE 4 VACUUM CONTACTOR ENCAPSULATED COL CIRCUit (pRE-rARED Rpm FACTORY) TYPICAL SiZE 5 VACUUM CONTACTOR ENCAPSULATED COL MONT, (PRE-WIRED ER004 FACTORY) •

GROUND MITES WITH THIS NOTATION SHALL BE MIRED USING #12 AND (GRN) TORE DBE P/N 394077 PER MSHA APPROVAL, ALL OTHER GROUND WKS SHALL BE 06 AwG (GRN) DOT P/N 120960. GROUND MILKS SHALL MIRE TO MACHINE FRAME.

• SEE NOTE 2

FOR INFORMATION ALL DIMENSIONS ARE IN MILLIMETERS THIS DRAWING IS THE PROPERTY OF DOT AMERICA INC. REPRODUCTION OR USE Or THIS DWG MAY BE DONE 400000011012 JNLESS NOTED OTHERWISE NOWITHOUT THE WRITTEN CONSENT OF DOT AMERICA We. to NumBER

1117-4) (R17-1) 19172i R17-3 1116-4 R18-I R16-21 0416-3 016-5 VI) f2)

C.O. 1.

THE INTRINSICALLY SAFE CIRCUITS WRED 1110 THE MAIN CONTROL CASE HAVE BEEN TESTED BY THE MINE, SAFETY. AND HEALTH ADMINISTRATION (1,I5HA) 10 PROVE THAI THEY CANNOT CREATE AN ARC OF SuFFK3ENT TEMPERATURE TO IGNITE GAS. ANY SUBSTITUTION OR ELIMINATION Or PARTS RILL VOW THE MACHINE AND CREATE A HAZARDOUS CONDITION. 2.

WARES 24. 25, 45, 46, 259. 260 (INTRINSICALLY SAFE WRING) SHALL BE MIRED METH OS AND, 600 VOLT VARE(LIGHT BLUE), DBT P/N 394089. BUNDLE SEPARATELY THESE MARES IN ORDER TO KEEP THEM SEPARATE FROM NON-LS, CONTROL ORES. 3.

WARES Z 2A. 157 TO THE NCO FACEPLATE SHALL BE WIRED WITH flISAIVG (Ml).e • ALL WRING FROM THE MCU FACEPLATE TO THE NEAREST DEICE OR TERMINAL BOARD SHALL BE WRED MATH /18 AK, BLK MIRE, DOT P/N 173955 UNLESS OTHERWISE NOTED (EX. GIID).

A 4. MIRES 2, 2A, 20, 2C, 20, 2G5, 155. 157, 802, 804. 805 SHALL BE DARED WITH 916 AWG (WHY), 081 P/N 226640. it ALL OTHER 120 VAC AND DC CONTROL WIRES SHALL BE MIRED WIN /16 AMO (BLK) DOT P/N 296871. sh 5. WIRES X2, Y2, 702. 704, 705 SHALL BE WIRED WITH #12 AMC (WIT), DBE P/N 206821* MARES XI, YI, 701, 703, 706 SHALL BE WIRED WIN 912 ANC (BLK), DOT P/N 2051318, 6. ALL CURRENT TRANSFORMERS (CTs) MUST BE LOCATED AND TIE-WRAPPED If NECESSARY TO 10 AVOID THE ICROD BEING DAMAGED 10 VIBRATION OR COMING IN CONTACT WITH EXPOSED TERMINALS. 7. ALL CABLE JACKETS SHALL PROTRUDE THROUGH THE GLAND ASSY STUFFING BOX A MINIMUM DISTANCE OF ix.

INSTALL EXTERNAL SHIELDING ON CABLE 21 BETWEEN THE MANN CASE 10 THE DISPLAY CASE. GROUND ONE SIDE OF THE EXTERNAL SHIELDING TO MACRE GROUND. THE SHIELDING FROM 185 TO THE THE 1150 PLUG MUST HAVE ONE SIDE GROUNDED TO MACHINE

GROUND. MATERIAL:

00 HEW OMAR RE%

DESORPTION

WEIGHT LB

TOLE: 01/02/06 F. CLONES

DST P/N UNITS AmENE0 IY 01/02/06 RAW DIMENSIONS MATERIAL SO FT/LIN F7 t/wAm FAO runs in DATE DOT AFRICA 11/14/03 DATE NAME 4/4: 300955 DOC #2835 REV '

WIRING DIAGRAMS, 30M, ENERGY WEST MCU944, IGBT DC DRIVES MODEL ND.: FIRST USED:

605895 SAMAR

0:

SHEET Or 4

BI377591 10

a

7

6

4

5

3

2

1

NOTES:

SAFE SUFFICTENT

1. THE INTRINSICALLY CIRCUITS WRED INTO THE MAIN

BY THE MINE, SAFETY, AND CONTRE4. CASE HAVE BEEN TESTED HEALTH ADMINISTRATION (MSHA) TO PROVE THAT THEY CANNOT CREATE AN ARC OF TEMPERATURE TO IGNITE GAS. SUBSTITUTION OR EUINNATION OF PARTS WILL VOID THE MACHINE AND CREATE A HAZARDOUS CONDITION. 2. IMES 24, 25, 45, 46, 259, 260, (INTRINSICALLY SAFE wRiNO) AWG, 600 VOLT 11ARE(L4G4IT BLUE). DOT SHALL BE WRED WITH P/N 394089. BUNDLE SEPARATELY THESE WIRES IN ORDER TO KEEP THEM SEPARATE FROM CONTROL WIRES. • 3. TARES 2, 2A. 157 TO THE MCU FACEPLATE SHALL BE WIRED WITH /IBM (W11). • ALL WRING FROM THE KU FACEPLATE TO NEAREST DEVICE OR TERMINAL BOARD SHALL BE TARED WITH /IS AWG, 1NX WIRE, DBE P/N 173955 UNLESS NOTED (EX. OHO).

A 4. WIRES 2, 2A, 28, 20, 2O, 2GS, 155, 157, 802, 604, 805 SHALL BE WIRED ALL OTHER 120 VAC AND DC CONTROL AIRES SHALL BE WRED 111TH ARC (BLK) DOT P/N 296871.

12, 702 704. 705 SHALL BE WIRED WIN 512 ARC (WIT), DOT P/N 296823.* MARES XI, Y1, 701, 703, 706 SHALL BC AIRED WM 512 AWG (ELK), DBE P/N TRANSFORMERS (CU) MUST BE LOCATED AND 6. AU. 10 TO THE TOROID BEING TYE-WRAPPED IF COMING RI CONTACT 114TH EXPOSED DAMAGED TO TERMINALS. 7. ALL CABLE JACHEIS SHALL PROTRUDE THROUGH THE GLAND

TO MAIN CONTROL CASE

ANY

NON-I.S.

(NOT IN CONTROL CASE — LOCATED LEFT REAR OF MINER)

110TARY PATCH OM)

1441ING R010.1tY

111211

OTHERWISE MTH 516 AWG

LEFT E—STOP --0-1031)

* 5.116WIRES X2, 296818.

CURRENTNECESSARY VIBRATION OR

- 5(152) -170(132)-0-

l&-% H=1

0-d

f.--1V '11:141

41-1—

THE

DOT P/N 296840. &

AVOO

TIE1 AWG APPROVAL.

‘40.RED USING GEZNINF Isillt tHrtalaTASN IIZLI 512 ARC (OLIN) col P/N 394077 PER LISHA (GRN) DB1 P/N ALL OTHER GROUND WIRES SHALLBE #16 GROUND WOES SHALL WILE TO MACHINE FRAME.

n. MOMENTARY

VATH SPRING RETURN

WIRE

128960.

CONTROL CASE MAIN ROTARY SWITCH O

CONTROL CASE E-STOP 1(181) 170(7132) -

LIGHTING ROTARY SW

POSITION STOPS IN SWITCH AS SHOW,/

af U U

wa

Sv c

PAVA-V-A-V-A-v-A-\

A 802(1A036)

— 7(792)

A

169(1132)

801(MCB5)

254(132)

*702(MC64

* 704(762) *

-69(132) 701(MCB3)

703(762)

0 V

El g rh II 18 A ii 4 4 41 4 4 4 OD IN r: 4•,,i ret I. in to

6 6 La' 6 5 8 5 2m2322m

N ...,..

I, 44.

ILIttti

SHAFT END OF SWITCH ALL ON

FAN OFF FAN W/CUTTER HEAD LIGHTS

OFF/ETRAM

AREA LIGHTS )

CND CHK ALL OFF

NOTE: MOUNT LS1 ROTARY SWITCH SUCH THAT COPPER TERMINALS 1, 5, 9, 13, (7. 21) ARE POINTING DOWNWARD ELSE LIGHTING OPERATION WILL NOT FOLLOW NAMEPLATE

THIS ORAitiN0 IS THE PROPERTY OF DBE AMERICA INC. NO REPRODUCTION OR USE or MS DRAWING MAY BE DORE 500000017012 00 NEW RELEASE WITHOUT THE METER CONSENT OF DST AMERICA El NUMBER REV DESCRIPTION 12

WEIGHT LDS

MATERIAL:

FOR INFORMATION

9

8

-FAG DATE NAME

DB7 P/N MATERIAL RAW DIMENSIONS

0100 11.0 DATE

s/P4: 300995

I

6

DATE

NAME

DRAWN NY .01,Aulpe F. 0.011E8 5141REV SHECKES BY 01/00/06 UNITS CLOMES RENEWED SY 01/02/08 SO FT/LIN FT DOT AMERICA 11/14/03

CMA9 DOC 0835 REV

ATTENTION 1

ty PROJECT MODEL FIRST USED:

SCALE 11111 1:1 WIRINGS

SCHEMATICS, 30M, ENERGY 00 WEST (CONTROL CASE FACE W)

301A

RIM

605894

SIMILAR TO;

I 1

SHEET 3 OF 3

BI377591 4

6 DUST_SPRAYS 1

[.14

2' DIA SUCTION MEE

7.5 GPM8(28 L) 500 PSI (35 BAR)

50 PSI BYPASS

S S

GATHERING 7 EAD ROD DOWN CUTTER HEAD CROSSOVER

30 GPM

(114 L.) 2500 PSI (172 BAR)

1750 RPM

MIDDLE CROSSOVER (ELECTRICAL) CONVEYOR RAISE PRESET 8 3000 PSI (207 BAR)

SEE NOTE 4

3 2 EA 175478 4 2 EA 604955 5 1 CA 174667 6 2 EA 604964 7 2 EA 398419 8 2 EA 312964

(--

REAR CROSSOVER

E.

USE TOP PORTION OF FRONT CROSSOVER

CUTTING HEAD RAISE PRESET E 3500 PS] (241 BAR) THERMAL ATMOSPHER RELIEF PRESET @ 5200 PSI (359 BAR)

CONVEYOR TAKE-UP

STABILIZER CONVEYTJR SWING

RADIO REMOTE/ OIL FILL

GATHERING (DHEAD ROD DOWN

PRESET AT 230 PSI (14 BAR)

CAT NO

10 3 EA 383997 11 2 EA 232210 12 3 EA 604959 13 19 3 CA 604958 15 3 EA 383E358 16 17 3 CA 171109 01 18 1 CA 171936 01 19 3 EA 390938 20 01 21 1 EA 169338 01 22 1 EA 204040 01 23 1 EA 236868 24 1 EA- 286981 25 1 EA 291446

J-565015414K001

J-499515

1-56466541RI001

GAUGE, PRESSURE 0-600 PSI (0-401 GAUGE, PRESSURE 0-1000 PSI (0-68) GAUGE, PRESSURE 0-4000 PSI (0-275)

J-499228 J-499229

J-555A72111X003 J-555A721MK004

MONET, TANK (LONG) MANIFOLD 2-UNIT SOLENOID PUMP HAND PISTON TYPE 20 GALLON PUMP, HYDRAULIC P330 (30/7.5 GPM) PUMP JET l'HPT

J-487315

J-C48731544K001 .1-565931614K001 1-1468702

CLEMENT. Sun CARTRIDGE ELEMENT, 10um CARTRIDGE ELEMENT, 10uA CARTRIDGE

STRAINER, I

117 166 206 488 101

<FOR 383858) (FOR 383858) (FOR 604958)

FILTER, 10uA PRESSURE OIL FILTER, MANIFOLD

27 1 EA 295690 28 29 1 EA 357691 30 31 1 EA 289047 32 33 1 EA 169073 34 1 EA_ 375219 as 36 1 EA 361674 37 38 1 EA 358510 39 40 2 EA 20410 41 48 1 EA 386634

REFERENCE DCOMENT V1/LOS .5

J-495527

CYL, CONVEYOR CHAIN TAKE-UP CYL CONVEYOR RAISE (TELESCOPIC) CYL, cotwcyria 56/111(1 445') CYL, CUTTING 110 RAISE CYL, GATHERM HEAD (350W1 GC) CYL STABILIZER

9

CV

2

..I/AdIXTIVS Ph ITE DESRIPTIE444 1 2 EA 335534 BREATHER, 40uA/30 CFM 3/4 'PT

SAE-12 .5 .5 .5

C-78005535 (-49227090

l'}IPT

VALVE. ANTI-cHATTER/mAINTENANcr VALVE, CHECK 3/4 NPT

E-923010I9

1-2 PSI J-41317136

VALVE, CONTROL 5AE-6 VALVE, CONTROL vG36 6-UNIT V/1430 COILS

J-520E007418004

6.5

J-555G317PC001

18

J-568G031MK001 J-5666031144002

46 64

VALVE, CONVEYORSHAIN TAKE-UP VALVE, GATHERING HEAD FLOAT VALVE, Korvin SOLENOID (120v) AE

VALVE RcLICE

A Er EA 362106 B EF EA 362109 C EF EA 362688 EF EA 357692 EF EA 357693 F EF EA 362108 EF EA 2879% H EF EA 287997 J EA 3504% K Er EA 256643 L EF EA 350493 14 Er EA 256642 N EF EA 362254 P 'CF EA 605242 R Er EA 362687 S 'CF EA 362107 T 'EF EA 295195 U Er EA 167600

100-1030 PSI

CARTRIDGE, NEEDLE VALVE (011-2) CARTRIDGE, RELIEF VALVE (OTY-2) CARTRIDGE, PRESSURE REDUCING VALVE CARTRIDGE SELECTOR VALVE (V/KNOB) CARTRIDGE SEOLIENCE VALVE (W/CREEK) FILTER, CARTRIDGE 75,,, MANIFOLD L-SHAPE (3/8 3/4 181) (3/4,3/4 NP1) MANIFOLD, L-SHAPE MANIFOLD, L14 CUTTER HEAD CYLINDER MANIFOLD LH TANK MANIFOLD, RR CUTTER HEAD CYLINDER MANIFOLD, RH TANK PLUG, ORIFICE .031 VALVE, BALL 2'NPT VALVE, CHECK 5 PSI VALVE, CHECK 5 PSI (011-21 VALVE LOAD HOLDING CARTRIDGE (FOR MR(-6 VALVE, POT OPER WATER NC I'NPT

J-5656979144002

7-499196

J-56538751'K004

11

E-49318734 J-5553247104001

5.1

28130 PSI 1193 DAR) 12-A WI

IN

WI

1212-C T2-

- -

7- A

11 : n

KAA-t!vER NEE STABILIZER 44444.4.41st smcc 2503 PSI <172 BAR) CONVEYOR RAISE 1400 PSI (97 BAR)

PtriA-LPAPER PILL-RAISE CP

SU TOP SSD DOT 1400 PSI (97 BAR)

RENA W

IN

T

1

a I

EN

17-i 12-r

11-SUCTION PORT

T2 -IL

77-C

SET AT 530 PSI 434 DAR)

CU TOP CD BOT

T7-0 T7-H 12-1:

T7-B 17-C 7-0

,..3,11.n

PaISSWE

T2-N 12-J

-T

17-1-

-K

EP I SI

T7

6F14

CENTERLINE OF MACHINE

0113 mysm-url CIAIL PAL-mm C1414

CONVEYOR SWING 1600 PSI (124 BAR) 4 PLACES

CSR TOP ESL BUT

(uSA-P1,041 GIP 44.u.-RAISE ft4

GATHERING HEAD

GNU TOP CHI) SOT

Puls4-40vER Ps4.1.-RAISE GNP

CUTTER RAISE

7rf CR PRSET e 1800 PSI (124 BAR)

PILOT

MANUAL FILL

YL

CFli1 TOP CHD DOT

11 120

OIL LEVEL FLOAT SWITCH

FILL

sou PSI 4207 BAR) NS I ES SET AT 1200 PSI (83 BAR)

ARE PRESE

#16

mATERIAL4

FOR INFORMATION ALL DIMENSIONS ARE IN MILLIMETERS Rico"TAR(mwtRIPNg"*"' "4"M"'""W‘ "' ypA 6,115000017091 01 comma /*MEM la WA .3 WM, Dn. rerktfif IV MIK [WI tongt6/FU X Z.410.

6, it:11001Y% lon 4000011216766 00 UNLESS NOTED OTHERWISE ittlVaLITZTh Ply Re Igtos ox,,A44 .,

I

—

lost 1s 4104144 IMO WU P Lary e...k,., kr.

ADDED 10212221440 ITCH 19 WAS 312524-14-6.6 CII,E CELE 2-14- „< RUCYRU3 P/N NV/ RELEASE 12-6•07 C11211011 EY Dm MATERIAL EE RUNNER Ku RESCRIPIEPRI DAZE 1/ 44300995

10

--RAW DIMENSIONS

WE IGHT LBS

- -

UNITS SD FT/L1N FT ---

OIL FILL 2-SUCTION PORT

NOTES, 1 NUMBER IN BOX DENOTES STAPLOK AND HOSE SIZE .

1/4 THRu 1-1/4 HOSES DOUBLE WIRE BRAID 1/4' ID HOSE 012 3/4 ID HOSE 06 = 3/8° ID HOSE 416 = 1' ID HOSE 118 = 1/2' ID HOSE 420 = 1-1/4 ID HOSE 2) HAIN CONTROL VALVE SOLENOIDS, BOTTOM SOLENOIDS OPERATE 'A' PORT TOP SOLENOIDS OPERATE PORT 3) WHEN MANUAL FILL/POWER FILL is NOT IN USE, HOSES MUST BE CAP TO PREVENT DIRT FROM ENTERING THE HYDRAULIC SYSTEM, 4) SPARES HOLES IN CROSSOVER TO BE IDENTIFIED AND CAPPED BOTH ENDS 3) HYDRAULIC TAW OIL CAPACITY = IOU US GALLONS (3791) HYDRAULIC SYSTEM OIL CAPACITY = 120 GALLONS (454 L) 5) FOR ACTUAL FIRE SUPPRESSION AND Dust/CODLING SEE ORDER 6) SHIP ITEMS 13 THRU 06 WITH MACHINE.

VR PRSET 1200 PSI (83 BAR)

T7-G

TANK PORTS DIPSTICK

461 .7 p4.1 :(

st 1 ,:-" G.

-6- 7

14441.

147 L

FORM OA .04.39

CME , EucTRus oin toe REV I

AT ENT1111NY

SCALE TITLE; Am SCHEMATIC, HYDRAULIC 30M3 I- O NU 11 1 IQ TI DRAviNG MODAL IC, 604962 30M3 NURSER SHEET I OF 1 FlAIl USED. 604961 ENERGY WET SIMIAN YE1331775/19,0102 I

BI377591 A

REVISIONS

2 A 3 A

A

5

A

6

A

7

A

8

A

9

A

I0

A

11

A

12

A

13

5680555

DESCRIPTION t2TINC,uAS-rf-TINTES

z F.

A

14

A

IRIS BRAVING CONTAINS CONCIIENTIAL WO/ATM iaab IS 1NE EXCLUSIVE PROPERTY1J Ty (VC 1C /COFER 'DE EGGIRENT 0/112 IPS MN. TENTS FUTE TO BE USED, REPRODUCED, OR DISGUISED IN VIRILE TOO IN PART 011141111 11-E PRIOR EXPRESS WRITTEN PERMISSION Cr TOT ANERICA

DIMENSIONS ARE IN INCKS UNLESS OTHERWISE SPECIFIED MEC 1 , 16 PI RI

CRAWLER CHAIN TAKE-UP CYLINDER CAT 486941 548F979 MK -1

STABILIZER SHOE CYLINDER 5676133 MK-1

WANT X

16

A

D BT AMERICA

4r• • PO BOX 1879, COLUMBUS, OHIO 43216

HYDRAULIC COMPONENT LOCATIONS 30M3

OWN ROLFE DOTE 9/02/03 OMUTA ZYCII AM 10/13/03 APMEAFED DESCRIPTION HYDR6ULIC COMPONENT LOCATIONS a LH HYDRAULIC COMPONENT LOCATIONS ORE, ,R11 HYDRAULIC COMPONENT LOCATIONS ORE

'DECKED COLE NATERIN. IME

A

GLOIDER 00002 IC

CAT ND 10111 0106 00< 5686557 56818556

4

VENT TEE 566A027 MK-1 1/4' NPT BALL CHECK VALVE CAT 499415 C499415 MK-/

I jekumwo.0 141

15

NOTES GATHERING HEAD CYLINDER CAT 499089 5476188 MK-1

CONVEYOR RAISE CYLINDERS 5675855 MK-I

I. FOR Lit HYDRAULIC COMPONENT LOCATIONS, REFER TO ORG 5686557.

2, FOR R.H HYDRAULIC COMPONENT LOCATIONS, REFER TO DRG 5686556,

CONVEYOR SWING CYLINDERS CAT 499515 5646654 HR-1

CONVEYOR CHAIN TAKE-UP CYLINDERS CAT 499527 5656154 MK-I

CUTTING HEAD RAISE CYLINDER 5676856 MK-I •

STABILIZER SHOE CYLINDER 5676133 MK-1

CUTTING HEAD RAISE CYLINDER 5676856 MK-1

GATHERING HEAD CYLINDER CAT 499089 5476188 MK-I

CONVEYOR CHAIN TAKE-UP CYLINDERS CAT 499527 5656154 MK-1

CONVEYOR SWING CYLINDERS CAT 499515 5646654 MK-1

CONVEYOR RAISE CYLINDERS 5676855 MK-1

1/4' NPT BALL CHECK VALVE CAT 499415 C499415 MK-I VENT TEE 5664027 MK-1

MK—I HYDRAULIC COMPONENT LOCATIONS

V

2 V

V 4

V

V

7

V

c2/

V

CRAWLER CHAIN TAKE-UP CYLINDER CAT 486941 5481979 MK-1

NT

lo

=PIT Xf

Ver STANDARD SPECIAL MI3[ 41 1 1 1)11 21 A

114.11. OW. BACitg

13_ 5686555

x

BI377591 12

TO ANTENNA CABLE

NOTES: (t. I. THE INTRINSICALLY SAFE CIRCUITS WRED INTO THE MAIN CONTROL CASE HAVE BEEN TESTED BY THE MINE, SAFETY, AND HEALTH ADMINISTRATION (115HititTO PROVE THAT THEY CANNOT CREATE AN ARC OF SUFFICIENT TEMPERA TO IGNITE GAS. ANY SUBSTITUTION OR ELIMINATION OF PARTS WILL MID THE MACHINE AND CREATE A HAZARDOUS CONDITION. 7..0 2. WRES 24, 25, 45, 46 269, 260 (INTRINSICALLY SATE WRING) SHALL BE WIRED WTH .16 AWG, 600 VOLT VARE(LIGHT BLUE), DOT P/N 394089.

BUNDLE SEPARATELY THESE WILES IN ORDER TO KEEP THEM SEPARATE FROM NON-LS, CONTROL MARES, • 3.

WIRES 2. 2A. 157 10 THE MCU FACEPLATE SHALL BE VAREO WITH #18AWG (WIT), ALL WIRING FROM THE MCU FACEPLATE 70 THE NEAREST DEVICE OR TERMINAL BOARD SHALL BE VA ED WITH #16 AWG, MK WIRE, DOT P/N 173955 UNLESS OTHERWISE NOTED (EX, CND).

A.4. was 2, 2A, 28, 2C, 20, 205. 155, 157. 802, 804, 805 SHALL BE VARED WITH I16 AWG (Mil), DOT P/N 2968411A ALL OTHER 120 VAC AND DC CONTROL WIRES SHALL BE MED VAN #I6 AWG (ELK) DDT P/N 298871.

WIRES X2, Y2, 702, 704. 705 SHALL BE MIRED WITH 012 AWG (WIT), 11€5.

DOT P/N 296821* WRES Xl, 11, 701, 703, 706 SHALL BE *RED WITH 112 AVM (BLIT), DOT P/N 2961518.

6. ALL CURRENT TRANSFORMERS (Cle) MUST BE LOCATED AND TYE-WRAPPED IF NECESSARY 10 TO AVOID THE TORO BEING DAMAGED TO VIBRATION OR COMING IN CONTACT METH EXPOSED TERMINALS. 7. ALL CABLE JACKETS SHALL PROTRUDE THROUGH 11-1E GLAND ASSY sturnem BOX A MINIMUM DISTANCE OF I/4'.

TO MAIN CONTROL CASE

1-13LKI27 2-101T 28 3-RE 32 4- 33 5-OR 34 6-BL 35 /13LKI36 13-RED/EILKI „

0 a N

0A 0 a a

36 35 34 33 32

TERMINAL LUGS

MUST USE PROPER LUG ON CABLES ACCORDING TO CONDUCTOR SIZE

0 0LI

00a

a a .1 of

Ed: GROUND ORES WITH THIS NOTATION SHALL BE WIRED USING #12 AWG (GRN) WARE DOT P/N 394077 PER LISHA APPROVAL. ALL OTHER GROUND WKS SHALL BE #16 AWG (OM) DOT P/N 128960. GROUND WIRES SHALL WARE TO MACHINE FRAME.

1

I -REDri 2-WH 472 3-BLK 413 4-YEL ...

5-GRNI126 8-01:6121

1-RE 311 12 3-B,LK 313 4-YEL 5- 124 6-ORNI121

-RE TI 2-1551 '12 3-EILK 13 4- YU ...

5-ORN0 26 6-GRN1121

1-RE 3T1 2-%15 3T2 3-I3LK 3T3 4-YE ...

124 56-GRNI121 I

COAXIAL

RADIO RECEIVER BOX

TO LEFT CLA MOTOR TO RIGHT CLA MOTOR

TO MAIN CONTROL CASE

TO TRANSFORMER BOX TO RIGHT TRAM MOTOR 27 28

OR/STALL EXTERNAL SHIELDING ON CABLE 21 BETWEEN THE MAIN CASE TO THE DISPLAY CASE. GROUND ONE SIDE OF THE EXTERNAL SHIELDING TO mACINE GROUND. THE SHIELDING FROM 185 TO THE THE 1158 PLUG MUST HAVE ONE SIDE GROUNDED TO MACHINE GROUND.

I

10 LEFT TRAM MOTOR

^1-RED ...Al ...S1 -3-GRN...A2 4-ELK ...52

I-REOIXL1 2-WHTIXL2 3-8LKIXL3 4-YELI ...

5-GRNI132 6-GRN 121

1-REDO... Al 2-W/IIII..51 3- GRN ...A2 4-ELK ...52

MAIN CONTROL CASE

ER

TO MAIN CONTROL CASE K TO MAIN CONTROL CASE

DISPLAY CASE

pa Alien brodiey

VersoViaw

CE woo<

1 -BLK 2-RED 6 3-BLU 9 4 -ORG 10 5-YEL 11 6-EIRN 12 7-RED/ELK 13 8-131.11/BLK 14 9-ORG/BL 15 1 -YERLN/B AL LK 2562

SEE SHEET 1, 2, 3, FOR ADDITIONAL MAEN CONTROL CASE CONTROL WRING

1

MAIN DISCONNECT CASE

110.43 12 -ELK/RED 23 13 -0FI LUG/9 /RCE 154 -9 -YEL/RED 111567 -917/BL -13 AEU 90 19 -RED/BLU -ORGAL 92

GRAPHIC DISPLAY UNIT "GDU" "I R"

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7 Al

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51

SEE SALES ORDER FOR TRAILING CABLE SIZE

6

JUMPER WARES 12-1C DEL Kv

SEE NOTE 9

ALL DIMENSIONS ARE IN MILLIMETERS UNLESS NOTED OTHERWISE 12 1

MATERIAL:

FOR INFORMATION THIS DRAWING IS THE PROPERTY OF DDT AMERICA NO REPRODUCTION OR USE OF THIS DWG MAY BE DONE 600000017012 BO NEW RELEASE WITHOUT THE WRITTEN CONSENT OF DOT AMERICA INC. ei MAMA ROY DESCIMPTioN 10

9

8

p1it2/0( FAC •••••••• DATE DATE NAME S/N: 300995

7

DBT P/N RAW DIMENSIONS MATERIAL

WEIGHT L85

DATE

NAME

DRAWN BY 01/02/00 F.CLOYRS CS AREY otrotro or DI UNITS RENEWED BY 01/02/06 F.CLOKS SO FT/LIN FT ciALA • DOT AMERICA 11/14/I rv'' DOC #2835 REV

5

4

ATTENTION

SCALE

1:1 PROJECT MOOEI. NO.: FIRST USED:

3

TITLE:

WIRING DIAGRAMS, 30M, ENERGY 6 WEST (DC DRIVES,RECVR,JBOX,DISCV lp Ette

SIMILAR TO:

7

605895

WET 4 OF 4 1

BI377591 1 REVISIONS Damen mor-VAS4y.wo

2

10

5

14

3

THIS D•AvIIK. CONTAAS COWIECNTIAL KTAI4ATIOR on IS 11-IE EXCLUSIVE PROPERTY Of nr mcgitA 14c.

NEITICR Tl9C DGCLIWAT KW IT'S UP1Min ME TO DE ustp, REPROEXED. 60 DISCLOSED R1 Idrar OR IN PART • ITADIT IRE p91(11 EIDNESS VRITTEN PED•ISSIC• Or DDT HIERICA WC.

NOTES. I. USE THIS DRG WITH DRGS 5680555 R. 5686557,

DIMENSIONS ARC IN INCHES SPECIFIED 118 ROLE MU 9/02/03

muss OTHER1115C SEQUENCE VALVE [1568A025 MK-) VENTURI ASSEMBLY

CEO

0-3000 PSI PRESSURE GAGE CAT 499230 555A72I MK-5

VENTURI ASSEMBLY OIL PRESSURE FILTER SAP 4229251 L/A 4410254 REPLACEMENT ELEMENT SAP 4225402 L/A 4410254X1

SOLENOID VALVE W/COIL__ 5656317 MK-I, 2 READ

STRAINER ASSEMBLY CAT 473692 198E747 MK-I SWING CHECK VALVE 3/4 CAT 67088 553,491 PG)

SOLENOID JUNCTION BLOCK - 14 CONNECTION5640445 MK-I

Cl

BOX 1079, COLUMBUS, OHIO 43216

R,H, HYDRAULIC COMPONENT LOCATIONS 30M3 ZYCH

DATE 10/14/03

A

WS OMER MBER

CONVEYOR TAKE-UP VALVE ASSEMBLY

EJECTOR ASSEMBLY CAT 448198 179E630 MK-1 2-UNIT SOLENOID MANIFOLD 5650216 MK-I

DBT AMERICA

•

0-1000 PSI PRESSURE GAGE CAT 499229 555A721 1-54-4 RH TANK --MANIFOLD ASSEMBLY 5650979 MK-I

1/4' NEEDLE VALVE CAT 140358 555,131 PGI 3/8 PRESSURE REDUCING/ --RELIEVING VALVE CAT 499517 0499517 MK-I

OIL LEVEL FLOAT SWITCH 5650216 MK-1

2/8' CHECK VALVE (W/54 SPRING) CAT 487320 5500795 14K-4

BREATHER VENT CAT 482393 C483293 HK-1

JUNCTION BLOCK DUMMY PLUG__ 5646445 MK-3, 2 READ

DIPSTICK 5650215 MK-1 >" MANUAL. OIL FILL

F

13

H

CRAWLER TAKE-UP VALVE (LOCATED IN CRAWLER COMPARTMENT)

0-400 PSI PRESSURE GAUGE 555A721 MK-6 PRESSURE MANIFOLD 5686033 MK'-7

•HYD PILOT OPERATED WATER VALVE - CAT 499196 5556247 MK-1 ✓ HYD PILOT OPERATED WATER VALVE --CAT 499196 5556247 MK-1

COUNTERBALANCE VALVE 5686037 MK-I MAIN RADIO CONTROL —VALVE ASSEMBLY 5656318 MK-1

1/4" 4-WAY CONTROL. VALVE CAT 481788 520E007 MK-4 SELECTOR VALVE 560A034 MK-I

0-3000 PSI PRESSURE GAGE CAT 499230 555A721 MK-5

60 MICRON PRESSURE FILTER - CAT 499492 C499492 14K-1

—0-1000 PSI PRESSURE GAGE CAT 499229 555A721 14K-4

0-3000 PSI PRESSURE GAGE - CAT 499230 555A721 14K-5 1/4" RESTRICTOR VALVE Wa2I ORIFICE CAT 486251 548A119 MK-3 1/4"CHECK VALVE (W/54 SPRING) CAT 487319 5500795 MK -I

FLOW METER 0-75 GPM - CAT 499273 C499273 MK-I

—2/8? PRESSURE REDUCING/ RELIEVING VALVE CAT 499517 C4995I7 MK-I

THERM HEAD VALVE ASSEMBLY

1/4' NEEDLE VALVE - CAT 140358 555131 P61

—60 MICRON PRESSER FILTER CAT 499492 C499492 MK-i MAIN PRESSURE FILTER --W/DIRT INDICATOR 548E112 MK-5

L

REPLACEMENT ELEMENT CAT 442579 165D502 MK-2

3/8" RELIEF VALVE (HIGH PRESSURE) CAT 499358 547F208 14K-5

PRESSURE MANIFOLD - 5676925 MK-1 R,H, HYDRAULIC COMPONENTS

1/2' RELIEF VALVE (W/BYPASS CHECK) CAT 499512 C499512 MK-1

K

rim

STANDARD SPECIA 11&31A1 1 1 11121 I

5686556

BI377591 16

15 V A,SHDOWN

14

13

11

12

HOSE

10

6

9

5

NOTES: 1) NUMBER IN BOX DENOTES STAPLE* AND HOSE SIZE THRU 1-1/4 DOUBLE WIRE BRAID 1112 = 3/4 ID HOSE 1416 .

ID HOSE #20 . 1-114 HOSE

114 = 1/4 ID HOSE 116 = 3/8 ID HOSE 48 . 1/2 ID HOSE

PRESSURE: 250 PSI (DYNAMIC) MINIMUM 500 PSI MAXIMUM

5) SCRUBBER WATER OPERATIONS NORMAL VALVE "C" OPEN VALVE 'A' & 'B' CLOSE BACKELUSH STRAINER: VALVE "B' OPEN VALVE 'A' & 'C' CLOSE SUMP WASHOUT= VALVE 'A' OPEN VALVE 'B' & 'C' CLOSE

STRAIGHT OR

DIRECTIONAL SPRAYS LEFT HAND OR RIGHT HAND • SPRAYS

r

SET 100 PSI

3 PLACES

VALVE 'A'

VALVE 'B'

4

ELEMENT, FILTER VATER FILTER, WATER 150/N

(1,161 2 PLACE

f

1

2 CAT 031

DESCRIPTION

REFERENCE DeCUMIENT VT/LOS

150ur,

GAUGE, PRESSURE 0-160 PSI (0-11 BAR> GAUGE PRESSURE 0-600 PSI (0-42 BAR)

6 1 7 1 EA 257613 RAMFOLD, PRESSURE 01 5 1 EA 400233 MANIFOLD, PRESSURE 01 9 EA 619132 MANIFOLD. PRESSURE 10 II 5 EA 171523 NOZZLE, SPRAY 114' G9-10 SQUARE PATTERN 01 12 196 EA 295166 NOZZLE, SPRAY 3/8° NP1 (511-3/ 13 14 1 EA 291446 PUMP, JET NAT 15 16 1 EA 167626 STRAINER DIFFUSER 1-1/2 x NPT 1/2 NAT (01 17 1 EA 396419 STRAINER, 1' 1502F, 18 1 EA 295690 STRAINER, Y l'NPT 15 (g] 20 6 EA 289098 VALVE, BALL 1/2' FM 21 2 EA 172069 VALVE, BALL 3/1' NPT (01 22 2 EA 601977 VALVE MALL 3/4 OPT 3-VAT 23 1 EA 170149 VALVE, BALL I' NPT 11/TFREADED MOUNTING 24 1 EA 171096 VALVE BALL I-1/4' NAT 25 26 2 EA 167600 VALVE, NC 2-VAT FiLDT OPERAIED NPT F11 27 1 EA 604951 VALVE NEEDLE 1/2 OPT BRASS 01 28 1 EA 390022 VALVE PRESSURE REDUCK 1-1/ 4 NAT 29 2 EA 295524 VALVE, PRESSURE. PECULATOR 1/2 !PT 30 1 EA 283321 VALVE RELIEF 1/2 APT ATMOSPHERIC

(03

3) FOR HYDRAULIC SYSTEM SEE UNIT 420 ON ORDER 4) WATER JACKET CLEAN-OUT ONLY

SPRAYS

MANUAL DOLING VATER

FLOW; 10 GPM MINIMUM FOR COOLING

2) FOR FIRE SUPPRESSION SYSTEM SEE UNIT 355 ON ORDER

AL SCRUBBER BACRFLOSH

MANUAL SCRUBBER VATER

WATER SUPPLY REQUIREMENTS

3

4

ITERIOTYJiletTROS PlO 1 1 Ell 384385 1 EA 384055 3 (01 4 5 EA 171108 EA 387091 5

J-547452510;002

22

10.3 J-469671 0-50012988

_I-C469671/11(001 J-566045810003

.6

J-453375

J-514D341HI(002

.5

E-49227090

4

J-469149

E-92005545 J-O469149MK001

2.6

J-499397

J-C4993971.1X091

J-487167

J-C457167/1K001

3

J-499I96

J-5550247101001

5.1

J-5676950144001

..;,.TZS;TrMT'KmZ,RI::;';;:;:Z:T,::;TN,p•T:4*X4M7c4:A;1:4ZATMS:R.;Z.IRTSZ:,.;:f.RCS:r;;A.12;,:x;$•::;;;;:;;;;;;; ;,RZ$RW:::;::::'f:

SET e 50 PSI

A REF 5 REF C REF D REF E REF F REF G REF H REF J REF K REF L REF H REF

4 PLACES

3 PLACES

EA 400.370 EA 300900 CA 4503% EA 6)04.26 EA 302050 EA 3OK40 EA 30S:a9?

EA 63531)2 EA :111129 EA EA 40373 EA 204303

MANIFOLD, CH FRONT SPRAY 20-UNITS (019-31 MANIFOLD, CH SPRAY 5-UNITS (OTT-B) MANIFOLD, CH BOTTOM SPRAY 5-UNITS (TITY-a) MANIFOLD, CLEANING SPRAYS 2-1,411 MANIFOLD, 411 CH SIDE SPRAY 7-UNITS MANIFOLD, RH CH MK SPRAY 7-UNITS NANDIX,D, SCRUBBER BACKFLUSH SPRAYS MANIFOLD, SCRUBBER SPRAYS MANIFOLD, SIDE SPRAYS (CITY-2) MANIFOLD, SOLENOID

2-UNIT

MANIFOLD, THROAT SPRAY

J-56563131141001

B-UNITS

J-5656317E0101

VALVE, MODIFIED SOLENOID (120V)

7 PLACES

70 FIRE SPRAY BLOCK SEE NOTE P

SEE NOTE 2

TOP. ...,BLt

5 PLACES

,MACHINE POMP

REAR CROSSOVER TO FIRE SPRAY

CLA MOTOR

MOTOR

MIDDLE CROSSOVER

SUMP DUMP — IN CUTTER HEAT

1/4 HOSE (STAPLOKI, HYDRAULIC LINES

BLOCK

SEE NOTE 3

-SEE NOTE 2

RH

GATHER I NE,

HEAD CROSSOVER

SIR 00 PLACES

FRONT CROSSOVER

SEE NOTE

CLEANING PLACES

SPRAYS

Dr

C

29 PLACES

CEWII ROL

CASE

SET E 359 PSI

TRANSFORMER PRESET CRACK AT 350 PSI

PH

CL A MO TOR

TRAM MOTOR

CUTTING MOTOR

3 PLACES PLACES

4 PLACES WA

A

ALL DIMENSIONS ARE IN MILLIMETERS UNLESS NOTED OTHERWISE 1

Huntti HOSE

7 PLACES

SEE NOTE F.'

FOR INFORMATION MI EU=A 0 WWI tir 3.y.s korks. k. )1A1) WM lOOM ES 0080.

600000017091 MISIMOL MI IMMO 010 M. Wiloatt, Al'). gatsat0 mar IMPI k )1 IS POM IMINO EMMA II Ifixr.,€€ &sip, 1,RM corem MI 60=0016466 101114110 IM OD& =M. SIMI OS 80IL013 0=0 Mk US Mai of. WA PM 0 IS Main 0310. WSW III I. kt... tot. El 141-448 k

14

SEE NOTE 4

12

0010m/04 AND 050E0 SIMMI DESCRIPTION

OW WIC 5/I0 193304

n

Cl

MATERIAL:

wEIGHT LOS

%CYRUS P/N MATERIAL

UNITS

RAW DIMENSIONS

ST7 FT/LAN

TITLE: SCHEMATIC, DUST/COOLING WATER 0

T

FORK OA 04.39 BUCYRUS 01/01/05 REV I 11

604963

REST 05E0604%1 (4E0611 VCS

SI

17

MEET 1 01

BI377591 1 A REVISIONS

2

A

3

A

4

A

5

A

6

A 7 A

A

9

A

10

11

A

A

LH WASHDOWN HOSE CONNECTION

12

A

13

A

14

KORKATION AND IS THE ENCLAIS)VC 568G- 554 X PROPEse`t Cr IV AMERICA INC

CUTTING HEAD DUST SPRAY LA —0-400 PSI PRESSURE GAUGE 555A721 MK-6 FIRE SPRAY SYSTEM ACTIVATE —1/4' BALL VALVE CAT 473725 5290343 MK-I

PRESSURE REGULATOR (SCRUBBER) CAT 466579 0466578 MK-I 0-160 PSI PRESSURE GAUGE CAT 499226 555A721 14K-1

SUMP STRAINER BACK FLUSH —3/4' BALL VALVE CAT 469149 C469149 MK-1

16

A

15

THIS D9A1s1 CONTAINS WIDE,ITIAL

--REAR-TO-FRONT

DESCRINICK (ZOK-VAS-FIT-DRIES

D B T AMERICA

MEITNER Tlf. te.PCMCNI 101 IT'S CONTugs Si! ID 1£ MCP. RIMMED PO BOX 1879, COLUMBUS, OHIO 43216 DR sisansto IN ovss co IN PART WNW lit 6RlQlt EXPRCSS 604)TIEN PERMISSION OF 118T MERICA DAG

WATER SYSTEM COMPONENT LOCATIONS 30M3

DIMENSMS WE IN INCHES UNLESS OlkIERWISE SPECIFIED VAC 1.10 1 rear 1101:Ylir NAVW ROLFE WE 9/02/03 MRECMD ZyC,./4 DIEM!) CILIE DATE 10/02/03 APPROVED

TUBE MANIFOLD 5670144 MK-1 1/4' SPRAY NOZZLE G6-10 SQUARE SPRAY PATTERN - OTT 3 CAT 469671 C469671 MK-1

SUMP BACK FLUSH 1' BALL VALVE 499397 C499397 MK-1

3/8' SPRAY —NOZZLE - OTY 3 566A657 MK-I

SUMP PUMP ASSY 5686010 MK-1

SPRAY MANIFOLD —5686561 MK-1

SCRUBBER SUMP STRAINER CAT 483375 5140341 MK-1

3/8' SPRAY NOZZLE - DIY 6 566A657 MK-1 LH MOTOR UNDERSIDE 6-SPRAY MANIFOLD 5680193 MK-1

CUSTOKR !NKR P40

L.H. SPRAY MANIFOLD 5660559 MK-I 3/8' SPRAY —NOZZLE - OTY 7 566A657 MK-1

SUMP DUMP

FRONT SPRAY MANIFOLD 5676997 MK-1 3/8' SPRAY NOZZLE - OTY 10 566A657 MK-I

FRONT SPRAY MANIFOLD 5670997 MK-I 3/8' SPRAY NOZZLE - OTY 10 966A657 MK-I

THROAT SPRAY BLOCK 5646243 MK-I NOT USED.

DUST MANIFOLD 5660430 MK-3

FRONT SPRAY MANIFOLD 5670997 3/B' SPRAY NOZZLE - OTY 10 566A657 MK-1

-400 PSI PRESSURE GAUGE 55A721 MK-6 PRESSURE MANIFOLD 5680033 MK -7 I' HYD PILOT OPERATED WATER VALVE CAT 499196 5550247 MK-I

0-400 PSI PRESSURE GAUGE 555A721 MK-6

2-UNIT SOLENOID MANIFOLD 5650316 MK-1

1-1/4' BALL VALVE CAT 487167 0497167 MK-1

SOLENOID VALVE W/CDIL - OTY 5656317 MK-I

1/2' PRESSURE 150un STRAINER 5676303 MK-I

I' HYD PILOT OPERATED WATER VALVE CAT 499196 5550247 MK-1

1/4' REVERSE FLUSHING 150url STRAINER 5670311 11X-1

FLOW METER 0-75 GPM CAT 499273 C499273 MK-1

1/2' RELIEF - ATMOSPHERIC VALVE 567A950 MK-1 (MOUNTED ID BACK OF CONTROL CASE)

LSPRAY MANIFOLD 5696561 MK-I 3/8' SPRAY —NOZZLE - OTT 3 566A657 MK-1

RH MOTOR UNDERSIDE 6-SPRAY MANIFOLD 5686194 MK-I 3/8' SPRAY NOZZLE - OTT 6 566A657 MK-I

3/B" SPRAY —NOZZLE - OTT 7 566A657 MK-I R.H. SPRAY MANIFOLD 5680560 MK-1

RH WASHDOWN HOSE CONNECTION 1/2' BALL VALVE CAT 469165 530F788 MK-6

PRESSURE MANIFOLD 5676925 MK-1 \/

'74-7-o47

SIANDARD SP CIAL "'

OEM Hull

568 554

BI377591 12

11

10

9

8

2

6

ITENOT Y7J/M ilUCTRUS P/N DESCRIPT ION 1 EA 314799 ELEMENT, 6111Lin MIMED SS (FOR 168108) 2 1/4 NPT 3 1 EA 168108 FILTER, 60Lim, PRESSURE

NOTES 1) NUMBER IN BOX DENOTES STAPLOK AND HOSE SIZE: 1/4 THRU I-1 /4 DOUBLE WIRE BRAID #4 = 1/4 ID HOSE #12 = 3/4 ID HOSE #6 = 3/8 ID HOSE #16 = ID HOSE #8 = 1/2 1D HOSE #20 = 1-1/4 HOSE 2)LOCATE PER WATER BRACKET LOCATION DRAWING SEE UNIT 382 ON ORDER. 3)DUST CIRCUIT ILLUSTRATED SHOWN FOR REFERENCE ONLY FOR ACTUAL DUST CIRCUIT SEE UNIT 350 ON ORDER, 4)FIRE SPRAY CIRCUIT SHOULD BE CHECK EACH SHIFT,

5 6 7

6

IR EA 167576 1.

EA

coi

9 2 EA (.01 10 EA 11 12 1 EA 13 14 1 EA 15 16 2 EA 17 18 2 EA 19 2 EA

NOZZLE, SPRAY

GG-10

1/4 NPT

354529

VALVE, SLND 12VDC I-UNIT PCNNCIR

172165 172060

VALVE, BALL VALVE, BALL

167805

VALVE., CHECK

167600

VALVE, PILOT OPERATED NC 2-WAY

173176

VENT, BREATHER 0/4 NPT SINTERED BRONZE>

605194 343795

WELDMENT, DELUGE SPRAY WELDHENT DELUGE SPRAY

1/4 NPT 3/4 NPT 1/4 NPT I' NPT

CAT NO

1 REFERENCE =WENT VIILBS J-C499492.140002

J-499492

J-C49949214001

.5

J-487891

J-C48789111K001

.2

J-473725 J-469149

J-529D343MK001 J-C469149NK001

1.9 2,6

J-499415

J-C499415HK001

.4

J-499I96

J-555G247K4.001

5.1

J-4699I8

J-555A246HK002

.1 11.4 11,4

PAINT HANDLE RED SEE NOTE 2

PLACES

3 PLACES

012f

4fr

v

zN:

FRONT CROSSOVER NOT USED

CROSSOVER AR CROSSOVER

3 PLACES

3 PLACES 144 1-11

SEE NOTE 2

WATER INLET

PAINT HANDLE RED SEE NOTE 2

wASHOWN HOSE

ALL DIMENSIONS

FOR INFORMATION

ARE IN MILLIMETERS

blts Kama Isar,4P0r1f Ir Urns kern. W.. MCI 10102 POC10 0 WAX. Of Mew opt =IWO NJ am LEL, offecita, Orf, blimit( B most cram ytr4.

EMI Of 10:01104mi ft lixyr.s 0.1, 1.0 KM CIO% 141 MAGI OE 61020091 rot COW* 0440151e1,4100.115Uablit) KtIlliki ttatAtion vliti lit Immo use. 1.0k 5110,1 0 tS mutt& KM 001ALT 9 tans kcsor, ira.

UNLESS NOTED OTHERWISE . mo Bk, ,

1

11

Essoa

10

MATERIAL: 600000017091 01 0194 CHANGED ANII ADDER SCHEMATIC 600001016806 00 WV RELEASE CI NuMBER REV DESCRIPTION

2..,19,0, COLE 1?-19-07

DATE

COLE

2,0.06 BUCYRIJS P/N

COLE 06511 or DATE 14.

995

MATERIAL --

__ RAW' DIMENSIONS ---

WEIGHT L BS _.....

DOWN BY CHECKED BY

UNITS ieviE161 SD FT/LIN FT Rt

DATE 2,-19-08

2-19-08

" Fe0R -1R 9-68 064.04111.39 01/04/08 REV I

Birmus

A T TENT I OW 1,1%

II

k I

wow

is

SCALE

1:1

II T LE

SCHEMATIC, DELUGE FIRE

30M3

CD

PROJECTION

N

RAVING RODEL NO. 50M3 604965 NLIm R "--4CE/ I OF 1__.

FIRST USED-6041961 ENERGY VEST SIMII!AR TO 3317

BI377591 1

10

REVISIONS

11

2

568G558

Kulifinucw 1mm zcw-vm-111,

DELUGE SPRAY BLOCK CAT 487890 552F912 MK-1 FIRE SPRAY SYSTEM A

VATE

1/4' BALL VALVE CAT 473725 5290343 11K-1

1/4' SPRAY NOZZLE 06-10 --CONE SPRAY PATTERN - QTY 3 CAT 487891 C487891 MK-I

16

1

4

1

THIS DRALIM CIDEIKNI Cf:**11:(.411h.

INFEIRSATION AND IS TIC EXELDSWE HI ACY CE DDT MEDICA CONKITIER PNC tePRIENT ICH TEPOS AK ID lit USED, DEPRIDUCED, DR DISCLOSES 10,1 IAESE 1ST ITT DAM 4itliCO7 THE PIM EGRESS URITIEk KRIDSSION I DV ourRICA DC,

DBT

air

AMERICA

P13 BOX 1879 OLUMEUS. GNI 43216

DELUGE FIRE SPRAY COMPONENT LOCATIONS 30M3

DIKNSIONS ARE IN INCHES UNLESS OTNE11WISE SPECIFIC 1 SC—WPM C 1.8 At PM% Ra E DAIS 4/02/03 m moat) COLE DAIS 9124/03 WOMB

z

CH

1=1:

rL _

_

PILOT - OPERATED WATER VALVES CAT 499196 5556247 MK-I REAR-TO-FRONT , - DUST SPRAYS - DELUGE FIRE SPRAYS - SCRUBBER SPRAYS REF DRGS 8451-030-00 -02-00 (HYDRAULIC SYSTEM) 5676953 (WATER SYSTEM)

(1-

. ...

1/4' BALL VALVE CAT 473725 5290343 MK-I

FIRE SPRAY SYSTEM ACTIVATE

1/4' BALL VALVE CAT 473725 5290343 MK-I FIRE SPRAY SYSTEM DEACTIVATE

SOLENOID VALVE 12VDC 1830527 MK-2 1/4' CHECK VALVE CAT 499415 C499415 MK-1 1N1L1NE FILTER CAT 499492 0499492 MK-1

1/4' SPRAY NOZZLE GO-I0 --CONE SPRAY PATTERN - QTY 3 CAT 487691 C487891 11K-1 DELUGE SPRAY BLOCK CAT 467890 552F912 11K-1

BREATHER VENT CAT 469918 555A246 11K-2

568G249

I/410AR

eel

PECI AL

DM WIN

568G558

NV

BI377591 A

3

A

4

A

A

6

A

7

8

A

REvISIONS

A

9

A

10

A

11

A

12

A

13

5660379

dtwAroncs TIOFC-VAS -BT - oaTE)

2. WHEN FILLING GEAR CASES, REMOVE OIL LEVEL PIPE PLUGS TO PREVENT DAMAGE TO SEALS,

A

AS NECESSARY IN THE EVENT AN IMMEDIATE REPAIR CANNOT BE CARRIED OUT, 5, HYDRAULIC TANK CAPACITY IS 300L (20 USLAL)

16

A

15 a.

DBT AMERICA

Ar.404*

PO BOX 1879, COLUMBUS, OHIO 43216 IILE

DIMENSIONS ARE IS INCHES UNLESS GimERVISE SPECIPIED ii L I tosteTwsH, 5t41 W REtt DATE 05/20/02 METED NECKED ZYCII DATE Mi2o/02 oeTHE&TO

4. IF GEAR CASE LEAKS ARE INDICATED, CHECK

NOTES L FOR LUBE POINT LOCATIONS, REFER TO DRAWING 5660372.

14

A

COWIDENTIAL PRAvFHG CONT, INFIRIATIEH M Tor EXELIPSWE PROFERTY Or DOT AKVIGA WITHER THE DOCuT4ENT FM ctrx• loos Atit ia DE USED, REPROLu:ED, OR IHSOLOSED TN WHOLE D2 rk POT V.I1HEul THE OTHER EMUS VRITTET4 PERHISSW Or D131 AHER1CA thC.

LUBRICATION CHART 30M2

A

IWOuca IOiDER

ZYCH

3. APPLY GREASE TO MOTORS SLOWLY TO ALLOW TIME FOR GREASE TO PASS THROUGH RELIEF,

C NO

20 SHIFTS

8 CU. CM,

N/A

N/A

NO

20 SHIFTS

8 CU. CM.

N/A

N/A

GREASE GUN

NO

20 SHIFTS

8 CU, CM.

N/A

N/A

GREASE GUN

NO

20 SHIFTS

8 CU. CM.

N/A

N/A

30 SHIFTS

60 SHIFTS

LUBE INTERVAL

GREASE GUN

NO

GREASE GUN

LUBRICANT TYPE

CUTTING MOTOR

L ITHIUM COMPLEX GREASE

2

GATHERING HEAD MOTOR

3

MOTOR DUST COLLECTOR

4

PUMP MOTOR

HIGH TEMPERATURE LITHIUM COMPLEX GREASE HIGH TEMPERATURE LITHIUM COMPLEX GREASE HIGH TEMPERATURE L ITHIUM COMPLEX GREASE

5

INPUT CUTTING GEAR CASE

ISO 220 EP GEAR OIL

MANUAL. FILL

YES

3 SHIFTS

6 LITERS

6

MAIN CUTTING GEAR CASE

ISO 220 EP GEAR OIL

MANUAL FILL

YES

3 SHIFTS

30 LITERS

30 SHIFTS

60 SHIFTS

60 SHIFTS

60 SHIFTS

7

INPUT GATH HPG

6

MAIN GATH

RCS'

GEAR CASE

HIGH TEMPERATURE

ISO 220 EP GEAR OIL

MANUAL FILL

YES

3 SHIFTS

11 ! 1TERS

ISO 220 EP GEAR OIL

MANUAL FILL

YES

3 SHIFTS

19 LITERS

60 SHIFTS

60 SHIFTS

P GEAR OIL

MANUAL. FILL

YES

3 SHIFTS

38 LITERS

360 SHIFTS

60 SHIFTS

9

TRAM GEAR CASE

10

CRAWLER IDLER ROLLER

ISO 220 EP GEAR OIL

MANUAL FILL

YES

3 SHIFTS

F LITERS

360 SHIFTS

60 SHIFTS

11

MAIN HYDRAULIC TANK

ISO 68 AW HYD OIL

MANUAL. FILL

YES

3 SHIFTS

SEE NOTE 5

AS NEEDED

- 60 SHIFTS

12

CUTTING HEAD PIVOT

EP2 MULTI-PURPOSE GREASE

GREASE GUN

Nn

3 SHIFTS

50 CU, CM.

N/A

ISO 220

13

GATHERING HEAD PIVOT

EP2 MULTI-PURPOSE GREASE

GREASE GUN

NO

3 SHIFTS

50 Cu. CM,

N/A

N/A

CONVEYOR RAISE PIVOT

EP2 MULTI-PURPOSE GREASE

GREASE GUN

NO

3 SHIFTS

50 CU. CM.

N/A

N/ A

15

CONVEYOR SWING PIVOT

EP2 MULTI-PURPOSE GREASE

GREASE GUN

NO

3 SHIFTS

50 CU, CM.

N/A

N/A

STAB SHOE PIVOT <FRAME) EP2 MULTI-PURPOSE GREASE

GREASE GUN

Ni]

3 SHIFTS

50 CU. CM,

N/A

N/A

N/A

17

UPPER CUTTING CYL PIN

EPF MULTI-PURPOSE GREASE

GREASE GUN

NO

3 SHIFTS

50 CU, CM.

N/A

18

LOWER CUTTING CYL PIN

EPF MULTI-PURPOSE GREASE

GREASE GUN

NO

3 SHIFTS

50 CU. CM.

N/A

N/A

19

UPPER GATH HO CYL PIN

EP2 MULTI-PURPOSE GREASE

GREASE GUN

NO

3 SHIFTS

50 CU. CM.

N/A

N/A

LOVER GATH HD CYL FIN

EPF MULTI-PURPOSE GREASE

GREASE GUN

NO

3 SHIFTS

50 CU.

N/A

N/A

21

UPPER CONV RAISE CYL FIN EP2 MULTI-PURPOSE GREASE

GREASE GUN

NO

3 SHIFTS

50 CU. CM,

N/A

N/A

22

LOVER CONV RAISE CYL PIN EP2 MULTI-PURPOSE GREASE

GREASE GUN

NO

3 SHIFTS

50 CU. CM.

N/A

N/A

23

FRONT CONV SWING CYL PIN EP2

GREASE GUN

NO

3 SHIFTS

50 CU, CM,

N/A

N/A

N/A

N/A

ULT1-PURPOS

GREASE

24

REAR CONV SWING CYL PIN EP2 MULTI-PURPOSE GREASE

GREASE GUN

NO

3 SHIFTS

50 CU, CM.

25

UPPER STAB SHOE CYL PIN

EP2 MULTI-PURPOSE GREASE

GREASE GUN

NO

3 SHIFTS

50 CU, CM.

N/A

N/A

26

LOVER STAB SHOE CYL PIN EP2 MULTI-PURPOSE GREASE

GREASE GUN

NO

3 SHIFTS

50 CU, CM,

N/A

N/A

BUCKET

NO

3 SHIFTS

AS NEEDED

N/A

N/A

AS NEEDED

N/A

N/A

20 CU. CM,

N/A

N/A

27

CRAWLER CHAIN

WASTE OIL

28

CONVEYOR CHAIN

WASTE OIL

BUCKET

NO

3 SHIFTS

29

CONVEYOR TAKE-UP SHAFT

EP2 MULTI-PURPOSE GREASE

GREASE GUN

NO

3 SHIFTS

X/

X/

X 1-

II

F

N/A

14

20

K

SAMPLE INTERVAL

ITEM DESCRIPTION

16

H

UNIT CAPACITY

REPLACEMENT INTERVAL

FILTERING REQUIRED

FILLING METHOD

5600990

wSTANDARB

K

SPCC1AL.

st

B

5

66379

BI377591

MERGENCY STOP

H SIDE VIEW

DUST COLLECTOR FAN MOTOR

LH DLA KOTOR DIE

H TRACTION MOTEIR

LH CUTTER MOTOR

MOTOR I

ME u'ENCY T

DISPLAY BOX

\

RH TRACTUR MOroR

TRAM TRANSFORMER LA

AUXILIARY BOX

RH CUTTER MOTOR

MOTOR

RH SIDE VIEW .'t

CONTROL CASE

BI377591 1

A

1

10

12

REVISIONS

3

568557

DESCNIATIOTT

TDOAE-WAS-JET-DATER

1 1/2' PIPE PLUG CAT 64577 553.471 PG1

LH TANK MANIFOLD CAT 499018 551A591 MK-1

BREATHER VENT CAT 483393 0483393 MK-I

3/8' CHECK VALVE (NO SPRING) CAI 456139 C456139 MK-1

2' PIPE PLUG CAT 66354 553,471 PG1

0-1000 PSI PRESSURE GAGE CAT 499229 555A721 MK-4

14

A

DIKENS1ONS ARC EN INCHES UNLESS 011-ERASE SPECIE I) MN Ito SCALE 1,e t rikkV$V,',

41.

Ar..41 41.

DAZ E

16

DBT AMERICA

PO BOX 1879, COi.UM11US, OHIO 43216

L.H. HYDRAULIC COMPONENT LOCATIONS 30M3

INCW ROLFE BATE 9/02/03 DIKE

COLE

A

15

A

rkt5 tgAVNG DIATOMS CONFIDENTIAL beaRRALION MID IS THE EXCLUSIVE PROPERTY OF DOT ...KOMP. INC. NEITHERDOELMENI NUN IT'S CON• ISKTS ARE TO DE USED, REPTITIONCED, ON DISCLOSED IN WIDE DR PE MX NENCATT INC ADM OLDNESS WRITTEN PERMISSION OD DOT AMERICA INC.

ED

COSTOPIE OSSEO NT

ZYC“

9/09_/03 APPROVE

8 NOTES;

3/8' RELIEF VALVE CAT 485094 C465094 MK-1 R PACER PUMP, (MOUNTED TO MANIFOLD)

1. USE THIS DRAWING IN CONJUNCTION WITH DRAWINGS 568G555, ANTI 5695556.

OIL PRESSURE FILTER CAT 499510 5640200 MK-1 MAGNET, TANK CAT 487315 C487315 MK-1

REPLACEMENT ELEMENT CAI 499509 5646280 MK-2 3/8' PILOT OPERATED CHECK VALVE CAT 481104 532E572 MK-I

TANK TOWER

FLOW REGULATOR CAT 486426 547F845 MK-1

7 -

(MOUNTED IN CRAWLER) --HYDRAULIC TANDEM PUMP 5680203 MK-1

(MOUNTED IN CRAWLER) CIL PRESSURE FILTER 565G313 MK-1

SUMP WATER PUMP/ MOTOR ASSY (PACER) CAT 486457 DWG 548E943 MK-1

2' Y-STRA1NER 5670271 MK-1

REPLACEMENT ELEMENT 5650313 MK-2

K

L

L,H. HYDRAULIC COMPONENT LOCATIONS 4

\/

V

cT

V

n

\/

TR

‘i

56 in46 In

X/

e,; STANDARD SPECIAL tiONFATTI FRIT1 14, 4

B 5686557

BI377591 10

REVISIONS DESCRIPTION (ZONE•idAS-ST-DATES

12

11

NOTES!

A

A

13

A

DINENSIFAS ARE IN INCFES UNLESS OTHERWISE SPECIFIED I 10 ler SOLE

e

SEQUENCE VALVE 568A035 MK-1

VENTURI ASSEMBLY O1L PRESSURE FILTER SAP #229251 L/A #410254 REPLACEMENT ELEM N SAP #225402 L/A #410254X1

STRAINER ASSEMBLY CAT 473692 198E747 MK -1

SOLENOID VALVE W/COIL 5650317 MK -I, 2 REDD

SWING CHECK VALVE 3/4 CAT 67088 553,491 PG1

SOLENOID JUNCTION BLOCK - 14 CONNECTION 5646445 MK -I

MON

ZTCPI

EuSTENER MITER IC

CONVEYOR TAKE-UP VALVE ASSEMBLY

EJECTOR ASSEMBLY CAT 448198 179E630 MK -1 2- UNI I SOLENOID MANIFOL D 5650316 MK -1

Si/t/

R,H, HYDRAULIC COMPONENT LOCATIONS 30M3

[Mai R€ FE DATE 9/02/03 DIRECTED uccitED COLE DATE 15/14/03TAPPROVED

0-3000 PSI PRESSURE GAGE CAT 499230 5554721 MK -5

16

15

DB T

I. USE THIS DRG WITH BROS 5686555 & 568G557.

VENTURI ASSEMBLY

14

THIS DRAWING CONTAINS CONEIRENTIAL 4 RiCERSATION AAR IS TAE ETRAUSIVE /1•4./ AMERICA PROPERTY Eie NT MERTES INC • NEITHER ME 110£1.44ENT NOR IT'S MNltMS Mt TD DE USU. PCM9AltD, PO BOX 1879. COLUMBUS, OHIO 43216 ON WDEILS. UR IN PART OR SS T NTINIEST ENE PRIOR EIRDEST3 WITTEN pertilisSION OE SqT ratitiel, pc

5686556

0-1000 PSI PRESSURE GAGE CAT 499229 555A721 144-4 RH TANK NIFOL 0 ASSEMBLY 5656879 MK-1

I/4' NEEDLE VALVE CAT 140358 555.131 PG1 3/8 PRESSURE REDUCING/ RELIEVING VALVE CAT 499517 C499517 MK-I

OIL LEVEL FLOAT SWITCH 5650216 MK-1

2/8' CHECK VALVE (W/50 SPRING) CAT 487320 5500795 MK-4

BREATHER VENT CAT 483393 0483393

JUNCTION BLOCK DUMMY PLUG 56404 45 MK -3, 2 PLOD

MK-1

DIPSTICK 5656215 MK -1 MANUAL OIL FILL

\

CRAWLER TAKE-UP VALVE (LOCATED IN CRAWLER COMPARTMENT)

0-400 PSI PRESSURE GAUGE 555A721 MK-6

COUNTERBALANCE VALVE 5686027 MK-

PRESSURE MANIFOLD 5680033 MK-7

MAIN RADIO CONTROL VALVE ASSEMBLY 565E1318 MK -1

1/4' 4-WAY CONTROL VALVE CAT 481788 520E007 MK-4

r

HYD PILOT OPERATED WATER VALVE CAT 499196 5550247 MK-1

SELECTOR VALVE 5684034 MK-1

HYD PILOT OPERATED WATER VALVE CAT 499196 555E1247 MK-1 lA

0-3000 PSI PRESSURE GAGE CAT 499230 5554721 MK -5

FLOW METER 0-75 GPM CAT 499273 C499273 MK-1

--3/8' PRESSURE REDUCING/ RELIEVING VALVE CAT 499517 0499517 MK

THE RINE! HEAD VALVE ASSEMBLY 60 MICRON PRESSURE FILTER CAT 499492 C499492 MK -1

—0-1000 PSI PRESSURE GAGE CAT 499229 555A721 MK - 4

0-3000 PSI PRESSURE GAGE CAT 499230 5554721 MK -5 1 / 4 ' RES TRIO OR VALVE W/.031 ORIFICE CAT 486251 5484119 MK -3

—60 MICRON PRESSER FILTER CAT 499492 C499492 14K-1

1 / 4THECK VALVE (W /5# SPRING) CAT 487319 5506795 MK -1

MAIN PRESSURE FILTER W/DIRT INDICATOR 548E112 MK-5

1/4' NEEDLE VALVE CAT 140358 555.131 PG1

REPLACEMENT ELEMENT CAT 442579 1650502 14K-2

3/8' RELIEF VALVE (HIGH PRESSURE) CAT 499358 547E208 MK-5

PRESSURE MANIFOLD 5670925 MK-1 R.H.HYDRAULIC COMPONENTS

1/2' RELIEF VALVE (W/BYPASS CHECK) CAT 499512 C499512 MK-1

5676947 N./

/

/

ANDARD SPEC] AL

."13•111 EMI

5686556

BI377591 1 A REVISIONS

2

A

3

A

4

A

5

A

6

A

7

A

A

9 _A

13

10 A 11 A 12 A

A

fries-VAS.re.10/Ey

14

15

A

THIS Nif6/1180 CCWAIRS CDNFINATIAY.

r768G555

DESCRIPTICM

PROK.0” F& Mg *ERICA VCRhCIIHER 119E NYC...0(Nt 111111 At( SB BC i3SC0. REPIZONJCUI, DISCLOSED €1,4 ilifILS PR IN PAM vItil0Jr THE PRIM EICPRESS VinnEk PORAISS100 CS 09T AMERICA NC.

DIMENSIONS ARE IN INCHES

STABILIZER SHOE CYLINDER 5670133 MK-1

CRAWLER CHAIN TAKE-UP CYLINDER CAT 486941 548F979 MK-1

QUART

IRO DRg„

VENT TEE 566A027 MK-1

16

PI) BOX 1875, COLUMBUS, OHIO 43216

HYDRAULIC COMPONENT LOCATIONS 30M3

UNLESS DTI€RVISE SPECIfIED SCALE 116 I sr....c MO W+ Kook RoLFE BATE 9/02/03 DYRECIED DfiXED fat WE 14A1ERIAL 14if

A

DBT AMERICA

Kampnow PM PS 11( FiCLUS1V£

ZYCH

10/13/03 ANstvt0

CUSTOSCP 5 55

CAT IA) DI1IU

DESCRIPTION

A

HYDRAULIC COMPONENT LOCATIONS 2 LH. HYDRAULIC COMPONENT LOCATIONS 3 R.H. HYDRAULIC COHCIINENT LOCATIONS 4 5

¢4z• Ir•E

5685557 5685556

B

NOTES: 1/4' NPT BALL CHECK VALVE CAT 499415 C499415 MK-1

GATHERING HEAD CYLINDER CAT 499089 54 70188 MK-1

CONVEYOR RAISE CYLINDERS 5676855 MK-1

FOR L.H. HYDRAULIC COMPONENT LOCATIONS, REFER TO DK 5680557, 2, FOR R.H. HYDRAULIC COMPONENT LOCATIONS, REFER TO DRG 5686556

CONVEYOR SWING CYLINDERS CAT 499515 5646654 MK-1 •

17 CONVEYOR CHAIN TAKE-UP CYLINDERS CAT 499527 5650154 MK-1

CUT TING HEAD RAISE CYLINDER 5670856 MK-

STABILIZER SHOE CYLINDER 5670133 MK -1

CUTTING HEAD RAISE CYLINDER 5676856 MK- i

GATHERING HEAD CYLINDER CAT 499009 5470188 MK -1

K

CONVEYOR CHAIN TAKE -UP CYLINDERS CAT 499527 5650154 MK-1

CONVEYOR SWING CYLINDERS CAT 499515 5646654 MK-1

CONVEYOR RAISE CYLINDERS 5676855 MK -1

114' NP T BALL CHECK VALVE CAT 499415 C499415 MK-1

L

VENT TEE 566A027 MK-1

MK-1 HYDRAULIC COMPONENT LOCATIONS

CRAWLER CHAIN TAKE-UP CYLINDER CAT 486941 548F'979 MK-1

5670

1. ...,,STANDARE IlkeitolA I 1

SPECIAL

11121 1

~Br-568G555

BI377591

NUMBER

PEW

RAT1, Ar

=

•

..•

:

•

.

.

SPE "

:

.

":"

•

: :"

".

::•:

::

:"

, •

•

COOLING ••• • • • .

•

.•

BI377591 14 KSFMAthYt tiWr-VAS-BY-MTFI A

NTS BRAVING GCNIYAIN, S CGICHIENT61.

ENRININTION AND IS IFIL CYCLUSIV£ PRCKRIY Ff DBT 1,06PICA INC. NEHICR TIE DOCIKNE NCR IT'S CONTENTS ME 61 EC tan, RCIVIIINVCCD, ITT NiSCLOSED IN lite..E DR III PART WilKkg 1SC PRIM EXPRESS %AMIN FTRIIISSION 6' DIH iNCRICA INC.

NOTES, I, FOR LURE POINT DESCRIPTIONS, REFER TO DRAWING 5660379.

P. WHEN FILLING GEAR CASES, REMOVE OIL LEVEL PIPE PLUGS TO PREVENT DAMAGE TO SEALS.

4, IF GEAR CASE LEAKS ARE INDICATED, CHECK AS NECESSARY IN THE EVENT AN IMMEDIATE REPAIR CANNOT BE CARRIED OUT.

YDRAULIC TANK MANUAL FILL

HYDRAULIC TANK [ DIPSTICK

LEGEND 1

CUTTING MOTOR GATHERING HEAD MOTOR DUST COLLECTOR MOTOR PUMP MOTOR

[REMOVE PIPE PLUG

000

GREASE GREASE VENT VENT

p

/am

0

00/ _

0

TO CHECK LEVEL REMOVE PIPE P LU OIL SHOULD FILL LOVER SIGHT GLASS TOP SIGHT GLASS PTY SHOULD BE

2 Ci 4 5 6 7

INPUT CUTTING GEAR CASE MAIN CUTTING GEAR CASE INPUT GATH HO GEAR CASE

B 9 IC 11

MAIN GATH HD GEAR CASE TRAM GEAR CASE CRAWLER IDLER ROLLER MAIN HYDRAULIC TANK

12 13

CUTTING HEAD PIVOT GATHERING HEAD PIVOT CONVEYOR RAISE PIVOT

14 15

TO CHECK LEVEL REMOVE PIPE PLUG OIL SHOULD FILL LOVER SIGHT GLASS, TOP SIGHT GLASS SHOULD BE EMPTY

REASE VENT

0

0

PEASE VENT

0 0

NT

CUSIOIER DRIER P13

ITEM DESCRIPTION

LEVEL CHECK

0 0

ZYCH

NO

TO FILL

YDRAULIC TANK MANUAL FILL

LEVEL CHECK SIGHT GLASS MUST BE FILLED

LUBRICATION DIAGRAM 30M3

TO FILL MOVE PIPE PLUG

EVEL CHECK

LEVEL CHECK

OX 1079, COLUMBUS, OHIO 43216

DIMENSIONS ARE IN INCHES UNLESS OTHERWISE SPECIFIED jic 10i SCALE 1,20 4.41,C INARAFC Woo REH DATE 07 /24/03 DERCCTEp crrocal ZYCH DAIS 07/24/03 0'41010

3. APPLY GREASE TO MOTORS SLOWLY TO ALLOW TIME FOR GREASE TO PASS TRIKIUGH RELIEF.

0

D B T AMERICA

0000 00

REMOVE COVER

16 17 18

CHECK LEVEL WITH CUTTING HEAD ON GROUND

19 20 21 22 23

/v00

CONVEYOR SWING PIVOT STAB SHOE PIVOT (FRAME) UPPER CUTTING CYL PIN LOVER CUTTING CYL PIN UPPER GATH HD CYL PIN LOWER OATH HD CYL PIN UPPER CONV RAISE CYL PIN LOWER CONV RAISE CYL PIN FRONT CONV SWING CYL PIN

REAR CONV SWING CYL PIN 24 25 UPPER STAB SHOE CYL PIN

if4,

00

26

iii

~ lr

28 29

27

LOWER STAB SHOE CYL PIN CRAWLER CHAIN CONVEYOR CHAIN CONVEYOR TAKE-UP SHAFT

litc 40 0 irs krCHECK LEVEL WITH CUTTING HEAD ON GROUND REMOVE COVER

0 0 0000

LEVEL CHECK SIGHT GLASS MUST BE FILLED

0 0 0 0 0 0 5666378

ANTIARD SPECIAL

11 'WI

566 280

SpeedMining, Inc. 125915 13 0MContinuous Miner

Tr

Cutter Motor FeedbackDifferential Factor: Cutter Motor Feedback Proportional Factor: Maximum Sump Speed: Minimum Sump Speed:

E !

Cutter Motor FeedbackSet Point:

Parameter Descriptions:

MCU 944 P/N:

Transmitter PIN:

a, 0 E cu —) 6. o = = C.)

cv

co Tr In co

5 , 03

N. co a) 0

Cutter Lower Overide:

cv M

'IL In r"

CO

,

Methane Monitor Override:

r• N N N

Low Oil Alarm:

N4.

CO N

Speed 30M944MCUSettings_12-18-06.xls

+/- 10.0%

co N co to

Right Armature Voltage Trim Adjustment

5

0

LO 1.-LO CO

+1- 10.0%

is)

Left Armature Voltage Trim Adjustment

PCT

o %—.

LO Cr)

Right Armature Current Set Point:

Off,CO,FH,CS/FH

PCT or PS/PCT

Disabled-Enabled/Disabled

Disabled-Enabled/Disa bled

Disabled-Enabled/Disabled

Off,CS,PS/Off 11.1.11111.111MMII

4--

25Low OilLockout:

24

0.3 to 15/7

180-600/300

-12.5 to 12. 5/-3.0

O

23Machine Stop Shutdown Function:

Tilt Switch:

tx)

PA Ventilation:

200-400/344

r--

Motor OverloadReset Time:

200-400/344

O

C'7

Brake Release Delay:

co to O O ,,6 Tr

co

Scrubber Off Delay:

CO Tr co

Scrubber Stagger Delay:

co CO Tr co

5,10,30,50 Default 10

o co

See Fan Settings Chart

75-150/132

150-550/550 i N. N. LO

Fan Motor Size:

Cutter Raise Overide:

Fan Instantaneous Trip Set Point:

0

0.5-5.0/2.0

0

C4 CD

!Pump Instantaneous Trip Set Point:

6 co

co.

Conveyor Instantaneous Trip Set Point:

LC) N. LO C \I -r-

0.1-1.5/0. 3

0) N— N. CV C\ I c-

Cutter Instantaneous Trip Set Point:

Ti• co in to cy 6

125-250/175

AdjustedSettings

15342-1010

Houston, Pennsylvania

DBT America Inc. 2045 West Pike St.

Date: 12/18/06

Tr co

Fan Jam Delay:

0-280 Amps/ 184

Unit Default Settings

944 MCUSetting Parameters

Job Number:

Customer:

17 to co M co M

CO mi: CO c--

BI377591

BI377591 15

1

14

13

12

11

10

1

9

8

M

NO

•

Tr

PP

---

0

%

0 0 0 0 0

0 0 0 0

CPC * 0 ° ___Q 0 i_Q I--- f1

PO

110

he

P4

P2

[

F740 :

0

0

---Cd MD a°

0

(441:

0

. 0

.0000 000

c lifoig

LQ.41)i.

0

jz

0 :

ELF

0,

RI

R3

0 0„,cii

p _ --.

1

2

[

e000 000000 00 00

16

R1-I NOT USED R1-2 FAN WATER SPRAY SOLENOID R1-3 AUX SOLENOID 146 (MOMENTARY) RI-4 DUST SUPPRESSION CONTACTOR R1-5 CUTTER RAISE SOLENOID R1-6 GATHER HEAD FLOAT SOLENOID R2-1 SOLENOID POWER-120VAC (L) R2-2 SOLENOID POWER-120VAC (L) R2-3 CUTTER LOWER SOLENOID R2-4 CONVEYOR RAISE SOLENOID R2-5 CONVEYOR LOWER SOLENOID R2-6 CNVYR SWING LEFT SOLENOID R2-7 CNVYR SWING RIGHT SOLENOID R2-8 STAB UP SOLENOID R2-9 STAB DOWN SOLENOID R2-10 GATHER HEAD RAISE SOLENOID

B

R7-1 PUMP CURRENT (+) R7-2 LEFT CUTTER CURRENT (+) R7-3 RT CUTTER CURRENT (+) R7-4 LT CONVEYOR (+) R7-5 RT CONVEYOR (+) R7-6 FAN tl (+) R8-1 CURRENT MONITOR COMMON (-) R8-2 CURRENT MONITOR COMMON (-) RB-3 0 TO 5VDC A/D IN SPARE fl1 R8-4 0 TO 5VDC A/D IN SPARE 02 R8-5 MACHINE VOLTAGE LINE R8-6 MACHINE VOLTAGE COMMON R8-7 MAIN TRANSFORMER RTD R8-8 SPARE RTD 03 R8-9 SPARE RTD 01 R8-I0 SPARE RID 02

FIRE SUPPRESSION (+) R21-1 POWER CENTER TRIP R2I-2 POWER CENTER TRIP BREAKER ON (+) R21-3 EARTH GROUND BREAKER RESET (4) R21-4 AC NEUTRAL INPUT I2VDC SOLENOID COMMON 12 VDC OUTPUT (SWITCH COMMON) R21-5 AC LINE INPUT LOW OIL LOCKOUT LOW OIL ALARM R22-1 BATTERY POWER ACTIVE SPARE 12 VDC INPUT #1 R22-2 5 VDC POSITIVE R22-3 5 VDC COMMON R14-I TRAM LEVER +5VDC R22-4 12 VDC POSITIVE R14-2 TRAM LEVER COMMON R22-512 VDC COMMON R14-3 RIGHT TRAM SIGNAL R22-6 CONTROL PENDENT POWER/DATA R14-4 RIGHT FORWARD TRAM R14-5 RIGHT REVERSE TRAM R14-6 LEFT TRAM SIGNAL NOTES: R14-7 LEFT FORWARD TRAM R14-8 LEFT REVERSE TRAM 1) 12VDC INPUTS SPARE FOR FUTURE USE . CONNECT R15-1 RADIO SYSTEM TX(+) R13-5 TO ISOLATED CONTACTS AND TH EN TO ANY R15-2 RADIO SYSTEM TX(-) INPUT, R13-6 TO R13-8. (3 TOTAL) R15-3 RADIO SYSTEM RX(+) R15-4 RADIO SYSTEM RX(-) R15-5 RADIO SIGNAL COMMON 2) AC INPUTS ON R9 ARE RELATIVE TO 120 VAC COMMON CONNECTED TO R16-1 DISPLAY TX (+) R16-2 DISPLAY TX (-) R12-8.

R16-3 DISPLAY RX R16-4 DISPLAY RX (-) 3) MINER TYPE SELECT TABLE R16-5 DISPLAY COMMON RH-6 R11-7 R17-I IrDo COMMS DATA A 25M-0 OFF OFF R17-2 IrDo COMMS DATA B 25M-1 OFF ON R17-3 IrDa COMMS COMMON R17-4 +5,00 VDC OFF 25M-2/3 ON R18-1 DRIVE SYSTEM DATA A ON 30M ON R18-2 DRIVE SYSTEM DATA B R18-3 DRIVE SIGNAL COMMON R18-4 NOT USED

R13-I R13-2 R13-3 R13-4 R13-5 R13-6 R13-7 R13-8

R3-1 AUX OUTPUT 147 (LATCHED) R9-1 CONVEYOR REV JOG R3-2 AUX OUTPUT 07 (LATCHED) R9-2 CNTRL GND FAULT R3-3 AUX OUTPUT 08 (LATCHED) R9-3 MANUAL FAN START PB R3-4 AUX OUTPUT #8 (LATCHED) R9-4 PUMP START R3-5 CONVEYOR REV CONTACTOR R9-5 CONVEYOR START R3-6 FAN CONTACTOR (SCRUBBER) R9-6 CUTTER START R4-1 120 VAC LINE R10-1 RTD COMMON R4-2 120 VAC LINE R10-2 RTD COMMON R4-3 AUX OUT fi5 (MOMENTARY/PUMP) R10-3 HAULAGE TRANSFORMER RTD R4-4 LOW OIL ALARM R10-4 SPARE RTD #4 R4-5 CNTRL GND FAULT ALARM R10-5 RT CUTTER WINDING RTD R4-6 LIGHTS R10-6 LT CUTTER WINDING RTD R4-7 PUMP CONTACTOR R10-7 LT CONVEYOR RTD R10-8 RT CONVEYOR RTD R4-8 LEFT CUTTER CONTACTOR R10-9 PUMP MOTOR RTD R4-9 RIGHT CUTTER CONTACTOR R10-10 FAN MOTOR #1 RID R4-10 CONVEYOR FWD CONTACTOR R5-1 REDUNDANT RIGHT CUTTER R11-1 MACHINE STOP R5-2 REDUNDANT RIGHT CUTTER R11-2 LEFT STOP R5-3 REDUNDANT LEFT CUTTER R11-3UT ER RUN R5-4 REDUNDANT LEFT CUTTER R11-4 UM RUN R5-5 AUX OUTPUT #2 (LATCHED/PUMP)R11-5 CONVEYOR RUN R5-6 AUX OUT #1 (MOMENTARY/PUMP) R11-6 MINER TYPE SELECT 01 R19-1 S800 COMMS DATA A R39-25800 COMMS DATA B R6-I 120 VAC LINE R11-7 MINER TYPE SELECT 142 R19-3 S800 COMMS SIG COMMON R6-2 120 VAC LINE R11-8 METHANE MONITOR OK R19-4 NOT USED R6-3 BREAKER ON (ALTERNATE) R12-1 CB2 BREAKER AUXILIARY R6-4 BREAKER OFF (ALTERNATE) R12-2 EMERGENCY TRAM ENABLE R20-1 FIELD PROGRAM - COM R6-5 BRAKE RELEASE R12-3 (SCRUBBER) MANUAL FAN R20-2 FIELD PROGRAM - RX R6-6 SPARE 01 R12-4 CUTTER RUN WITH FAN R20-3 FIELD PROGRAM - TX R6-7 SPARE #2 R12-5 CUTTER LOCKOUT R20-4 FIELD PROGRAM - CTS R6-8 MMO CONTACT R12--6 MOTOR START ENABLE R20-5 FIELD PROGRAM - RTS R6-9 AUX OUTPUT 03 (MOMENTARY) R12-7 REMOTE R6-10 AUX OUT #4 (LATCHED/PUMP) R12-8 120 VAC INPUT COMMON (R9/R11/R12)

FOR INFORMATION ALL DIMENSIONS ARE IN MILLIMETERS THIS DRAWING IS TIC PROPERTY If DOT ANERRA INC. 6=00014239 91 143DIFIEATIENs As PER CERVIS LPDAIE NO REPRODUCTION OR USE Er THIS DRAWING KAY DE DONE WWWNST 00 CV RELEASE JNLESS NOTED OTHERWISE WITHOUT THE wR1T1EN CEMENT IF DOT AMERICA El PAMIR REV DESCRIPTION 16 14 1 15 13 I 12 1 10 11 I

MATERIAL: A/29/06‘

kis

AJM

xon

6/21106 DATE

DATE NAME SIN.

125913

03/1540 001 I

9

DDT P/N MATERIAL

-I

8

PURCHASE FROM CERVIS: MASTER CONTROL UNIT BUILT TO CERVIS DRAWING: 04150550 CERVIS PART NUMBER: MCU-944

OTIB1

WEIGHT LBS

SPECIFIC

617

RAW DIMENSIONS

UNITS SD FT/LIN FT

X

0.1

7

NW f V

CMP9

PIP% 044.64.46, DDT &IRMA 1/14/04 REV 0

DBT

PROACUM MODEL fitlr FIRST USED.

SCALE 1:1

TITLE.

MASTER CONTROL UNIT MCU-944

DITAVINT. i0 MRCP SIMILAR TO:

336452 I

SHEET I Ir 2

0

BI377591 16

15 1 14

13

12

9

r 10

5 1 4 1 3

6

7

2 L

L R21 POWER CENTER TRIP << << 3

6

AC (N) AC (L)

K

J

INTERNAL POWER SUPPLIES

>> GATHERING HEAD FLOAT SOLENOID 5A >> CUTTER RAISE SOLENOID

R1

R22

« 12 5 VDC POSITIVE << 3 5 VDC COMMON << 4 12 VDC POSITIVE << 12 VDC COMMON << PENDENT PDWER/DATA<<

R2 •

TX(+) TX(-) R 15<< 3 RX(+) TO RADIO << 4 RX(-) RECEIVER << 5 COM << TX (4) R16«1 TX (-) 3 RX (+) TO DISPLAY << A RX (-) RS-485 <E COM

• • •

« 12

H

<< RIN!‹ I

TO DC DRIVE HAULAGE CONTROLLERS 3 << 4 RS

G

C

COM RX 3 TX 4 CTS RTS

METHANE MONITOR OK < MINER TYPE SELECT #12< MINER TYPE SELECT #1 < CONVEYOR RUN < PUMP RUN < CUTTER RUN < LEFT STOP < MACHINE STOP < I 8 120 VAC COMMON (R9/R11/R12) <<REMOTE < MOTOR START ENABLE < CUTTER LOCKOUT < CUTTER RUN WITH FAN < (SCRUBBER) MANUAL FAN < EMERGENCY TRAM ENABLR CB? BREAKER AUX <

.

SERIAL PORT 111 INTERNAL MICROPROCESSOR AND SERIAL INTERFACE PORT 112 CIRCUITS

1 > SOLENOID POWER-120 VAC(L) 3 > SOLENOID POWER-120 VAC(L) >> CUTTER LOWER SOLENOID 45 >> CONVEYOR RAISE SOLENOID CONVEYOR LOWER SOLENOID 6 >> >> CNVYR SWING LEFT SOLENOID CNVYR SWING RIGHT SOLENOID 87 >> >> STAB UP SOLENOID 9 >> STAB DOWN SOLENOID 10 >> GATHERING HEAD RAISE SOLENOID 6 >> FAN CONTACTOR (SCRUBBER) 5 >> CONVEYOR REV CONTACTOR

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R4

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A

10 >) CONVEYOR FWD CONTACTOR 9 >> RIGHT CUTTER CONTACTOR 8 >> LEFT CUTTER CONTACTOR 7 >> PUMP CONTACTOR 6 >> LIGHTS 5 >> CNTRL GND FAULT ALARM 4• >> LOW OIL ALARM >> AUX OUTPUT 115 (MOMENTARY/PUMP) > 120 VAC LINE > 120 VAC LINE 4

R5

1

• 120 VAC INPUT 1115 120 VAC INPUT 1414 120 VAC INPUT #13 120 VAC INPUT #12 120 VAC INPUT #11 120 VAC INPUT 010 120 VAC INPUT #9 120 VAC INPUT #8 120 VAC INPUT #7 120 VAC INPUT 116 120 VAC INPUT #15 120 VAC INPUT 114 120 VAC INPUT 113 120 VAC INPUT #2 120 VAC INPUT #1

•

R6

PUMP CURRENT<

>> SPARE #10 >>

,

» >> SPARE #8

10 >> AUX OUTPUT #4 (LATCHED/PUMP) ? >> AUX OUTPUT #3 (MOMENTARY) 8 >> METHANE MONITOR OVERRIDE CONTACT ;? >> SPARE #2 !' >> SPARE #1 '-' , >> BRAKE RELEASE : >> BREAKER RESET (ALTERNATE) " >120 VAC LINE >120 VAC LINE

R11

LEFT REVERSE CONTACT < LEFT FORWARD CONTACT< LEFT TRAM SIGNAL< RIGHT REVERSE CONTACT< RIGHT FORWARD CONTACT < RIGHT TRAM SIGNAL< TRAM LEVER COMMON << TRAM LEVER +5VDC OUT <<

8 7 6 5 4 3

R14 INTERNAL POWER SUPPLIES 5.0 COMMON +5.0VDC OUT 12VDC INPUT 111 12VDC INPUT #2 12VDC INPUT #3

6 5 4

2

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+12VDC

NOTES:

R12

1) R13-5 PROVIDES +12 VDC OUTPUT WHICH MUST BE SWITCHED (VIA ISOLATED SWITCHES) TO TERMINALS R13-6, R13-7, OR R13-B. 2) AC INPUTS ON R9 ARE RELATIVE TO 120 VAC COMMON CONNECTED TO R12-8.

L

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R7

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B

L

R8

R13

SPARE 12 VDC IN #1 < LOW OIL ALARM < LOW OIL LOCKOUT < +12 VDC OUTPUT (SWITCH COMMON)<< 12 VDC SOLENOID COMMON (-) << BREAKER RESET (4)0 BREAKER ON (+)<< FIRE SUPPRESSION (+)<<

5 >> BREAKER ON (ALTERNATE)

INPUT #14 INPUT #13 INPUT #12 INPUT #11 INPUT #10 INPUT 119 INPUT 118 INPUT • 417

ANALOG INPUT #6 ANALOG INPUT #5 ANALOG INPUT #4 ANALOG INPUT #3 ANALOG INPUT #2 ANALOG INPUT #1

FAN #1 CURRENT< RIGHT CONVEYOR CURRENT< LEFT CONVEYOR CURRENT< RIGHT CUTTER CURRENT< LEFT CUTTER CURRENT<

3 >> SPARE #9

PROGRAMMING PORT

ANALOG ANALOG ANALOG ANALOG ANALOG ANALOG ANALOG ANALOG

SPARE RTD 1#2< SPARE RID #1< SPARE RID #3 < MAIN TRANSMFORMER RID < MACHINE VOLTAGE COMMON < MACHINE VOLTAGE LINE < SPARE 0 TO 5VDC A/D INPUT #2< SPARE 0 TO 5VDC A/D INPUT 111< CURRENT MONITOR COMMON< CURRENT MONITOR COMMON<

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SERIAL PORT 115

RIO

120 VAC INPUT #21 120 VAC INPUT #20 120 VAC INPUT #19 R9 120 VAC INPUT #18 120 VAC INPUT 1417 (SEE NOTE 2) I 120 VAC INPUT #16

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BI377591

DBT Continuous Miner TX944 Operation Manual

Publication Date: March 2006 FILE: DBT Miner TX-944 Manual- I Color.DOC

Revision 0

BI377591

PUBLICATION DISCLAIMER AND COPYRIGHT This document is based on information available at the time of its publication.

While efforts have been made to be accurate, the information contained herein does not purport to cover all details or variations nor to provide for every possible contingency in connection with troubleshooting and maintenance. Features may be described herein which are not present in all systems. DBT assumes no obligation of notice to holders of this document with respect to changes subsequently made.

DBT makes no representation or warranty, expressed, implied, or statutory with respect to, and assumes no responsibility for the accuracy, completeness, sufficiency, or usefulness of the information contained herein, No warranties of merchantability of fitness for purpose shall apply.

BI377591

GENERAL SAFETY NOTICES This section addresses some general safety guidelines involved with DBT products. These guidelines are intended to promote safe usage of equipment.

This section is not intended to replace present safety practices at your site.

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

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

SAFETY RECOMMENDATIONS Ghosting (gosting), v., I: Unplanned movement by machines that use Computer Control Technology.

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

General Safety Notices

BI377591

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

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

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

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

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

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

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

General Safety Notices

BI377591

MANUAL CONTENTS Table of Contents Please read the important information contained in the above section titled GENERAL SAFETY NOTICES.

Section/Paragraph

Page

SECTION 1. SYSTEM COMPONENTS

1

1.1 Introduction 1.2 System Components 1.2.1 Transmitter (TX944) 1.2.2 EncIstation

1 1 1 2

SECTION 2. OPERATIONAL SAFETY FEATURES

3

SECTION 3. GENERAL OPERATION

5

SECTION 4. TRANSMITTER MODEL TX944 LED DESCRIPTION

9

4.1 BATTERY/UMB MSG 4.2 ERROR 4.3 LINK REQUEST/SHUTDOWN 4.4 SWITCH ACTIVE/LOW BATTERY 4.5 TRAM ENABLE/INACTIVITY 4.6 LINK ACK/COMMANDED POWER DOWN SECTION 5. OPERATION 5.1 Routine Operation 5.2 Controls 5.2.1 CUTTER STOP 5.2.2 CUTTER START 5.2.3 CONVEYOR REVERSE 5.2.4 CONVEYOR STOP

9 10 10 10 11 12 13 13 13 13 13 13 14 Manual Contents

BI377591

5.2,5 CONVEYOR START 5.2.6 FIRE 5.2.7 LIGHTS 5.2,8 DUST OFF 5.2.9 DUST ON 5.2.10 FAN OFF 5.2.11 FAN ON 5.2.12 PUMP STOP 5.2.13 PUMP START 5.2.14 CUTTER HEAD LOWER 5.2.15 CUTTER HEAD RAISE 5.2.16 GATHERING HEAD FLOAT 5.2.17 GATHERING HEAD RAISE 5.2.18 CONVEYOR SWING LEFT 5.2.19 CONVEYOR SWING RIGHT 5.2.20 CONVEYOR LOWER 5.2.21 CONVEYOR RAISE 5.2.22 BREAKER RESET 5.2.23 BREAKER ON 5.2.24 STAB LOWER 5.2.25 STAB RAISE 5.2.26 TRAM ENABLE 5.2.27 SHIFT 5.2.28 MSTOP OVERIDE 5.2.29 ENABLE 5.2.30 TX POWER ON 5.2.31 TX POWER OFF 5.2.32 TRAM HIGH 5.2.33 TRAM LOW

14 14 14 15 15 15 15 15 16 16 16 16 16 17 17 17 17 17 17 18 18 18 18 19 19 19 19 19 20

SECTION 6. TRAMMING

21

SECTION 7. MACHINE DISPLAYS FOR VARIOUS ACTIONS

23

SECTION 8. POWER DOWN EVENTS

43

8.1 Loss of Communication, Low Battery and Inactivity Power Down 8.2 Commanded

Manual Contents

43 44

BI377591

SECTION 9. BATTERIES

45

SECTION 10. RECEIVER FEATURES

47

SECTION 11. IMPORTANT WARNING BULLETIN

49

SECTION 12. COAL MINE SAFETY AND HEALTH

59

Manual Contents

BI377591

List of Figures Figure Figure 3.1 Transmitter Teach-Learn Umbilical Connection Figure 3.2 Transmitter Teach-Learn Silver Plug Figure 4.1 Transmitter LEDs Figure 4.2 Transmitter Face Plate Layout Figure 6.1 Transmitter Tram Levers Figure 6.2 Display Tram Control Signal Figure 7.1 Display Remote Runtime Status Figure 7.2 Display Fault Log Figure 7.3 Display Miner Overview Figure 7.4 Display Default Remote Runtime Status Figure 7.5 Display Pump Motors Status Figure 7.6 Display Fan Motor Status Figure 7.7 Display Cutting Motor Status Figure 7.8 Display CLA Motor Status Figure 7.9 Display Tram Motor Status Figure 7.10 Display I/O Status (Page 1) Figure 7.11 Display I/O Status (Page 2) Figure 7.12 Display I/O Status (Page 3) Figure 7.13 Display I/O Status (Page 4) Figure 7.14 Display Help {Page 1) Figure 7.15 Display Parameter Machine Stop Shutdown Function Figure 7.16 Display Parameter Tilt Switch Figure 7.17 Display Tram Levers Not Centered Figure 7.18 Display Pump Start Toggle Stuck Figure 9.1 Transmitter Batteries Figure 10.1 Radio receiver Model RX944 LED Descriptions Figure 12.1 Red Zone - It Hurts to be in The Red Zone

Manual Contents

Page 6 6 9 12 21 22 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 45 47 59

BI377591 Page 1 of 60

SECTION 1.

SYSTEM COMPONENTS 1.1

Introduction This manual describes the operation and maintenance of the radio control system using the model TX944 transmitter/endstation. Specific sections of this manual are used to explain each major component of the complete remote control system, their general operation, and a general trouble shooting section. Please read this manual in its entirety and become familiar with the systems operation before controlling energized equipment. Understanding the operational features of the system is REQUIRED for safe operation.

1.2

System Components The system consists of a transmitter/endstation and a receiver. The OEM completes the entire machine by adding electro/hydraulic interface components as well as relay/contactor hardware for the motor stop/start and/or machine shutdown.

1.2.1 Transmitter (TX944) The TX944 is a mobile hand operated transmitter for the radio control system. The enclosure is black polycarbonate and is rated to the specifications of a NEMA 4 enclosure. Inside the transmitter enclosure is the RF, CPU - Switch PCB, and an internal antenna. The radio frequency is modulated around a center frequency of 466.2500Mhz. Output power is approximately 20mW used in a pulsed operation. Machine operations are hand operated via the 8 pushbuttons, 13 toggle switches, 2 tram levers and a large red machine stop button. All functions on the transmitter are labeled clearly; at any time during operation if a label comes off or is covered with dust it is recommended for safe operation that it be replaced SECTION 1

System Components

BI377591 Page 2 of 69

or cleaned before continuing operation. For operator feedback there are six LEDs used to show BATTERY LIFE, ERROR, LINK REQUEST/SHUTDOWN, SWITCH ACTIVE/LOW BATTERY, TRAM ENABLE/INACTIVITY, and LINK ACKNOWLEDGE/COMMANDED POWER DOWN. Batteries are removable. Replacement batteries are removed and replaced via a compartment on the side of the transmitter.

Only batteries that are approved by MSHA for use with this transmitter should be used.

1.2.2 Endstation The endstation operation is accomplished by connecting the endstation cable to the bottom of the transmitter. The operation of the endstation will be exactly the same as the operation of the handheld in the transmitter mode. As soon as the transmitter is connected to the machine by using the endstation cable the system will use the endstation as the only source to control the machine. The endstation will now have full control of the receiver. If a transmitter and endstation are on at the same time the endstation will be in control because the MCU will have sensed a connection with an endstation. It will also exchange serial numbers with the endstation and will only respond with that transmitter.

Receiver/Decoder (RX944) The RX944 is a compact receiver for the remote control system. Inside the extruded shell are the PCBs used to receive the transmitted signal, decode and validate it, and repackage the data stream for transmission to the MCU via a RS232 serial link. The receiver features 4 leds on the front to aid in the operation of the system. The antenna attachment is located on the face of the receiver.

System Components

SECTION 1

BI377591 Page 3 of 60

SECTION 2.

OPERATIONAL SAFETY FEATURES

Transmitter Features: 1. Switch Scan PWR Up- Each time the transmitter is switched on, all switches are scanned to ensure they are in an inactive state. The transmitter will send an error code to the MCU specifying which switch is not working. In the event that more than one switch is stuck the MCU will display only one until it is corrected then it will display the next one affected. This will repeat until all switches are cleared.

The transmitter can be shut down with the TX POWER OFF button or the MACHINE STOP BUTTON. 2. Low Voltage Shutdown- Battery voltage is continuously monitored by an analog input channel of the micro-controller and the transmitter will shut itself down before the voltage decays to a value which could possibly affect proper micro-controller operation. The transmitter will display the cause of the shutdown by lighting the "low battery" led while shutting down transmitting low voltage shutdown commands..

3. MACHINE STOP- This transmitter incorporates a distinctive large red button labeled OFF. Upon depressing this button a string of Power Down commands will be sent to the receiver and the machine will commence operation. Activating the MACHINE STOP BUTTON will also trip the power center relay if set in the menu screen of the MCU. 4. Two Hand Start- Outputs which mandate additional safety consideration such as motor starts which require two-handed initiations. They usually include an enable button. Additionally, a time delay is incorporated such that both buttons must be held for a

SECTION 2

Operational Safety Features

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period of time before the function is enabled. The pump start will require that the enable button be pressed first then the pump start toggle switch be thrown.

5. Inactivity Shutdown-All transmitters utilize an internal timer which is reset by the operation of any switch. If this timer expires then the transmitter and machine will shut down. The inactivity time for the TX944 is 5 minutes,

Operational Safety Features

SECTION 2

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SECTION 3.

GENERAL OPERATION

NOTE: Upon power-up, all transmitter functions must be OFF. This includes all latched functions. If any transmitter functions are engaged upon receiver power-up, the receiver will regard that transmitter as faulty and it will begin to send error information to the MCU to be output on the display. These stuck button error messages will not be entered into the error log. Resetting all transmitter/endstation functions to idle position will reset this safety feature.

Startup Procedures: To begin, there are different start up procedures. One involves the transmitter

having never before operated the miner. Another involves the transmitter having previously operated the miner. Another still, if the transmitter was the last one to operate the miner.

If this is the first time that the transmitter is going to be used with the miner then it will have to be recognized in using the umbilical cord.

The first time a transmitter is used with the machine or the first time the transmitter is used after another transmitter is used you must go through a "Teach Learn" sequence. The transmitter will have to be turned upside down and the port for plugging the umbilical cord will be visible on the bottom. It is easily recognizable by the silver cap on the end. See Figure 3.1.

SECTION 3

General Operation

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Page 6 of 60

Figure 3.1 Transmitter Teach-Learn Umbilical Connection Remove the plug by unscrewing the black ring and plug the umbilical into it (See Figure 3.2.) and press the ON button

Figure 3.2 Transmitter Teach-Learn Silver Plug The left top led, UMB MSG, (umbilical messages) and the left bottom led, LINK REQ, (link request) will flash and then the, LINK ACK, (link acknowledge) will flash once for verifying that the serial number provided by the MCU is the same one as in it memory or twice for logging in it in memory as a new machine that it is connected to. The description of the LEDs are discussed in the next section.

General Operation

SECTION 3

BI377591 Page 7 of 60

Once this process is done the handheld can be used as an endstation or unplugged from the machine and used as a transmitter. Since the machine unit holds only one serial number (transmitter's ID ) and the handhelds only hold one serial number at a time (machine unit's ID ) They.will only communicate with each other. If there is another handheld in the area it will not communicate with the machine but it might cause some interference such as a lower number of messages per second that the system is capable of operating, If the transmitter is the last one that had been used with the miner then there is no need to go through the "teach learn" sequence again, The transmitter can now be turned on and operated normally, The transmitter will not work as a "radio transmitter" without the silver plug attached and screwed in the bottom of the unit.

SECTION 3

General Operation

BI377591 Page 9 of 60

SECTION 4.

TRANSMITTER MODEL TX944 LED DESCRIPTION

Figure 4.1 Transmitter LEDs

4.1

BATTERY/UMB MSG In transmitter mode, this LED will blink at a rate to give a general indication of the battery condition. A rapid blink indicates a relatively full battery and a slow blink indicates a relatively weak battery. When approximately 8 hours of battery life remains, this LED will enter a different blink pattern. There will be two blinks followed by a longer pause and then two blinks again. This pattern will continue indicating

SECTION 4

Transmitter Model TX944 LED Description

BI377591 Page 10 of 60

that fresh batteries are needed. When in umbilical mode, this LED blinks indicating that a message has been sent to the MCU. The blink rate should be steady at 10 times per second.

4.2 ERROR This LED indicates an internal error within the transmitter and it should be replaced. Note that all LED's come on briefly during power up. The ERROR LED on briefly at power up is normal. When this LED is on after power up, the transmitter should be returned for repair.

4.3

LINK REQUEST/SHUTDOWN When the transmitter is connected as an umbilical, it will attempt to LINK to the MCU (refer to TEACH/LEARN discussion). This LED will blink for each link request sent to the MCU. When the transmitter switches off, this LED serves a second purpose in that it indicates that a shutdown is in progress and power down messages are being sent to the MCU. At the same time, one of three other LED's will indicate why the transmitter is powering down: Commanded (Operator initiated), Inactivity or Low Battery (see following paragraphs).

4.4

SWITCH ACTIVE/LOW BATTERY After power this LED is used to indicate a "stuck switch". ALL switches must be in their neutral or safe position before the transmitter is allowed to become operational. If after power up (i.e. TX PWR ON depressed), this LED illuminates and stays illuminated (solid) then there is a"stuck" switch. In this condition, no other switches on the transmitter will be operational. The transmitter will send the error condition to the MCU and the system will display which switch is "stuck". This switch must be replaced before proper operation will resume. After power up, any switch that is operated will result in this LED being solidly on while the switch is operated. In this manner, all switches can be verified locally at the transmitter. To see if the transmitter switch is being properly read, operate the switch and observe the SW ACTIVE LED. Note that only one

Transmitter Model TX944 LED Description

SECTION 4

BI377591

Page i i of 60

switch can be operated at any time as this LED is common for all switches. Also while in normal operation, certain switches are timed to maintain safety features, primarily two handed starts. If for example the ENABLE button is held down for more than 25 seconds, then the transmitter will enter an error mode. If this occurs then all command will cease to operate and an error code will be sent to the machine. To resume normal operation, the ENABLE button must be released. Switches that are timed in this manner are: • ENABLE • SHIFT • TRAM ENABLE • PUMP START • CONV START • CONV REV • CUTTER START Note that in normal operation, all of these switches are held operated for only short periods of time. A constantly held condition would be abnormal and defeat two handed starts and make other enabled functions unsafe. Therefore, these switches are monitored and timed during normal operation to prevent the possibility of a constantly on switch.

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

4.5

TRAM ENABLE/INACTIVITY This LED indicates that the tram levers are armed (active) and that any operation of the tram levers will result in machine movement.

Conversely, if this LED is off, then the tram levers are dead.

SECTION 4

Transmitter Model TX944 LED Description

BI377591 Page 13 of 60

SECTION 5.

OPERATION

5.1

Routine Operation Routine transmitter operations are all the functions performed after the system has initialized and established communications. Routine operations of the transmitter's functions are as follows. Please refer to FIG 4 for the location of the switches/buttons and train levers

5.2

Controls

5.2.1 CUTTER STOP This command is activated by moving the lever forward. The lever is momentary and does not have to be held in this position. The screen will display cutter stop. This toggle switch will be scanned during startup.

5.2.2 CUTTER START This lever activates the cutters. This action requires the enable button to be pressed concurrently. This lever is momentary and does not have to be held in this position. The toggle switch will be scanned upon startup. If the switch is held for more than 25 seconds an error will occur and the transmitter will issue standard motor shutdowns and display the error on the view screen.

5.2.3 CONVEYOR REVERSE This button will start the conveyor in the reverse direction. This action requires the enable button and the CONVEYOR lever held in the START position while pressing the CONVEYOR REVERSE BUTTON. This button will be scanned upon start up and will generate an error visible on SECTION 5

Operation

BI377591 Page 14 of 60

the view screen if it pressed when starting up the transmitter. This button will generate an error if it is pressed for more than 25 seconds,

5.2.4 CONVEYOR STOP Moving the conveyor lever to the stop position will send a signal to stop the conveyor. The switch will be scanned upon startup and if held while starting up it will generate an error that will be displayed on the view screen.

5.2.5 CONVEYOR START This action will start the conveyor. This action requires the enable button to be pressed concurrently. This lever is momentary and does not have to be held in this position. The toggle switch will be scanned upon startup.

If the switch is held for more than 25 seconds an error will occur and the transmitter will issue standard motor shutdowns and display the error on the view screen.

5.2.6 FIRE This action will start the fire suppression on the miner. The lever is momentary and does not have to be held in this position. The switch will be scanned upon startup and if held while starting up it will generate an error that will be displayed on the view screen.

5.2.7 LIGHTS This action will activate and deactivate the lights. This function is latched function. It will turn on the lights when the toggle switch is pushed and released. If pushed again the light will be turned out. This switch will be scanned upon startup and if held while starting up it will generate an error that will be displayed on the view screen.

Operation

SECTION 5

BI377591 Page 15 of 60

5.2.8 DUST OFF This function will turn off the dust spray. This function is latched function. This switch will be scanned upon startup and if held while starting up it will generate an error that will be displayed on the view screen.

5.2.9 DUST ON This function will turn on the dust spray. This function is latched function. This switch will be scanned upon startup and if held while starting up it will generate an error that will be displayed on the view screen.

5.2.10 FAN OFF This action will turn off the fan (scrubber). This function is latched function. This switch will be scanned upon startup and if held while starting up it will generate an error that will be displayed on the view screen.

5.2.11 FAN ON This action will turn on the fan (scrubber). This function is latched function. This switch will be scanned upon startup and if held while starting up it will generate an error that will be displayed on the view screen.

5.2.12 PUMP STOP This function will turn off the pump. This switch will be scanned upon startup and if held while starting up it will generate an error that will be displayed on the view screen.

SECTION 5

Operation

BI377591 Page 16 of 60

5.2.13 PUMP START This function will start the pump. This action requires the enable button to be pressed before the lever is activated. This lever is momentary but has to be held in this position for half a second before the transmitter will transfer the command. The toggle switch will be scanned upon startup. If the switch is held for more than 25 seconds an error will occur and the transmitter will issue standard motor shutdowns and display the error on the view screen

5.2.14 CUTTER HEAD LOWER This function will lower the cutter head. This switch will be scanned upon startup and if held while starting up it will generate an error that will be displayed on the view screen,

5.2.15 CUTTER HEAD RAISE This function will raise the cutter head. This switch will be scanned upon startup and if held while starting up it will generate an error that will be displayed on the view screen.

5.2.16 GATHERING HEAD FLOAT This function will allow the Gathering head to float. This switch will be scanned upon startup and if held while starting up it will generate an error that will be displayed on the view screen.

5.2.17 GATHERING HEAD RAISE This function will raise the Gathering head. This switch will be scanned upon startup and if held while starting up it will generate an error that will be displayed on the view screen.

Operation

SECTION 5

BI377591 Page 17 of 60

5.2.18 CONVEYOR SWING LEFT This function will swing the conveyor to the left. This switch will be scanned upon startup and if held while starting up it will generate an error that will be displayed on the view screen.

5.2.19 CONVEYOR SWING RIGHT This function will swing the conveyor to the right. This switch will be scanned upon startup and if held while starting up it will generate an error that will be displayed on the view screen.

5.2.20 CONVEYOR LOWER This function will lower the conveyor. This switch will be scanned upon startup and if held while starting up it will generate an error that will be displayed on the view screen.

5.2.21 CONVEYOR RAISE This function will raise the conveyor. This switch will be scanned upon startup and if held while starting up it will generate an error that will be displayed on the view screen.

5.2.22 BREAKER RESET This function will reset the breaker. This switch will be scanned upon startup and if held while starting up it will generate an error that will be displayed on the view screen.

5.2.23 BREAKER ON This function will turn on the breaker. This switch will be scanned upon startup and if held while starting up it will generate an error that will be displayed on the view screen.

SECTION 5

Operation

BI377591 Page 18 of 60

5.2.24 STAB LOWER This function will lower the stab in the back of the machine. It will operate as long as the switch is thrown or until the limit is reached on the miner. This switch will be scanned upon startup and if held while starting up it will generate an error that will be displayed on the view screen.

5.2.25 STAB RAISE This function will raise the stab in the back of the machine. It will operate as long as the switch is thrown or until the limit is reached on the miner.

This switch will be scanned upon startup and if held while starting up it will generate an error that will be displayed on the view screen.

5.2.26 TRAM ENABLE This toggle switch whether pushed left or right will activate the tram enable on the transmitter. It will be active for 2.5 seconds until a tram lever is activated. If at the end of 2.5 seconds the trains are not activated the enable will go out and all train activity will be disabled. The function will not engage until the tram levers are in the center position. The tram enable will also be reset if the pump start is activated. The tram enable is checked upon start up and if active at startup will cause an error to be displayed on the view screen. This toggle switch will generate an error if held on for more than 25 seconds and will send shutdown codes.

5.2.27 SHIFT This button is yellow on the transmitter and will be used in conjunction with the lower right 5 toggle switches. On these switches are the functions that they will command. This switch will be scanned upon startup and if held while starting up it will generate an error that will be displayed on the view screen.

Operation

SECTION 5

BI377591 Page 19 of 60

5.2.28 MSTOP OVERIDE This button will override the machine stop button on the left side of the miner. This button should be held down while the pump is started and during tramming. This switch will be scanned upon startup and if held while starting up it will generate an error that will be displayed on the view screen.

5.2.29 ENABLE The enable button will be used in conjunction with other switches. These switches will be marked with their function in green. This switch will be scanned upon startup and if held while starting up it will generate an error that will be displayed on the view screen. This toggle switch will generate an error if held on for more than 25 seconds and will send shutdown codes.

5.2.30 TX POWER ON This push button is the "ON" button for the transmitter. This is the only function of this button

5.2.31 TX POWER OFF This button will turn off the transmitter. It will initiate a shutdown sequence that will shut off all pumps and put the machine in a safe state.

It will transmit these command 20 times and then shut off the transmitter.

5.2.32 TRAM HIGH This button will put the miner in high tram. The button is a latch function. This button will only put the miner in high tram. While in high tram pressing this button will have no effect. This switch will be scanned upon startup and if held while starting up it will generate an error that will be displayed on the view screen.

SECTION 5

Operation

BI377591 Page 20 of 60

5.2.33 TRAM LOW This button will put the miner in low tram. The button is a latch function.

This button will only put the miner in low train. While in low train pressing this button will have no effect. This switch will be scanned upon startup and if held while starting up it will generate an error that will be displayed on the view screen.

Operation

SECTION 5

BI377591 Page 12 of 60

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

4.6

LINK ACK/COMMANDED POWER DOWN During the TEACH/LEARN process, this LED indicates that a link response (acknowledgement) has been received back at the transmitter from the MCU. If the transmitter was re-linked back to the same MCU (machine), then this LED will flash once. If this is a new link to a different MCU (machine), then this LED will flash twice. Upon shutdown, this LED will illuminate in conjunction with the SHUTDOWN LED to indicate that the reason the TX shut off was a commanded power down (operated initiated) as a result of the operator pressing either the MACHINE STOP mushroom head or the TX PWR OFF pushbutton.

MACHINE ,-0 7 O HIGH sTP

ENABLE

MSTOP OVR

slop

0p '

REVERSE

TRAM

LO ER

ENABLE

RAISE

0

FIRE

CONVEYOR

PUMP,

DUST

CONVEYOR TA hIN -

0

a

FIRE

o

C? NI

MAN

LOWER

LEF1 *PI

FAN

RAISE

imiloRiaT

C7)

0

0

LIGH _._ S

-,

LIGHTS

.7. f

FL

LOWER

0 RAISE:

0 RAISE

0

Figure 4.2 Transmitter Face Plate Layout

Transmitter Model TX944 LED Description

SECTION 4

BI377591 Page 21 of 60

SECTION 6. TRAMMING

There are two tram levers on the transmitter. They each control one of the trains.

See Figure 6.1.

Figure 6.1 Transmitter Tram Levers Before tramming can occur the hydraulic pump must be started. See PUMP START. Once this has been done then the Tram Enable must be pressed either to the left or the right. The enable switch lever is the first lever to the right of the tram levers. See Figure 6.1.

The train lever must be operated within approximately 2 '/2 seconds after the enable is activated or the function will timeout and the enable will have to be pressed again to activate the trams, When the tram enable is active the train enable light will be lit, See Figure 6.1 for location of this LED. There are 3 tramming speeds available to the operator. The first is SUMP. It is the lowest of speeds and is used while digging into the coal face. This speed will automatically be engaged when the miner comes into contact with the coal face. It

SECTION 6

Tramming

BI377591 Page 22 of 60

will also be automatically selected when one tram is used alone or the trams are operated in different directions ("splitting the cats"). The miner will default on start up to the next speed, LOW TRAM speed. HIGH TRAM speed can be selected by pressing the high tram button on the transmitter.

The relationship between lever position and speed command can be seen on the view screen on the miner. The train control signals from the transmitter can be seen in the lower left portion of the screen labeled TRACTION FT/MIN. See Figure 6.2 below.

TRANSMITTER IOOSTATLIS RF SIGI AL ittASGiSEC BATTERY 8.5u

BOTTOM MOTOR CURREIIL (A) L

535

CUTTIO MOTOR"TEMP; (C)-

R

PUMP MOTOR

200

CIA MOTOR CURRENT (A) (C) 200

145

MACiIIIIE VOLTAGE (V) 2000 -

TPAMMOTORCURRENT'fA) L

- 375

FA1rMOTOR BEFORE BUTTER

TRAM MOTOR VOLTAGE (V) L 500

1000 ---

Figure 6.2 Display Tram Control Signal

Tramming

SECTION 6

BI377591 Page 23 of 60

SECTION 7.

MACHINE DISPLAYS FOR VARIOUS ACTIONS

On the miner itself there is a view screen that can be accessed by the operator of the transmitter. To navigate the menu system use the yellow shift button with the switches that have yellow labels. Refer to Figure 7.1 the Breaker Reset/on switch is also used to page up or page down in the menu system. Next to it, the Conveyor lower/raise switch is to change the value inside the menu. Up meaning to increase the value and down to decrease the value.

Following is a list of menus accessible by the operator of the transmitter in order that they occur on the miner. The default menu is Remote Runtime Status and is what the machine will display when started up.

SECTION 7

Machine Displays for Various Actions

BI377591 Page 24 of 60

25N10

•

TR/MISR-I- TER I 00STATV, RF :111*51;f3E(..

BATTERY 13.5v

CUTTING MOTOR CURREIIT (A)

L

535

R

41LA:1410TOR CORR IIT:(4):.

146

r1/1 4 4dIRIE VOLTAGE (V) 20,00.t"'

TRACT1011 ET)M111

- : CUTTIIIG MOTOR TEMP (C)

C,LA MoTOR TEMP (C') R — 200

TRAM MOTOR CURREOT (A) 375

(C) 200 —

FAIT mptOR BEFORE:COT TER

(A)

TRAM M OTOR VOLTAGE (V) 500

1000 DRIVE WiScpiroEP.'.

20 20.

Figure 7.1 Display Remote Runtime Status

Machine Displays for Various Actions

SECTION 7

BI377591 Page 25 of 69

TRAIISGUTTEFt 100STATUS

RP SIGNAL OATTERY 8.5v

I I MSG , SEC

33,6 / 211- 12 2 666 •808 3 .33001 3016: A ar Motor Overload il-mli A AN1 ° 031026275 p P RCiti31im T for 5 sec.

3/21/200 .,0:01 n ulvypPe Y ss ItSd dh°01ww AM AO e. outp l_f1111.11r°0--wrC 1 evi-le0e°Yflyi1°-C 3/21/2006 0:2u:, ut error1-1°° T Li3 -Relay e°/ to k°eIrj Pf 3/2//2006 7 32:00 AM AA001.Bacakplune s C BP2C) B Trailler: °10-Ena 3/20 PM ble Pt/511E1unon t°uicilki: CPU pP:Mmfr 3/20/2006 5: 40:21 1 iTrraum irn pCii /2006 135:4 pm A001•Beck lutie Transfer Fault: CPU 10

'tr

tear irM

LI.

Figure 7.2 Display Fault Log This is the fault log screen. The machine will display faults and errors that occur during its operation. Only those faults that cause a motor to unintentionally shutdown will be logged into memory for later analysis.

An example is if the miner is shut down when the MACHINE STOP Button is pressed it will be displayed here. If the miner stops because of an over temperature on the cutter motor then it will be displayed here and logged into flash memory.

SECTION 7

Machine Displays for Various Actions

BI377591 Page 26 of 60

4w% 25ri10

TRAMMITTER 100STATUS 11F SIGHAL !,11EMSGISEC GNITtik :8.5v

101.%110 1

D BT

103 PUMP MOTOR

LEFT LEFT CLA MOTOR CUTTING MOTOR

rylOTOR TEMPERATURES RIGHT RIGHT TRAM }(FORMERCIA MOTOR CUTTING MOTOR

E71 •., Copyright {c) 2004-2005, DST ,Omer Ica Inc.

Figure 7.3 Display Miner Overview This menu is a graphical overview motor currents and motor temperatures. Also displayed is the temperature of the tram transformer. Also useful is the display of the machine voltage.

Machine Displays for Various Actions

SECTION 7

BI377591

Page 27 of 60

25M0 TRAI1S1vIITTER 100STATUS

Ari

RF SIGIIAL

DB: T

I iu1S(ii.(SEC

BATTEN

CUTTING MOTOR CURREUT (A) L

535 ----

R

PUMP. rylf_PT.011

COTTRIO:MOTOR TEMP IC R

L

(C) 200

100 --

0 CLA MOTOR CURREUT (A) L

CLA MOTOR TEMP (C)

R

200

1,15

VOLTAGE (V.) 2000

1000—

FAIIMCITOR BEFORE CUTTER

{c)

(A) 75

TRAM MOTOR VOLTAIGE (V)

TRACT1011 ET41111 R

R

L

500

187 -4

Figure 7.4 Display Default Remote Runtime Status This menu is the default menu that is displayed when the miner is powered up.

It will show currents and temperatures for all the motors graphically. In the upper right corner it will show the status of the transmitter. The green light is to show a valid command is being transmitted. The bar graph changes color depending whether they are high or low. The battery voltage of the transmitter is shown. A Red battery text will indicate that the battery is very near empty. The battery should be changed if the battery text is red in color.

The RF signal indicates the relative strength of the RF signal. A low signal does not mean that there is a loss of information transmitted to the miner. Remember, SECTION 7

Machine Displays for Various Actions

BI377591 Page 28 of 60

the signal is digital in nature and will either work or not work. So a low value for the strength will mean that the miner is approaching a point where signal loss can occur. This graphic can be used to tell if there is something wrong with the transmitter. If you hold the transmitter near the antenna and there is a low signal then you should investigate the antenna cabling first and then the transmitter should be checked for low power output. Another diagnostic tool is messages/second. When there is an active command this number should be around 8 to 12. If the transmitter is idle for 1 second this will decrease to 4 to 7 messages/second to save battery life. If there is interference from another transmitter then this will decrease the number of valid packets (messages) from the transmitter and the number will be smaller.

251V10 TRA11Sfy1liTER 100STATUS RF SIGI1AL,

BATTERY 9.r+

T

FLA

3/21:Q006

500 400

8:56:41 AM

8:57:41 AM

Figure 7.5 Display Pump Motors Status Machine Displays for Various Actions

SECTION 7

BI377591 Page 29 of 60

This screen gives a detailed view of the pump motor and its history for one minute.

The screen will display immediately the pump motor current and the temperature in the blue bars graphs. In the graphics area the current will be shown from right to left, the right most side of the screen will be the most recent measurements.

The transmitter status box ie., battery, rf signal etc will be active in this screen.

TRA.1.1.6rv1)T TER 1p!-.isTA-rtifi RF

t.LA

3/2112006

500 400 300

100 9:03:25 AM

9:02:25 AM

Figure 7.6 Display Fan Motor Status This screen gives a detailed view of the fan motor and its history for one minute.

The screen will display immediately the fan motor current in the blue bar graph. In

SECTION 7

Machine Displays for Various Actions

BI377591 Page 30 of 60

the graphics area the current will be shown from right to left, the right most side of the screen will be the most recent measurements.

The transmitter status box ie., battery, rf signal etc will be active in this screen.

TRAIISMITTER1OOSTATus RF SBIBAL I fy15G,SEC BATTERY 8.5v

31.21 !2006

10:09:21 AM

9:09121 AM

Figure 7.7 Display Cutting Motor Status In this menu the left and the right cutting motors currents and temperatures will be displayed and the history for one minute.

The screen will display immediately the cutting motor currents and the temperatures in the blue bars graphs for each motor. In the graphics area the

Machine Displays for Various Actions

SECTION 7

BI377591 Page 31 of 60

current will be shown from right to left, the right most side of the screen will be the most recent measurements. The right cutter motor will be colored green and the left motor will be colored blue.

The transmitter status box ie., battery, rf signal etc will be active in this screen.

TRANSMITTER1OOSTATUS

•

RF skatAL EC/ATMY 8.5u

FLA

El LEFT

11 MS& SE(

3/21t2006

500

9:16:42 AM

9:17:42 AM

Figure 7.8 Display CLA Motor Status This screen will display the CLA left and right motor status. The blue bar graphics will display the immediate values for the current and temperature. In the graphics area will be a one minute history of the motor currents. The current will be shown from right to left, the right most side of the screen will be the most recent

SECTION 7

Machine Displays for Various Actions

BI377591 Page 32 of 60

measurements. The right CLA motor will be colored green and the left motor will be colored blue.

The transmitter status box i.e., battery, rf signal etc will be active in this screen.

TRANSMITTER OOSTATIJS . , ilATTERY, 8.5v

'11 1 rv1SG'14C.

500 400

9:29;55iANI

Figure 7.9 Display Tram Motor Status In this menu the tram motor status will be displayed. The currents and the voltages for the left and right motors will be displayed as blue bars for the immediate values. A 1 minute history will be displayed for the voltage and the current for each motor. The left motor current will be blue. The left motor voltage will be red.

The right current will be displayed in green. And the right voltage will be displayed in pink.

Machine Displays for Various Actions

SECTION 7

BI377591 Page 33 of 60

The transmitter status box i.e., battery, rf signal etc will be active in this screen.

TRAIISMITTER 160STATUS RF SlOtIAL BATTERY

LOCAL PUMP START

PUMP RUN LT:P.:.:.R.W....k...:.CURRENT LIMIT RANGE MACHINE LOCAL CUTTER START 9UTTR'RUN RT DRIV E CURRENT LI MIT RANGE CTRL CIRCUIT LOCAL!:..0...ONVEY6R117.ART..

ONVEYOR RUN • TILT SWITCH ENABLE CONVEYOR REVERSE JOG! TRAM.::!ENABLE.:.

1;p.qiWF...:AN START `EFT CUTTElk::'MOTOR<FEEDEIACK:

CUTTERS RUN WITH FAN MODE MANUAL FAN MINER TYPE MODE C B1'1I 2 INO C ER N VTEYYPBOEIRTB#1 AUx BREAKER #2 EMERGENCY TRAM claTER:;.L.0CKOUT LT-4pK.NovvLEDGE 4 W.121.D.OrAy. LOW0i4440.cIKOUTi, LOW OIL ALARM .

METHANE MONITOR CK Tf 12 VOC:INPUrSPARE PAVENTILATIORr ISET oefAuta LOCAL STARtENABLE

Figure 7.10 Display I/O Status (Page 1) This is page one of four screens that display input/output status.

SECTION 7

Machine Displays for Various Actions

BI377591

Page 34 of 60

le-H*1.1 25-mq

:1V.0iSMITTER 100STATUS BATTERY .4. Sv

RI

11 MS(.1;i5fC

TX;'I:;UMB`PUMP: START

7

IGHT REVERSE TRAM CONTACT LEFT FORWARD TRAM CONTACT LEFT REVERSE TRAM CONTACT MACHINE STOP SHUTDOWN-FUNC TRANSMITTER AOTIVE 1 TRAM ENABLE ARMED

INFRARED ACTIVE " PAGE LIP BUTTO N ACTIVE PAOE.:00WR'BUTI".01+ACTIVE UP BUTTON ACTIVE DOWN BUTTON ACTIVE I MENU BUTTON ACTIVE BUTTON ACTIVE • SET • •• •TRAIW• STATUS H114:1.•••1:;i:41/V •

TX !UMB PUMP STOP TX !'.UMB CONVEYOR FWD START : TX !UMB CONVEYOR REV, START Txiltply15, apOypyipR STOP ^I TX IUMB CUTTER START

...1".FLIIv113:.E:HEADLIOHMON :„ I OFF TX !'UMB DUST SUPRESS ON TX 1 UMB FIRE SUPRESS ON !OFF T*:::huma!;!IVIA011.Nk$70::OX*R8ll:)k: f TX ! LIMB CUTTER HEAD RAISE TX ! UMB CUTTER HEAD LOWER TX ! UMB GATHER HEAD RAISE TX 1 UMB GATHERING :HEAD FLOAT TX ! LIMB CONVEYOR SWING RT

Figure 7.11 Display I/O Status (Page 2) This is screen two of four status screens. As you can see the transmitter was communicating with the miner as the transmitter active status light was lit. Also note that in the upper right hand corner the battery voltage value was being sent.

The receiver was measuring a moderate rf signal, no trains were active and no active command was being sent. The transmitter will always communicate with the miner even though there is no active command being sent.

Machine Displays for Various Actions

SECTION 7

BI377591 Page 35 of GO

TRANSMITTER NOSTAM; RF SIGBAL BATTERY 8.,v I I Msf,osEc.:

TX I UMB CONVEYOR RAISE TX!1 UMB CONVEYOR LOWER TX I: UMB STAB RAISE TX ! UMB STAB LOWER Ii.0; MAN UALFAN TX . . . ..•1,uma TR AM:•:H101,1,: COMM•AND Jf TX I UMB TRAM LOW COMMAND TX I UMB CONVEYOR SWING LT EN LO OIL ALM CONSTANT OUP T ENABLE LOW OIL ALARM FLASH ENABLE LOW OIL ALARM CUTTER ENABLE LO OIL L O CKOUT ENABLE LO OIL LOCKOUT PUMP FUTURE USE TMUMB MACHINE STOP

A PUMP CONTACTOR R100:::dtATEk,a9NTAcTOR 1. -,EFTeUTTER661"ITACTORCONVEYOR FWD 2' CONVEYOR REV CONTACTOR FAN qq..14717AtT01''''' BRAKE RELEASE CONTACTOR LOW OIL ALARM RN G.TRL CIRCUIT Oisic 4AuLfALAR 1 AC RELAY SPARE 41 AC-E.RELArSPARE.i12 AC RELAY SPARE A Ac,!.:Ag:v.:r.$ PARE#4.;::..#3 AC RELAY SPARE #5 # AC RELAY AC RELAY SPARE CONTACTOR

Figure 7.12 Display I/O Status (Page 3) This is page three of the status pages.

SECTION 7

Machine Displays for Various Actions

BI377591 Page 36 of 60

2 SMO TRAIIISMIT TER 1 UOSTATOS • BF SIII,AtAL 11 MS13SEC BATTERY _8,5u

DBT

AGRELAY:i.SPAFei.#8 , AC.:,.R01;Ar.SPARE:#9 AC RELAY SPARE #'10 ACRE4AY:''eA13P #11 DUST SUPPRESSION CONTACTOR : ' LIGHTS CONTACTOR SOLENOID OUTPUT SPARE #~I SOLENOID OUTPUT SPARE #2 L-JHU.itERRA10gs.04psipip OAtHER. HEAD FLOAT SOLENOID •• .c1)rtRi4pInfR,..sp400p CONVEYOR RAISE SOLENOID _ CONVEY IR LOWER SOLENOID CONVEYOR SWING LT SOLENOID tC/NVEY..."00.! SWING RT SOLENOID

STAB DOWN SOLENOID GATHERING HEAD RAISE SOLENOID BREAKER ON (AC) BREAKER RESET:(Ac) BREAKER ON (QC.) sREAKek:Estt:IpOj: FIRE .8u$KIARY.:::-0..ONTtAdT 7 AUXILIARY p...9"4Tpkci- 2 AUN141AIRytoNTA07:t1 AUX141AkrC.6.NTACT 4 AUXILIARY CONTACT 5 AUXILIARY CONTACT 6 AUXILIARY CONTACT 7 AUXILIARY OPNIACT 8

Figure 7.13 Display I/O Status (Page 4) This is page four of four status pages. These status lights can be used to diagnose a fault in the machine if needed. If a status light is on because a command has been sent by the transmitter then you know that the transmitter is ok. You know the receiver is ok and the computer inside the miner is getting the command. Next look downstream from the computer for a fault in the wiring or a bad component.

Machine Displays for Various Actions

SECTION 7

BI377591 Page 37 of 60

BT

;

TRAIISIATICR 100STATIJI RF SIGIVAL BATTERY 8 •5v

A011 -Transmitter shutdown low battery

Figure 7.14 Display Help (Page 1) This page will be for helpful hints in running the machine, It is not finished yet.

SECTION 7

Machine Displays for Various Actions

BI377591 Page 38 of 60

TRAIISMITTER 100filATUS • 111' BATTERY 8.5v 11 MSGiSEC.

MACHINE STOP SHUTDOWN FUNCTION

II •

Selects whether or not the operation of the machine stop button on either the umbilical control station or the transmitter will trip the power center, or only shut off the ',tulip.

The allowable v.alue. s •are: POWEWO:ENtEIRE:SRIP

PUMP'' HUT D WN Defaults to:::POWER'CENTER TRIP

Figure 7.15 Display Parameter Machine Stop Shutdown Function This screen is not accessible to the operator of the transmitter. The operator should be aware of the setting of this parameter. When the operator presses the Machine Stop button on the transmitter the value that this screen contains will decide if the power center relay will trip or not. This screen is accessible by using the IR pendent.

Machine Displays for Various Actions

SECTION 7

BI377591 Page 39 of 60

or „gm DBT'

• TRAIISMITTER 100STATUS --LIF SIGNAL 1 1 WISG4SEC 13ATTERY. 8,6v

TILT SWITCH

Selects whether the operation of the tilt switch in the tiansi-nitter/umbilical control station will shut down the pump motor.

The allowable values ale Disabled and Enabled Defaults to Disabled.

Figure 7.16 Display Parameter Tilt Switch This screen is not accessible to the operator of the transmitter. The operator should be aware of the setting of this parameter. The tilt sensor always sends the signal to the MCU but is only acted upon if this menu item is set. This screen is accessible by using the IR pendent.

SECTION 7

Machine Displays for Various Actions

BI377591 Page 40 of 60

TRANSMITTER 100STATU5 PF S11311AL

BATTERY 8.5%4

CUTTING MOTOR:COMMIT fA) 535

Ii IVISO,SEC

COTTURI MOTOR TEMP (C) L R 200 —

CIA MOTOR TEMP (C) L R

(C) 200

FA!! MOTOR BEEORE CUTTER

100

TRAM Mt)TOR 4:3URREIIT:(A) ile*TAQRAV) 2000-- =

L

375

1000 ORlyk:p.0,50)rkfc

Figure 7.17 Display Tram Levers Not Centered This menu shows what happens when the tram levers are not in the center position when the transmitter is turned on. The error in red states the first error the transmitter sees in itself. It is saying that the left tram lever is stuck. With all error conditions such as stuck buttons on power up and stuck motor function switches and enables the transmitter will only send these error codes and can not be used until all errors are cleared.

Machine Displays for Various Actions

SECTION 7

BI377591 Page 41 of 60

TRAIISMITTER '100STATUS RF SIGRAL LI MSGiSEC BATTERY 87 5v

c0F1109:MOTORVOR.Rf0t14: L

535 -

R

CUTTIRG MOTOR TEMP.(Cy R L 200

100

0.

CLAM TOR CURR 11T (AI 200

145

MACWIIE

TRAM MOTOR CORREITE .F1

2:000

FAR MOTOR BEFORE 47:UTTER

TRAM MOTOR VOLTAGE (V) L R - 500

:1.000 DAVE rvIS(31SEC

20

20

Figure 7.18 Display Pump Start Toggle Stuck This menu shows what happens when the pump start toggle is held in the start position. The error is sent and visible on the screen.

SECTION 7

Machine Displays for Various Actions

BI377591 Page 43 of 60

SECTION 8.

POWER DOWN EVENTS

NOTE: Read LEDs from left to right.

There are currently four types of shut down modes for the RX944 receiver. They are a "commanded power down", "low battery shutdown", "inactivity shutdown", and "loss of signal". They are two separate and distinct ways of shutting down remote control operations.

8.1

Loss of Communication, Low Battery and Inactivity Power Down A loss of communication power down is not initiated, but occurs due to a loss of communication between the transmitter and receiver for 2 sec.

Typically, this occurs when a battery is weak, circuit malfunction occurs, the transmitter is out of range, or the antenna is being blocked or has a broken connection affecting the transmitter range. When the receiver sees a loss of communication, a two-part power down occurs. After one second the receiver will: 1. Clear all non-latched outputs( Front/Rear Cylinders, and Tram commands) 2. Set the power down bit in the Allen Bradley serial message (if a PLC is installed) 3. Clear all outputs to OFF, Removing power from PUMP MOTOR. 4. Wait for 2 sec. For power to be removed. If this does not occur, the receiver will return to a search condition and wait for a transmitter to turn ON.

SECTION 8

Power Down Events

BI377591 Page 44 of 60

A low battery shutdown will display on the machine screen that the reason for shutting down was due to low battery voltage.

After 5 minutes the transmitter will auto shutoff. This will include shutdown messages sent to the MCU to turn off motor and hydraulic functions.

8.2 Commanded A commanded power down is initiated by pressing the stop button on the handheld. It can also be shut down by pressing the machine stop button.

The hand held will start and send 20 power down commands and then shut off. If in the menu system page "Machine Stop Shutdown Function", the power center trip value is set then the command will be sent to trip the power center relay.

Power Down Events

SECTION 8

BI377591

Page 45 of 60

SECTION 9. BATTERIES

Figure 9.1 Transmitter Batteries One of the most beneficial features of the new transmitter style is its power design.

The TX9XX has a continuous operational life of approx. 120 hours. The power source is two 9 volt batteries. A BAT LED monitors battery life. A fast flashing LED means that battery strength is good. A slow flashing light means that the batteries are more than half used up. A double blink —pause- double blink LED means the batteries need to be changed (approx. 8 hrs left). The transmitter will run until the batteries are dead, but performance and range will diminish quickly and could be unsafe if trying to operate from a long range. When LED double blinks the batteries should be replaced. The battery compartment is polarized so the batteries can be inserted but the contact will only be made with the batteries in the correct orientation. Inside the compartment one contact is larger than the other

SECTION 9

Batteries

BI377591 Page 46 of 60

corresponding to the larger contact on the battery. The battery compartment door should be closed with the screws finger tight.

Batteries

SECTION 9

BI377591 Page 47 of 60

SECTION 10.

RECEIVER FEATURES

Redundant Watchdog - The receiver incorporates the internal watchdog as described for the transmitter. In addition the receiver circuits include an external hardware based watchdog circuit to reset all outputs in the event of a microcontroller failure. This circuit is redundant to the internal watchdog and monitors the constant toggling of a dedicated I/O pin. Steady state values on the I/O pin, either low or high, will trip the external watchdog and reset the receiver.

NOTE: Any time during operations that communications are lost between the transmitter and the receiver all outputs of the receiver will be cleared and it will begin scanning for the transmitter that contains the last serial number that was connected to it.

2 3 4 5 6 7 8

Ri

'1

R 2345

Figure 10.1 Radio receiver Model RX944 LED Descriptions

SECTION 10

Receiver Features

BI377591 Page 48 of 60

1. Watchdog, blinks once per second to indicate that power has been applied and than internal processor is alive and working.

2. Pre-Ample Detect, blinks to indicate that transmitter on the correct frequency has been detected. This LED should blink approximately 10 times per second as soon as a transmitter is switched on in the vicinity of the machine.

3. Valid Message, blinks to indicate that valid messages from a transmitter on the correct frequency are being received. Note: This does NOT mean that the transmitter is the serial number that has been "TAUGHT" to the Machine Control Unit. All transmitter messages that pass the CRC tests are passed to the MCU for evaluation.

4. Link LED, indicates that a sufficient number of messages are being received to qualify as a "link" and the system should not drop out.

Led's 5 through 8 are for future use.

Receiver Features

SECTION 10

BI377591 Page 49 of 60

SECTION 11.

IMPORTANT WARNING BULLETIN

WARNING! FAILURE TO READ THIS BEFORE INSTALLATION CAN RESULT IN INJURY OR DEATH. It is the responsibility of the installation technician to read and understand the following prior to installing and RX944. It is crucial that during installation of any RX944 the mode be unique to any other receiver in the area. At the time of installation a definitive check on the modes of all receivers in the area must occur.

Note the modes of each receiver and select a mode that is unique for the installation. Failure to do so may result in two receivers accepting signals from one transmitter. Two machines would be controlled by one transmitter resulting in unwanted movement. This is essential to ensure safe operation.

BELOW IS MSHA PROGRAM INFORMATION BULLETIN P03-03 RECOMMENDED DESIGN SAFEGUARDS FOR PERMISSIBLE REMOTE CONTROLLED MINING MACHINE

SECTION 11

Important Warning Bulletin

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U.S. Department of Labor

Mine Safety and Health Administration 1100 Wilson Boulevard Arlington, Virginia 222093939

ISSUE DATE: FEBRUARY 25, 2003 PROGRAM INFORMATION BULLETIN NO. P03-3 FROM: MARK E. SKILES Director of Technical Support RAY McKINNEY Administrator for Coal Mine Safety and Health ROBERT M. FRIEND Administrator for Metal and Nonmetal Mine Safety and Health SUBJECT: Recommended Design Safeguards for Permissible Remote Controlled Continuous Mining Machines Who needs to have this information?

Operators of underground coal or gassy metal and nonmetal mines, manufacturers of remote controllers and remote controlled continuous mining machines, Mine Safety and Health Administration (MSHA) enforcement personnel, miners' representatives, state mining agencies, and other interested parties need this information.

Important Warning Bulletin

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BI377591 Page 51 of 60

What equipment is affected by this bulletin?

This Program Information Bulletin (PIB) applies to new designs of permissible remote controlled continuous mining machines approved under Title 30 of the Code of Federal Regulations (30 CFR), Part 18 and to existing approved equipment in use in the mines as well. It applies to remote controllers that are portable and hand carried, or worn on the operator's body, to remotely control continuous mining machines from a location off the machine but in close proximity to and in visual and audible range of the machine being controlled. It is applicable to remote control systems using radio, infra-red or direct tethered electrical connection methods.

What is the purpose of this bulletin?

The purpose of this bulletin is to inform the mining industry of recommended safety design features for remote controlled continuous mining machines. These recommendations could help reduce the number of accidents resulting from the use of such equipment. This bulletin recommends safety design features for the following functions: (1) Remote Emergency Stop Devices, located on remote controllers, that initiate an emergency shutdown function on remote controlled continuous mining machines; (2) Prevention of accidental activation of machine tramming functions; and (3) Reduction of the machine slew rate when the tram controls are split or singularly activated.

What is the background for this bulletin?

A review of thirteen fatal accidents involving the use of remote controlled continuous mining machines since 1988 reveals that two of these accidents were associated with the accessibility of the remote emergency stop device. Three SECTION 11

Important Warning Bulletin

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accidents involved the bypassing of mechanical interlock safety devices on tram controls and eight accidents involved accidental activation of the tram controls.

Concerns With the Design of Remote Emergency Stop Devices In one accident, a remote controlled continuous mining machine operator was fatally injured when he was crushed between the continuous mining machine and coal rib. The remote controller did not have an emergency stop device that was readily accessible in the event of an emergency. In another accident, a maintenance helper sustained fatal crushing injuries when he became trapped between the conveyor boom and the mine roof. The chain conveyor• became activated due to an electrical short inside the remote controller. The availability of a readily accessible emergency stop device may have saved the victim's life.

Good ergonomic design for• a remote emergency stop device allows the device to be quickly and easily activated in an emergency. The device should be readily accessible, prominently located, and clearly differentiated from other controls.

Existing emergency stop devices do not consistently utilize these design features, and as a result, confusion and delays in activating the device in an emergency situation can occur.

Concerns With Bypassing Mechanical Interlock Safety Devices on Train Controls There have been three fatal "caught-between" type accidents where the mechanical interlocks on the remote controller tram controls were defeated by the use of tape, thereby bypassing protection against accidental activation. Taping the interlocks was identified as a contributing factor to all three accidents.

PIBs P97-31, P98-19, and P00-14 were issued to emphasize the importance of the mechanical interlocks and warn of the safety hazards associated with bypassing this safety feature. The use of same-hand activated mechanical release devices on train controls proved to be inconvenient and difficult to operate over a working

Important Warning Bulletin

SECTION 11

BI377591 Page 53 of 60

shift and are often bypassed by machine operators. These devices have not proven to be an effective means for preventing accidental activation.

Concerns With Accidental Tram Control Activation A review of accident data identified eight reported accidents (fatal or nonfatal) involving accidental tram control activation on remote controlled continuous mining machines. Of these eight accidents, four (including one fatal) have been attributed to a cable falling across the remote controller while it was left unattended, causing the tram controls to be activated. The other four were attributed to unintentional body contact. The need to prevent accidental tram control activation is recognized and has been addressed in most designs. However, all designs should incorporate these safety features to prevent accidental activation of the tram controls. Accident analysis has also identified the need for limiting the maximum slew rate of the machine under tram control settings that produce a pivoting action of the machine. Limiting the slew rate under these conditions has the potential to reduce pinning hazards to operators unintentionally positioned at machine pinch points.

What is being recommended through this bulletin?

MSHA recommends certain design safeguards and training: I. Design Safeguards Equipment manufacturers should implement the design safeguards in all new designs. MSHA also recommends that manufacturers of existing approved remote controllers and remote controlled continuous mining machines currently in use modify their equipment, to the extent possible, to include the recommended safeguards. Design changes should be submitted for MSHA approval under 30 CFR, Part 18. Field testing of remote controlled equipment is recommended before a design is finalized and submitted for approval. MSHA's Experimental Permit Program may be used to allow field testing.

SECTION 11

Important Warning Bulletin

BI377591 Page 54 of 60

MSHA recommends that the following design features be addressed: Remote Emergency Stop Device The remote controller should be equipped with a remote emergency stop device that: (1) Overrides all other machine controls; (2) Removes power from machine movement actuators; and (3) Causes all moving parts to stop within the shortest possible time. Resetting of remote emergency stop devices requiring manual reset, or release of momentary action remote emergency stop devices, should not cause any function of the machine to operate. In mines utilizing extended cuts, the emergency stop device should cause the circuit breaker at the power center to trip rather than the onboard machine circuit breaker, if a circuit breaker is used for removing power from machine movement actuators.

The remote emergency stop device should be: (1) Differentiated from other controls by size (larger) or shape; (2) Located in a readily accessible, prominent location in the operator's direct field of vision on the remote controller's main control panel; (3) Colored red; (4) Activated by a pushing action perpendicular to the controller's main control panel surface. Note: For example, a red, mushroom-head shaped switch actuator, may be used for this purpose, but other designs meeting the general recommendation could be used.

The remote emergency stop device should be clearly labeled "Emergency Stop," and should be protected against the entry or buildup of coal, dust, or other foreign material that could hinder or block its activation. Ready access to the remote emergency stop device should not be hindered by the proximity of other controls or by mechanical guards. The design should consider the need for additional spacing when gloves are worn.

Important Warning Bulletin

SECTION 11

BI377591 Page 55 of 60

Operation of the remote emergency stop device should be tested during the machine pre-operational checks.

Accidental Tram Activation Protection All control devices, such as buttons, levers and joysticks, used for controlling the tramming function of remote controlled machinery, should be designed such that the tramming function stops when the device is released. The remote controller actuating controls for the machine tram function should be designed to reduce the likelihood of unintentional activation. Tramming functions can be activated when cables or other material fall on the controls, or with unintentional hand or body contact. Recessed selector switches, shrouded selector switches, deadman control, two-hand control, or sequential two-switch operation such as use of a tram function enable switch should be used. These safety features should be ergonomically designed, tamper-resistant, and not interfere with the normal operation of the mining equipment.

When sequential two-switch operation (train enable switch) is used, a tram function inactivity timer should be provided to disable the train function if the tram controls are not activated within a pre-programmed time period. The train function inactivity timer should be set as low as reasonably practicable, consistent with convenient machine operation. Five seconds is the recommended maximum inactivity timer setting.

The controls actuating the machine tramming function should be protected against the entry or buildup of coal, dust, or other foreign material that could hinder or block their activation or movement. Note: The use of rubber boots or other effective means could be used for this purpose.

The use of same-hand activated mechanical release devices on tram controls, such as lift-to-operate mechanical interlocks on tram control levers, should be eliminated. Note: Safeguarding devices that impede convenient operation and that prove to be tiring over a working shift are often bypassed by operators.

SECTION 11

Important Warning Bulletin

BI377591 Page 56 of 60

The use of a "global" guarding method, such as a raised guard rail surrounding all the switches on the control panel, is not a recommended method for preventing accidental tram control activation when used as the only prevention method. Note: This guarding method does not provide adequate protection against accidental activation by cables of various sizes or other foreign objects and may result in accidental control activation when using the guardrail as a carrying handle. Attention must be paid in the design to ensure that the use of any mechanical guarding methods does not hinder activation of the remote emergency stop device.

Machine Slew Rate Control Remote controlled machinery utilizing a machine tramming function should be equipped with control circuits that reduce the machine rotational slew rate when the tram controls are set with one control forward and one control reverse (split cat) or a single control forward or reverse (hard turn) position. When the tram controls are split or set in a hard turn position, the tram speed of the activated drive(s) should be limited to no greater than the slowest operational tram speed provided on the machine, in order to minimize the slew rate (rotational speed) of the machine.

The slew rate of the machine needs to be minimized to obtain a pivoting action of the machine that reduces potential "caught-between" type hazards to machine operators inadvertently positioned at machine pinch points.

II. Training MSHA recommends that mine operators establish safe work practices and provide training for personnel addressing the safe operation and maintenance of remote controllers and remote controlled continuous mining machines. The training should address all danger areas applicable to specific machines and mining operations.

Particular emphasis needs to be placed on the machine operator's and maintenance personnel's position when working near energized machines. Machine operators should be trained to check that safety features on remote controllers are operating Important Warning Bulletin

SECTION 11

BI377591

Page 57 of 60

properly and are not defeated. In addition, MSHA urges mine operators to regularly ensure that established safe work practices are being followed.

What is the authority for this bulletin?

Title 30 Code of Federal Regulations, Section 18.20(b), 57.12002, and 75.520.

Is this program information bulletin on the Internet?

This bulletin may be viewed on the World Wide Web by accessing the MSHA home page (http://www.msha.gov) and then choosing "Statutory and Regulatory Information" and "Compliance Assistance Information."

Who are the MSHA contact persons for this program information bulletin?

Coal Mine Safety and Health, Safety Division Erik Sherer, (202) 693-9523 E-mail: Sherer.EriVikloLgov Metal and Nonmetal Mine Safety and Health, Safety Division Thomas Loyd, (202) 693-9645 E-mail: Loyd.ThomadoLuov Technical Support, Approval and Certification Center David C. Chirdon, (304) 547-2026 E-mail: Chirclon.David@dolswv

SECTION 11

Important Warning Bulletin

BI377591 Page 58 of 60

Who will receive this program information bulletin?

MSHA Program Policy Manual Holders Underground Mine Operators Equipment Manufacturers Special Interest Groups Miners' Representatives Repair and Rebuild Facilities

Important Warning Bulletin

SECTION 11

BI377591 Page 59 of 60

SECTION 12.

COAL MINE SAFETY AND HEALTH

- INJURED- W1.41.iRS CRAW ROCK FWD ZONE

11

Figure 12.1 Red Zone - It Hurts to be in The Red Zone Entering the "RED ZONE" continues to result in mine fatalities and injuries. A recent non-fatal roof fall accident occurred that resulted in injuries to two miners who were working in the "RED ZONE", The miners were loading supplies onto the roof bolting machine from a battery scoop. The roof bolting machine was positioned at the mouth of an unbolted right crosscut and the scoop was positioned to the right-rear of the bolting machine with the bucket extending into the "RED ZONE". The miners were in front of the bucket, between the first and second row of roof bolts, moving supplies to the roof bolting machine when the roof material fell. Draw rock fell along the right rib of the unsupported area and extended into where the men were working, striking and

SECTION 12

Coal Mine Safety and Health

BI377591 Page 60 of 60

injuring both miners. Fortunately, the injuries were not life threatening.

Best practices to prevent such an accident from re-occurring include moving the roof bolting machine and the scoop to a safe area outby the newly developed crosscut. This would prevent the miners exposure to the hazards created by working close to the unsupported area or the need to perform work in the "RED ZONE".

Please take time to re-instruct all miners as to the location of the "RED ZONE" as shown in your mine's approved roof control plan. Working in the "RED ZONE" is not much different from working in an unsupported area. Roof material that begins to fall in the unbolted area doesn't always stop at the first row of roof bolts. When that happens, it hurts to be in the "RED ZONE".

Coal Mine Safety and Health

SECTION 12

BI377591

DBT

Remote Control System for Continuous Miners

Troubleshooting Guide

DBT America Inc. 2045 West Pike Street Houston PA 15342-1010

Publication Date: March 2006

Revision 0

BI377591

DBT PUBLICATION DISCLAIMER AND COPYRIGHT

- This document is based on information available at the time of its publication.

While efforts have been made to be accurate, the information contained herein does not purport to cover all details or variations nor to provide for every possible contingency in connection with troubleshooting and maintenance. Features may be described herein which are not present in all systems. DBT assumes no obligation of notice to holders of this document with respect to changes subsequently made.

DBT makes no representation or warranty, expressed, implied, or statutory with respect to, and assumes no responsibility for the accuracy, completeness, sufficiency, or usefidness of the information contained herein. No warranties of merchantability of fitness for purpose shall apply.

BI377591

DBT GENERAL SAFETY NOTICES

This section addresses some general safety guidelines involved with DBT products. These guidelines are intended to promote safe usage of equipment.

This section is not intended to replace present safety practices at your site.

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

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

SAFETY RECOMMENDATIONS Ghosting (gosting), v., I; Unplanned movement by machines that use Computer Control Technology.

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

General Safety Notices

BI377591

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

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

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

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

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

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

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

General Safety Notices

BI377591

MANUAL CONTENTS Table of Contents Please read the important information contained in the previous section titled GENERAL SAFETY NOTICES. Page

Section/Paragraph SECTION 1. HOW TO TROUBLESHOOT THIS SYSTEM SECTION 2. SYSTEM STATUS INDICATORS

3 3 3 6

2.1 Introduction 2.2 Status LED Functional Categorization 2.3 Status LED Response Analysis

SECTION 3. ALARMS, WARNINGS, AND DISPLAY INFORMATION..21 3.1 Coded Alarms and Warnings 3. 1. I Alarm Codes 3. 1.2 Warning Codes 3.2 Informational Messages

22 22 24 29

SECTION 4. COMPONENT IDENTIFICATION

31

4.1 Remote Control System Components 4.2 Remote Control System Components Tie-in

31 31

Manual Contents

BI377591

List of Tables Table Table 2.1 MCU944 LED Functional Categories Table 2.2a MCU944 Status LED Response Analysis (R1 & R2) Table 2.2b MCU944 Status LED Response Analysis (R3 & R4) Table 2.2c MCU944 Status LED Response Analysis (R5 & R6) Table 2,2d MCU944 Status LED Response Analysis (Rl 1 & R12) Table 2.2e MCU944 Status LED Response Analysis (R13 & R14) Table 2,2f MCU944 Status LED Response Analysis (R15 to R20) Table 2.2g MCU944 Status LED Response Analysis (R21 & R22) Table 2.3 TX944 Status LED Response Analysis Table 2.4 RX944 Status LED Response Analysis Table 2.5 CPS944 Status LED Response Analysis Table 2.6 DCD100 Status LED Response Analysis Table 3.1 Display Screen Top Banner General Description Table 3.2 Alarm Codes Table 3.3 Warning Codes Table 3.4 Informational Messages Table 4.1 System Components

Page 5 6 7 8 9 11 11 12 13 17 18 19 21 22 24 29 31

List of Figures Figure Figure 2.1 MCU944 Custom PLC Status LEDs Figure 2.2 TX944 Transmitter Status LEDs Figure 2.3 RX944 Receiver Status LEDs Figure 2.4 CPS944 Power Supply Status LEDs Figure 2.5 DCD100 DC Train Drive Status LEDs Figure 3.1 Display Screen Messages Figure 4.1 Remote Control System Components Layout

Manual Contents

Page 3 13 17 18 19 21 32

BI377591 Page 1 of 30

SECTION 1.

HOW TO TROUBLESHOOT THIS SYSTEM This system has visual troubleshooting aids to allow operators and maintenance personnel to quickly determine the cause of most operating faults. These troubleshooting aids consist of: WARNING: Before troubleshooting beyond the level of observing the fault log, read this entire manual and contact your supervisor.

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

• Fault Message - A machine local graphics display message that appears for 10 seconds when the system detects a fault.

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

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

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

When you experience any fault: Page to the fault log and try to redo faulted machine function while watching for fault message at display.

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

SECTION 1

How to Troubleshoot This System

BI377591 Page 2 of 30

When troubleshooting the system, the following points should be noted: ® The remote control system does not recognize problems in the machine hydraulic system unrelated to the pump motor.

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

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

How to Troubleshoot This System

SECTION 1

BI377591

Page 3 of 30

SECTION 2.

SYSTEM STATUS INDICATORS

2.1

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

A sufficient complement of status LEDs is provided on the MCU944 to assist in quickly determining the source of most problems that may arise during operation. Additional status LEDs are provided on the RX944, TX944, CPS944, and DCD100 units.

2.2

Status LED Functional Categorization The majority of status LEDs of interest in troubleshooting this remote radio control system are located on the MCU944. Each LED has a one-to-one correspondence with its connector pin. The layout of the connectors on the face plate is such that pins, and thus the LEDs, are grouped in functional categories as described in Table 2.1 and shown in Figure 2.1.

NOTE: LED locations on the MCU944 are with reference to their associated connector. The LEDs are located to the right of their connector.

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

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BI377591

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BI377591

Page 5 of 30

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

Table 2.1 MCU944 LED Functional Categories LED Loc.

Functional Category

R1-R6

A contact output. Either a solenoid output or a relay output, When ON, contact should be closed,

RI 1

120VAC inputs. When ON, 120VAC is present. For normal operation of the miner, MACHINE STOP (RI1-1) and LEFT STOP (R11-2) LEDs should be ON.

R12

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

R13

l 2VDC inputs and outputs.

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

R14

(Future Use)

R15

'fop LED: Flashes whenever the MCU944 is transmitting, At the moment, this will only occur during Teach/Learn. In Teach/Learn, the top LED will flash a minimum of three times during a successful Teach/Learn cycle.

Bottom LED: Flashes whenever the MCU944 has received valid messages from the Receiver (RX944). This can only occur if the mode is not LOCAL, checksum is valid, and proper transmitter is communicating to MCU944.

R16

Top LED: Indicates whenever the display is transmitting.

Bottom LED: Indicates when the display responds to the MCU944.

R17

'['op LED: Flashes whenever there is activity between the MCU944 and IR receiver.

RI8

Top LED: Flashes quickly (looks steady) whenever the MCU944 is transmitting.

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

R19

Not used.

R20

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

R21

Not used.

R22

Indicates voltage levels inside the MCU944.

Top LED: Indicates +5V is present.

Middle LED: Indicates +12V is present.

Bottom LED: Flashes whenever the MCU944 is in UMBILICAL mode with the TX944,

SECTION 2

System Status Indicators

BI377591 Page 6 of 30

Table 2.1 MCU944 LED Functional Categories LED Loc.

Functional Category

Rotary

Top LED: (Located left of the rotary switch) flashes whenever there have been multiple internal backplane communication errors inside the MCU944.

Switch

Other Three LEDs: Engineering Use,.

2.3

MCU944 Status LED Descriptions Use Tables 2.2 through 2.6 to troubleshoot the system using the status LEDs. Generally, LED locations and functions are associated with their respective connector designations Rx. Table 2.2 has been divided into several sub-tables to allow quick access to specific status LED analysis locations on the MCU944 from the Table of Contents.

Table 2.2a MCU944 Status LED Description (R1 & R2) LED Function

LED Loc.

Description

NOT USED

R1-1

Not Used

FAN WATER SPRAY SOLENOID

R1-2

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

AUX SOLENOID OUTPUT #6 (MOMENTARY)

R1-3

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

DUST SUPPRESSION

R1-4

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

CUTTER RAISE SOLENOID

R1-5

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

GATHERING HEAD FLOAT SOLENOID

RI-6

Active when gathering head float contact is closed.

This action will latch and is deactivated only when gathering head raise solenoid is active or pump is inactive. Requires pump active prior to use.

CUTTER LOWER SOLENOID

R2-3

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

CONVEYOR RAISE SOLENOID

R2-4

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

CONVEOR LOWER SOLENOID

R2-5

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

CNVYR SWING LEFT SOLENOID

R2-6

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

System Status Indicators

SECTION 2

BI377591 Page 7 of 30

Table 2.2a MCU944 Status LED Description (R1 & R2) LED Function

LED Loc.

Description

CNVYR SWING RIGHT SOLENOID

R2-7

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

STAB UP SOLENOID

R2-8

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

STAB DOWN SOLENOID

R2-9

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

GATHERING HEAD RAISE SOLENOID

R2-10

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

Table 2.2b MCU944 Status LED Description (R3 & R4) LED Function

LED Loc.

Description

AUX OUTPUT #7 (LATCHED)

R3-I

Active when contact is closed. Contact will latch upon momentary activation and is controlled from the transmitter.

AUX OUTPUT #8 (LATCHED)

R3-2

Active when contact is closed. Contact will latch upon momentary activation and is controlled from the transmitter.

CONVEYOR REV CONTACTOR

R3-3

Active when reverse conveyor contact is closed.

FAN CONTACTOR

R3-4

Active when fan contact is closed.

AUX OUTPUT #5 MOMENTARY

R4-3

Active when contact is closed, Action is momentary.

LOW OIL ALARM OUTPUT

R4-4

Active when contact is closed. Action is predicated upon configuration.

CNTRL GND FAULT ALARM OUTPUT

R4-5

Active when contact is closed.

HEADLIGHTS

R4-6

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

PUMP CONTACTOR

R4-7

Active when contact is closed.

LEFT CUTTER CONTACTOR

R4-8

Active when contact is closed,

RIGHT CUTTER CONTACTOR

R4-9

, Active when contact is closed.

SECTION 2

System Status Indicators

BI377591 Page 8 of 30

Table 2.2b MCU944 Status LED Description (R3 & R4) LED Function CONVEYOR FWD CONTACTOR

LED Loc. R4-10

Description Active when contact is closed.

Table 2.2c MCU944 Status LED Description (R5 & R6) LED Function

LED Loc.

Description

REDUNDANT RIGHT CUTTER

R5-1/2

Active when contact is closed.

REDUNDANT LEFT CUTTER

R5-3/4

Active when contact is closed.

BREAKER ON (ALT)

R6-3

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

BREAKER OFF (ALT)

R6-4

Active when Breaker OFF contact closed, Action is controlled from transmitter.

BRAKE RELEASE

R6-5

Active when Brake Release contact closed. Brake Release contact will activate when tram is authorized.

SPARE #1

R6-6

Active when spare contact closed.

SPARE #2

R6-7

Active when spare contact closed.

SPARE #3

R6-8

Active when spare contact closed.

AUX SOLENOID OUTPUT #3 (MOMENTARY)

R6-9

Active when contact is closed. Action is momentary.

AUX OUTPUT #4 (LATCHED/PUMP)

R6-10

Active when contact is closed. This contact requires that the pump be operating prior to use. Action is momentary and controlled from transmitter,

System Status Indicators

SECTION 2

BI377591 Page 9 of 30

NOTE: There are no LEDs associated with connector functions R7 through RIO. Table 2.2d MCU944 Status LED Description (R11 & R12) LED Function

LED Loc.

Description

MACHINE STOP

R11-I

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

LEFT STOP

RI 1-2

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

CUTTER RUN

R11-3

Active when 120VAC is present. When present, cutter motor operation is desired. When not present, this input will deactivate the cutter motors only in LOCAL mode.

PUMP RUN

R11-4

Active when 120VAC is present. When present, pump motor operation is desired. When not present, this input will deactivate the pump motor only in LOCAL mode.

CONVEYOR RUN

RI 1-5

Active when 120VAC is present, When present, conveyor motor operation is desired. When not present, this input will deactivate the conveyor motors only in LOCAL mode.

MINER TYPE#1

R1I-6

Active when 120VAC is present. Used in conjunction with miner type #2 input to notify the MCU944 whether CM is 30M, 25M0, 25M1, or 25M2/25M3.

RI 1-7

Active when 120VAC is present. Used in conjunction with miner type #1 input to notify the MCU944 whether CM is 30M, 25M0, 25M1, or 25M2/25M3.

METHANE MONITOR OK

RI I-S

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

CB2 BREAKER

R12-1

Active when 120VAC is present.

EMERGENCY TRAM

R12-2

Active when 120VAC is present.

MAN SCRUBBER (FAN) RUN

R12-3

Active when 120VAC is present.

CUTTER RUN WITH FAN

R12-4

Active when 120VAC is present.

CUTTER LOCKOUT

R12-5

Active when 120VAC is present.

MOTOR START/TRAM ENABLE (LOCAL)

R12-6

Active when 120VAC is present. This input must be present prior to any motor start in LOCAL mode.

MINER TYPE //2

SECTION 2

-

System Status Indicators

BI377591 Page 10 of 30

Table 2.2d MCU944 Status LED Description (R11 & R12) LED Function

LED Loc.

Description

REMOTE

R12-7

Active when I 20VAC is present.

ANY INPUT ON R9

R12-8

Active when I2OVAC is present at any input on connector R9.

System Status Indicators

SECTION 2

BI377591 Page 11 of 30

Table 2.2e MCU944 Status LED Description (R13 & R14) LED Function

LED Loc.

Description

FIRE SUPPRESSION

R13-1

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

BREAKER ON

R13-1

Active when Breaker ON contact closed. Controlled from transmitter.

BREAKER OFF

R13-1

Active when Breaker OFF contact closed. Controlled from transmitter,

+12 VDC OUTPUT

R13-1

Indicates +12V I/O have power.

LOW OIL LOCKOUT

R13-I

Active when low oil lockout input sensor is active,

LOW OIL ALARM

R13-I

Active when low oil alarm input sensor is active.

SPARE DC INPUT

R13-1

Unused

+5.0 VDC TO TRAM LEVERS

R14-I

Indicates +5V I/O have power,

RIGHT TRAM PROPORTIONAL SIGNAL

R14-I

NOT USED. Replaced with emergency tram pendant.

Proportional LED output directly related to the tram command in LOCAL mode.

RIGHT TRAM FWD CONTACT

R14-1

NOT USED. Replaced with emergency tram pendant.

Active when right forward command is given in LOCAL mode.

RIGHT TRAM REV CONTACT

R14-1

NOT USED. Replaced with emergency tram pendant.

Active when right reverse command is given in LOCAL mode.

LEFT RRAM (PROPORTIONAL)

R14-1

NOT USED. Replaced with emergency tram pendant, Proportional LED output directly related to the tram command in LOCAL mode.

LEFT TRAM FWD CONTACT

R14-1

NOT USED. Replaced with emergency tram pendant.

Active when left forward command is given in LOCAL mode.

LEFT TRAM REV CONTACT

R14-1

NOT USED. Replaced with emergency tram pendant.

Active when left reverse command is given in LOCAL mode,

Table 2.21 MCU944 Status LED Description (R15 to R20)

SECTION 2

System Status Indicators

BI377591 Page 12 of 30

LED Function

Description

LED Loc.

RADIO RECEIVER TX

R15-1/2

Active when MCU944 transmits out.

RADIO RECEIVER RX

R15-3/4

Active when MCU944 receives packets specific to its ID.

DISPLAY TX

R16-1/2

Active when MCU944 receives packets.

DISPLAY RX

R16-3/4

Active when MCU944 transmits out.

IR PENDENT TX

R17-1/2

Active when MCU944 receives valid packets.

IR PENDENT TX RECEIVED

R17-3/4

Active when MCU944 receives valid packets.

MCU944 TX TO TRACTION DRIVE

R18-1

Active when MCU944 transmits out.

MCU944 RX FROM TRACTION DRIVE

R18-2

Active when MCU944 receives valid messages.

R19

NO LEDS DOWNLOAD/DEBUG TX

R20-3

Active when MCU944 transmits out.

DOWNLOAD/DEBUG RX

R20-2

Active when MCU944 receives bytes.

Table 2.2g MCU944 Status LED Description (R21 & R22) LED Function

Description

LED Loc.

GP 10

R21

+5V

R22-2/3

Indicates when +5V is active. This voltage is required to operate the MCU944.

R-22-4/5

Indicates when +12V is active. This voltage is required to operate the MCU944 in normal modes. It is deliberately deactivated in battery mode until required.

+12V

UMBILICAL (PENDANT ACTIVITY) HARDWARE FAILURE (TOGGLE)

R22-6 SW Hole Plug

Unused

Indicates when transmitter is connected to the MCU944 via umbilical cable and is active.

Flashes whenever there is a hardware failure internal to the MCU944.

MODBUS COMM ERROR (TOGGLE) IR PENDANT COMM ERROR (TOGGLE) WRITE TO EEPROM (TOGGLE)

System Status Indicators

SECTION 2

BI377591 Page 13 of 30

Refer to separate documentation for additional information on the TX944 Transmitter. Use Figure 2.2 as a location reference for the TX944 Transmitter.

X PWR OFF 0

CUTTER

CONY

'X PWR ON STOP

CONVEYOR

ST

Figure 2.2 TX944 Transmitter Status LEDs Table 2.3 TX944 Status LED Response Analysis LED Function BATTERY/UMB MSG

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

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

SECTION 2

System Status Indicators

BI377591 Page 14 of 30

Table 2.3 TX944 Status LED Response Analysis LED Function

Description

ERROR

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

LINK REQUEST/SHUTDOWN

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

System Status Indicators

SECTION 2

BI377591 Page 15 of 30

Table 2.3 TX944 Status LED Response Analysis LED Function SWITCH ACTIVE/LOW BATTERY

Description NOTE: THIS LED HAS 2 FUNTIONS Switch Active: After power up this LED is used to indicate a "stuck switch".

•

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

•

If after power up (i.e. TX PWR ON depressed) LED lights and stays ON (solid) then there is a "stuck" switch.

In this condition, no other switches on the transmitter will be operational.

•

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

•

After power up, any switch that is operated will result in this LED being solidly ON while the switch is operated.

In this manner, all switches can be verified locally at the transmitter.

•

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

•

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

•

To resume normal operation, the ENABLE button must be released. Switches that are timed in this manner are ENABLE, SHIFT, TRAM ENABLE, PUMP START, CONV START, CONY REV, and CUTTER START,

Note In normal operation, all of these switches are to be operated for only short periods of time. A constantly held condition would be abnormal and defeat two handed starts and make other enabledfu unsafe. Therefore, these switches are monitored and timed during normal operation to prevent the possibility of a constantly ON switch.

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

SECTION 2

System Status Indicators

BI377591 Page 16 of 30

Table 2.3 TX944 Status LED Response Analysis Description

LED Function TRAM ENABLE/INACTIVITY

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

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

LINK ACK/COMMANDED POWER DOWN

NOTE: THIS LED HAS 2 FUNTIONS Link Acknowledge: During the TEACH/LEARN process, LED indicates that a link response (acknowledgment) has been received back at the transmitter from the MCU. I •

f the transmitter was re-linked back to the same MCU (machine), then this LED will flash once,

•

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

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

System Status Indicators

SECTION 2

BI377591 Page 17 of 30

The RX944 Receiver is approximately 6 inches long and 2 inches high. It is located on the Swing Panel of the Main Control Case of the 25M Miner and in the Radio Receiver Case of the 30M Miner. The device runs on 12V via R1-1 and R1-2.

RADIO RECEIVER MODEL RX944 1 2 3 4 5 6 7 8 0 0 0 0 0 0 0 0

R1 23 45 6 0

(gp

R2

1 2 34 5

0000000

L I

MN,04

Figure 2.3 RX944 Receiver Status LEDs Table 2.4 RX944 Status LED Description LED Function

LED

Description

WATCHDOG

l

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

PRE-AMBLE DETECTED

2

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

VALID MESSAGE

3

Blinks to indicate that valid messages from a transmitter on the correct frequency are being received. Note: This does NOT mean that the transmitter is the serial number that has been "TAUGHT" to the Machine Control Unit. Check top Right Hand Corner of Graphics Display for TX944 Serial Number (See Section 3.0),

LINK RECEIVED

4

Steady On: Indicates that a sufficient number of messages are being received from the TX944 to operate and the system should not drop out,

NOT USED

SECTION 2

5-8

Reserved for future use.

System Status Indicators

BI377591 Page 18 of 30

The CPS944 Capacitor Backup is approximately 6 inches long and 6 inches high. It is located on the Swing Panel of the Main Control Case of the 25M and in 30M Miners. The device runs on 120VAC via R2-2 and R2-3.

1 2 3 0 0 0

CAPACITOR BAC<UP MODEL CPS= 944 R1

R2

1 2 3 4 5

1 2 3

00000c0

0

0

0

00103

Figure 2.4 CPS944 Power Supply Status LEDs Table 2.5 CPS944 Status LED Response Analysis LED Function

LED

Description

+12VDC OUTPUT ACTIVE

1

Active in Battery Mode.

+5VDC OUTPUT ACTIVE

2

Active in Battery Mode.

120VAC INPUT PRESENT

3

Active when not in Battery Mode.

System Status Indicators

SECTION 2

BI377591 Page 19 of 30

The DCD100 DC Tram Drive is located in the Train Case of the 25M Miner and in the Control Case of the 30M Miner. The device runs on 120VAC via D1-1 and D1-2.

r A

AC TX /2Xl1,1/0 OUTRT LT 0 0 0 0 0 0 0 0 0 0 0 1 2 34 1 2.5 4 5 6 7 1 2 .15 4 5 15 7 8 91D

2 3 m Di

0

0

0

D2

0 0 0

0

0

0 0

0 0 0

A2

Al

0

0 0 0 0

0 0

0 0

D4

D3

AC

AC

0

Figure 2.5 DCD100 DC Tram Drive Status LEDs Table 2.6 DCD100 Status LED Response Analysis LED

Description

LOCAL FWD

I

Indicates FWD direction command in LOCAL CTRL.

LOCAL REV

2

Indicates REV direction command in LOCAL CTRL.

UNUSED

3

UNUSED

4

LED Function

AC PRESENT

AC

Indicates when 120 VAC power is available.

TRANSMIT OUT

TX

Indicates transmission by unit over serial COM port.

RECEIVED IN

RX

Indicates reception by unit over serial COM port.

WATCHDOG

WDG

Indicates unit is active and operating code.

PROPORTIONAL OUTPUT

OUT

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

FORWARD DIRECTION

RT (FWD)

Indicates when commanded output direction is FWD,

REVERSE DIRECTION

LT (REV)

Indicates when commanded output direction is REV.

SECTION 2

System Status Indicators

BI377591 Page 21 of 30

SECTION 3. ALARMS, WARNINGS, AND DISPLAY INFORMATION The purpose of this section is to provide service personnel with the complement of possible alarms, warnings, and information that are designed into the system for troubleshooting purposes. The system is capable of sensing many possible abnormal conditions associated with these message categories. When an abnormal state is sensed, an appropriate message is displayed on all screens for 10 seconds, in addition to being logged (see Section 1). The basic organization of the display screen message banner is provided in Figure 3.1 and Table 3.1.

`gyp. gusig!.t.o.‘ OAT TCRY....:

IIISGCSEC •••••,-, •

Figure 3.1 Display Screen Messages Table 3.1 Display Screen Top Banner General Description Description

Fine # 1

Fault log message, warning message, informational message block.

2

Miner type.

3

MCU944 mode.

4

Battery voltage.

5

Transmitter serial number.

6

Commanded input message indication.

7

Messages per second from transmitter.

8

RF signal strength.

9

Active input indicator.

SECTION 3

Possible Faults and Their Solutions

BI377591 Page 22 of 30

3.1

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

3.1.1 Alarm Codes Refer to Table 3.2 for the descriptions of system ALARM codes.

Table 3.2 Alarm Codes Description

Code A001 A002 A003 A004 A005 A006 A007 A008 A010 A011 A012 A013 A017 A018 A019 A020 A022 A023 A024 A025 A026 A027 A028 A029 A030 A03 1 A032 A033 A034 A035 A036 A037 A038 A039 A040

Backplane Transfer Fault: Backplane Transfer Fault: Backplane Transfer Fault: Backplane Xfer Fault: Backplane Transfer Fault: Relay Output Error Relay Output Error Relay Output Error Enable PushButton Stuck Transmitter shutdown Transmitter shutdown Transmitter shutdown Pump shutdown Pump shutdown Pump shutdown Pump shutdown Pump shutdown Pump shutdown Pump shutdown Pump shutdown Pump shutdown Pump Start toggle switch stuck Conveyor Reverse pushbutton stuck Conveyor Start toggle switch stuck Cony Shutdown Cony Shutdownt Conveyor Shutdown Conveyor Shutdown Conveyor Shutdown Conveyor Shutdown Cony Shutdown Cony Shutdown Conveyor Shutdown Conveyor Shutdown Cony Shutdown

Possible Faults and Their Solutions

CPU to PWM/Tram PCB CPU to Relay Card 1 CPU to Relay Card 2 CPU to Motor Current Analog Card CPU to RTD Analog Card Relay Card 1 Relay Card 2 Relay Card 3 Low battery Inactivity period expired Data link loss LOW OIL LOCKOUT for 5 sec, Tilt Switch Active Over Pump motor overload Conveyor Breaker opens (CB2) Pump Inst. Current Trip Pump Phase Imbalance Trip Pump Low Current Pump Start Switch held too long

Rt Motor Jam Current Lt Motor Jam Curren Right Motor Over Left Motor Over Right Motor Overload Left Motor Overload Rt Motor Inst Curr Trip Lt Motor Inst Curr Trip Right Trip Motor Phase Imbalance Left Motor Phase Imbalance Trip Rt Motor Low Current

SECTION 3

BI377591 Page 23 of 30

Table 3.2 Alarm Codes Code A041 A042 A043 A044 A045 A046 A05 t A052 A058 A059 A060 A061 A062 A063 A064 A065 A066 A067 A068 A069 A070 A072 A073 A074 A075.

A080 A081 A082 A083 A084 A085 A096 A097 A098 A099 A100 A101 A102 A103 A104 Al 12

Description Cony Shutdown Conveyor Shutdown Conveyor Shutdown CB2 (Conveyor Breaker) Conveyor Start Switch Conveyor REV JOG Switch Cutter Shutdown Cutter Shutdown Cutter Shutdown Cutter Shutdown Cutter Shutdown Cutter Shutdown Cutter Shutdown Cutter Shutdown Cutter Shutdown Cutter Shutdown Cutter Shutdown Cutter Shutdown Cutter Shutdown Cutter Shutdown Cutter Low Oil Lockout Cutter Shutdown Cutter Shutdown Cutter Start Toggle Switch Stuck Cutter Shutdown Fan Shutdown Fan Shutdown Fan Shutdown Fan Shutdown Fan Shutdown Fan Shutdown PLC to Rt Drive COMM Fault (All TRAM commands cleared) PLC to Lt Drive COMM Fault (All TRAM commands cleared) Machine Voltage Below Allowable Range (<80% Vnom) Machine Voltage Above Allowable Range (>117% Vnom) CurrentErrorCodeFutureUse Right Tram Motor Overload Left Tram Motor Overload Tram Enable Switch held more than 3 Sec without TRAM Tram Enable Switch Stuck Tram Shutdown

SECTION 3

Lt Motor Low Current Conveyor Reverse Switch Operated Conveyor Motor Current Differential Opens Held too long Held too long Right Motor Over Left Motor Over Right Motor Overload Left Motor Overload Rt Motor Inst. Curr Trip Lt Motor Inst. Curr Trip Right Motor Phase Imbalance Trip Left Motor Phase Imbalance Trip Right Motor Low Current Left Motor Low Current Cutter lockout switch opens Cutter Motor Current Differential LOW OIL ALARM for 5 sec Cutter Start Switch held too long Right Motor Jam Current Left Motor Jam Current CB2 Breaker Active Instantaneous Current Trip Overload Trip Phase Imbalance Trip Low Current Trip Over Jam Current Trip

Left Drive Phase A Overcurrent

Possible Faults and Their Solutions

BI377591 Page 24 of 30

Table 3.2 Alarm Codes Code A113 A114 A115 A116 A117 A118 A119 A120 A121 A128 A129 A130

Description Tram Shutdown Tram Shutdown Tram Shutdown Tram Shutdown Tram Shutdown Tram Shutdown Tram Shutdown Right Drive Limited Left Drive Limited Teach/Learn Successful Teach/Learn Failed Error

Left Drive Phase B Overcurrent Left Drive Bus OverVoltage Left Drive OverTemperature Right Drive Phase A Overcurrent Right Drive Phase B Overcurrent Right Drive Bus OverVoltage Right Drive OverTemperature Loss of Voltage Feedback Loss of Voltage Feedback

Control Ground Fault

3.1.2 Warning Codes Refer to Table 3.3 for the descriptions of system WARNING codes.

Table 3.3 Warning Codes Code W001 W002 W003 W008 W009 W010 W011 W017 W018 W019 W020 W021 W022 W023 W024 W025 W026 W027 W028 W029 W030

Description Conveyor Reverse won't start Conveyor Reverse won't start Conveyor Reverse won't start Cony Rev won't start Cony Rev won't start Cony Rev won't start Cony Rev won't start Conveyor Reverse won't start Conveyor Reverse won't start Conveyor Reverse won't start Conveyor Reverse won't start Conveyor Reverse won't start Conveyor Reverse won't start Conveyor Reverse won't start Conveyor Reverse won't start Conveyor Reverse won't start Conveyor Reverse won't start Conveyor Reverse won't start Conveyor Reverse won't start Conveyor Reverse won't start Conveyor Reverse won't start

Possible Faults and Their Solutions

Right Conveyor Jam Left Conveyor Jam time period between fwd/rev not expired R Cony Inst Trip Reset Time Not Expired L Cony Inst Trip Reset Time Not Expired R Cony low amp Trip Res Time Not Expired L Cony low amp Trip Res Time Not Expired Pump Off Conveyor Breaker Conveyor Stop Right Conveyor Overtemp Left Conveyor Overtemp Right Conveyor Overload Left Conveyor Overload Right Conveyor Inst. Trip Left Conveyor Inst. Trip Right Conveyor Low Current Left Conveyor Low Current Right Motor Single Phase Left Motor Single Phase Cutter

SECTION 3

BI377591 Page 25 of 30

Table 3.3 Warning Codes Code

Description

W031 W032 W033 W034 W035 W036 W037 W049 W050 W051 W052 W053 W054 W055 W056

Conveyor Reverse won't start Conveyor Reverse won't start Pump won't start Pump won't start Pump won't start Pump won't start Pump won't start Pump won't start Pump won't start Pump won't start Pump won't start Pump won't start Pump won't start Pump won't start Pump won't start

W057 W058 W059 W060 W061 W062 W063 W064 W065 W066 W067 W081 W082 W083 W084 W085 W086 W087 W088 W089 W090 W091 W092 W093 W094 W095 W096

Pump won't start Pump won't start Pump won't start Pump won't start Pump won't start Pump won't start Pump won't start Pump won't start Conveyor Fwd won't start Conveyor Fwd won't start Conveyor won't start Conveyor won't start Conveyor won't start Conveyor won't start Conveyor won't start Conveyor won't start Conveyor won't start Conveyor won't start Conveyor won't start Conveyor won't start Conveyor won't start Conveyor won't start Conveyor won't start Conveyor won't start Conveyor won't start Conveyor won't start Conveyor won't start

SECTION 3

Diff Spare Low Current Future Use Machine Voltage < 80% Vnom Machine Voltage > 117% Vnom Conveyor Jam Tilt Switch Active LH Machine Stop is OPEN (R11 Machine Stop is OPEN (R12 PUMP Stop is operated TRAM LEVERS are not centered Low oil lockout active for 5 sec (R14 Future Use Pump Motor Temp above 150 (140 after trip) Overload trip reset time not expired Inst trip reset time not expired Cutter Tram Breaker is not set (CB6) Conveyor Breaker is not set (CB2) Conveyor FWD Start is operated Conveyor REV Start is operated Pump Phase R Cony Jam trip reset time not expired L Cony Jam trip reset time not expired Time period between fwd/rev not expired Pump Off Conveyor Breaker Conveyor Stop Right Conveyor Overtemp Left Conveyor Overtemp Right Conveyor Overload Left Conveyor Overload Right Conveyor Instant Left Conveyor Instant Right Conveyor Low Current Left Conveyor Low Current Right Phase Left Phase Cutter Diff Conveyor Reverse

Possible Faults and Their Solutions

BI377591 Page 26 of 30

Table 3.3 Warning Codes Description

Code W097 W098 W099 W100 W101 W102 W104 W105 W107 W108 W109 W110 W1 1 1 W113 W117 W118 W124 W125 W126 W127 W128 W129 W130 W131 W132 W133 W134 W135 W145

Cutter won't start Cutter won't start Cutter won't start Cutter won't start Cutter won't start Cutter won't start Cutter won't start Cutter won't start Cutter won't start Cutter won't start Cutter won't start Cutter won't start Cutter won't start Cutter won't start Cutter won't start Cutter won't start Cutter won't start Cutter won't start Cutter won't start Cutter won't start Cutter won't start Fan won't start Cutter won't start Fan won't start Fan won't start Fan won't start Fan won't start Fan won't start Tram

W146

Tram

W147

Tram

W148

Tram

W149 W150 W151

Tram Tram Tram

W152 W153 W154 W157

Tram Error Tram Tram Tram won't start

Possible Faults and Their Solutions

Right Cutter Overload trip time not expired Right Cutter Inst trip reset time not expired Right Cutter Low Current Left Cutter Overload trip time not expired Left Cutter Inst trip reset time not expired Left Cutter Low Current Low Oil Lockout CB2 Breaker Active Ground Fault Haulage xformer overtemp Right Cutter Jam Left Cutter Jam CB2 breaker active Pump not running Right Cutter Overtemp Left Cutter Overtemp Diff Right Phase Left Phase Lockout Switch Open Low Oil Cutter must be started first Fan must be started first Fan Overtemp Fan Low Current Fan Overload Fan Instant Fan Phase Right Tram Analog Reference without direction Right Tram Direction without Analog Reference Left Tram Analog Reference without direction Left Tram Direction without Analog Reference Command without Tram Enable Command without Pump Running Command without Tram circuit breaker closed (CB6) Reset High Tram Timeout via Tram Enable Left Tram Overload Right Tram Overload Left Drive Phase A OverCurrent

SECTION 3

BI377591 Page 27 of 30

Table 3.3 Warning Codes Code W158 Tram won't start W159 W160 W161 W162 W163 W172 W173 W174 W175 W176 W177 W178 W179 W193 W194 W195 W196 W197 W210 W211 W212 W213 W214 W215 W216 W217 W218 W219 W220 W221 W222 W225 W226 W229 W230 W231

Description

Tram won't start Tram won't start System shutdown due to Power Center Trip Tram Tram MCU Serial Number out of range CutterLower Override due to Right Motor Cutter Lower Override due to Left Motor Cutter Raise Override due to Right Motor Cutter Raise Override due to Left Motor Tram won't Start Tram won't Start Tram won't Start Pump Shutdown LH Stop Operated Machine Stop Operated Conveyor Shutdown Cutter Shutdown Conveyor FWD Switch Operated at Start Up Conveyor REV Switch Operated at Start Up Cutter Start Switch Operated at Start Up Ventilation Only Switch Operated at Start Up Right Tram Reference Present at Start Up Left Tram Reference Present at Start Up Right Tram FWD Contact Closed at Power Up Right Tram REV Contact Closed at Power Up Left Tram FWD Contact Closed at Power Up Left Tram REV Contact Closed at Power Up Tram Enable Switch Operated at Start Up Aux relay 1 won't start Aux relay 2 won't start Cutter won't start Conveyor won't start Conveyor won't start Conveyor won't start Conveyor won't start

SECTION 3

Right Drive Phase A OverCurrent Left Drive Phase B OverCurrent Right Drive Phase B OverCurrent

Left Tram Communication Error Right Tram Communication Error

Left Drive Bus OverVoltage Right Drive Bus OverVoltage Left Drive Bus OverTemperature Pump Stop Operated

Conveyor Stop Operated Cutter Stop Operated

Pump off Pump off Machine stop override mode Machine stop override mode Machine stop override mode Machine stop override mode Machine stop override mode

Possible Faults and Their Solutions

BI377591 Page 28 of 30

Table 3.3 Warning Codes Code W232 W301 W302 W303 W304 W305 W306 W307 W308 W309 W310 W311 W312 W313 W314 W315 W316 W317 W318 W319 W320 W321 W322 W323 W324 W325 W326 W327 W328 W329 W330

Description METHANE MONITOR NOT OK Tram Enable toggle switch stuck in position Tram Enable toggle switch stuck in position Stab toggle switch stuck in Lower position Stab toggle switch stuck in Raise position Breaker toggle switch stuck in Reset positon Breaker toggle switch stuck in On position Conveyor toggle switch stuck in Lower position Conveyor toggle switch stuck in Raise position Cony. Swing toggle switch stuck in Left position Cony. Swing toggle switch stuck in Right position Gath. Head toggle switch stuck in Float position Gath. Head toggle switch stuck in Raise position Cutter Head toggle switch stuck in Lower position Cutter Head toggle switch stuck in Raise position Pump toggle switch stuck in Stop position Pump toggle switch stuck in Start position Fan toggle switch stuck in Off position Fan toggle switch stuck in On position Dust toggle switch stuck in Off position Dust toggle switch stuck in On position Fire/Lights toggle switch stuck in Fire position Fire/Lights toggle switch stuck in Lights position Conveyor toggle switch stuck in Stop position Conveyor toggle switch stuck in Start position Conveyor Reverse push button stuck Cutter toggle switch stuck in Stop position Cutter toggle switch stuck in Start position Shift push button stuck MStop Override push button stuck Enable push button stuck

Possible Faults and Their Solutions

SECTION 3

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Table 3.3 Warning Codes Description

Code W331 W332 W333 W334 W335 W336 W337 W338 W339 W342 W343 W344 W345 W346 W347 W348 W348

3.2

Tram High push button stuck Tram Low push button stuck Left Tram lever stuck Right Tram lever stuck Enable push button stuck Tram Enable Button stuck Pump Start push button stuck Conveyor Start push button stuck Cutter Start push button stuck Low Battery PowerDown TimeOut PowerDown Left Tram Command without enable Right Tram Command without enable tram enable and left tram simultaneous tram enable and right tram simultaneous Fan Button Stuck Motor Start before enable

Informational Messages A listing of the system informational messages is provided in Table 3.4.

Table 3.4 Informational Messages Description

SECTION 3

Possible Faults and Their Solutions

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Table 3.4 Informational Messages Description

Possible Faults and Their Solutions

SECTION 3

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SECTION 4.

COMPONENT IDENTIFICATION 4.1

Remote Control System Components The components that make up this system are listed in Table 4.1. With exception of the TX944, all other components of this radio control system are mounted on the machine and within a methane isolation barrier enclosure. The display may be mounted on the opposite side of the machine and in its own barrier enclosure.

Table 4.1 System Components Component MCU944 RX944 TX944 CPS944 RD U944 DCD100 Display

4.2

Description Custom PLC Radio Receiver Radio Transmitter Capacitor Backup Power Supply Emergency Pendant Interface DC Tram Drive Graphics Status Display

Remote Control System Components Tie-in The basic components and their interconnections are shown in Figure 4.1.

It may be necessary to use the TX944 Radio Transmitter to check the operation of the system during trouble analysis. It is assumed that maintenance personnel have been trained in the use of this equipment.

SECTION 4

Component Identification

BI377591

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Figure4.1 Remote Control System Components Layout

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