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ThismanualisintendedtoprovideGENERALproductinformationfor theModel25M0ContinuousMiner.Theillustrations,descriptionsand procedurescontainedinthispublicationapplyonlytoTHISmachine. BucyrusAmerica,Inc.reservestherighttorevisemodelsanddesigns withoutpriornotice.
ThisContinuousMinerwasmanufacturedundertheguidelines,proceduresandrequirementsoftheU.S.FederalCoalMineHealthand SafetyAct,CodeofFederalRegulations,Title30,Chapter1,Subpart0, Part75forundergroundcoalmines,andotherapplicablenon-U.S. regulatoryagencystandards.
Atthecompletionofthemanufacturingprocess,thisunitwasissuedthe appropriateapprovalnumbersandnameplatesindicatingitmetthe technicalrequirementsoftheseregulatoryagencies.Anychangetothe designorstructureofthisunit,withouttheconsentofBucyrusAmerica, Inc.andtheseregulatoryagencies,oranyrepairorreplacementof partscontrarytoBucyrusAmerica,Inc.’sinstructions,mayinvalidate theseapprovalsandrenderthisunitunsafetooperate.
StrictcompliancewithallFederalandStateMininglaws,regulations andpracticesregardingthesafeoperationandmaintenanceofundergroundminingequipmentandstrictadherencetotheinstructionsinthis manualisnecessaryforthepersonalsafetyofthoseworkingonor aroundthisunit.
Whilethismanualattemptstoanticipatethemostimportantoperations andmaintenanceneedsforthisunit,unforeseencircumstancesmay arisethathavenotbeenaddressedinthismanual.Ifanyconcernsor questionsarise,pleasecontactyourBucyrusAmerica.Inc.Service Representative immediately
Thisworkcontainsinformationprotectedundertradesecretandother intellectualpropertylaws,andisprotectedundertheU.S.Copyright Actof1976,asamended.Thisworkisprovidedunderlicenseandthe licenseisnon-transferable.Distributionandaccessislimitedonlyto authorizedpersonnel.Disclosure,reproduction,distributionorunauthorizedusemaybeaviolationoffederalandstatelawsandmaysubjecttheunauthorizedusertocriminalliability.
2. Yoursafety 3. Storageandtransport 4. Installation 7. Foryourinformation Aboutthismanual Aboutthismanual Thischapterprovidesimportantinformationmakingiteasierforyouto usethismanual.Youwillalsobegiveninformationonthestructureof themanualandthesymbolsandcharactersused.
Beforestartingtowork Takecaretoensurethattheoperatingmanualavailabletoyouis applicableforthetypeofequipmentormachineused.
Thisoperatingmanualisintendedfor:
BucyrusModel25M0ContinuousMiner
SerialNo.:N/A
andisonlypermittedtobeusedforequipmentofthistype.
Theoperatingmanualmustbeaccessibleatalltimestoallpersons workingonorwiththemachine.Itshould,ifpossible,alwaysbe availableattheplaceofoperation.
Sendforanewoperationmanualimmediatelyifthepresentmanualis nolongercompleteorhasbecomeillegible.
Whoisthisoperatingmanualintendedfor? Thisoperatingmanualisintendedforthosepersonswhoworkwithor onthemachine.Everypersonworkingonthefaceorintheintersectionbetweenfaceandentryorintheentrymustreadthisoperating manual.
Thisincludespersonswho:
■ areinchargeoftransport
■ performassembly/disassemblywork
■ operatethemachine
■ eliminatefaults
■ performdailyroutineworkonthefaceorintheentry
■ performmaintenancework
■ performrepairwork
supervisorypersonnelwho:
■ initiateand/orsupervisetheactivitiesjustindicated.
Beforestartingtowork Whatisthepurposeofthisoperatingmanual? Thisoperatingmanualisintendedtohelpyouworkefficientlyand safelywithourproduct.Itcontainsimportantinformationonallthe activitiesrelatedtothemachine.
Readthisoperatingmanualcompletelyandatease.Payspecialattentiontothesafetyinstructions.Trytomemorizetheappearanceandthe meaningofthesafetyandinstructionsymbols.
Ifanydetailsarenotclearlyunderstood,pleasecontactourservice department.Ourserviceaddressisgiveninthechaptertitled“Foryour information”.
Readthechapter“Foryoursafety”withspecialattention.Thechapter containsimportantinformationindicatingpossiblehazards.Observe theinformationgivenandfollowtheproceduralinstructions.
Charactersandsymbolsused Thefollowingcharactersandsymbolsareusedforsafetyinstructions andimportantinformationintheoperatingmanual.
Trytomemorizethesymbolsandtheirmeanings.
DANGER! Pointsinthetextmarkedwiththissymboldrawyourattentionto immediatelyimpendingdanger.Possibleconsequencesare: veryseriousinjuryorevendeath.
WARNING! Thesepointscontaininformationondangeroussituations.Possibleconsequencesare:veryseriousinjuryorevendeath.
CAUTION! Thissymboldrawsattentiontodangeroussituations.Possible consequencesare:lighttomoderatelyseriousinjuriesandmachinedamage.
NOTICE! Pointsinthetextmarkedwiththissymboldrawattentiontoharmfulsituations.Possibleconsequencesare:damagetothemachineordamageintheimmediatevicinity.
IMPORTANT! Pointsinthetextmarkedwiththissymbolcontainusefultipsand informationintendedtofacilitateworkforyou.Theydonotwarn aboutharmfulordangeroussituations.
■ Itemsinlistsaremarkedwithbullets.
– Pointsinsub-listsaremarkedwithalongdashatthestartof theline.
Pointsintextmarkedinthiswaydescribeindividualoperations. Followtheseinstructionsstepbystep.Theywillhelpyoucarryout yourworkfasterandmoreimportantly,safer.
Beforestartingtowork Yoursafety Thischapterprovidesvitalinformationforyoursafety.Payspecialattentiontothischapter.Thesafetyinstructionsandrulesofprocedure willhelpyoutoavoidhazardoussituationsandtoperformthenecessaryworkassafelyaspossible.
Themachinehasbeenmanufacturedinaccordancewiththestateof theartandgenerallyrecognizedsafetystandardsandregulations. Youandotherscan,nevertheless,beexposedtodangeroussituations e.g.asaresultofenvironmentalinfluences,machinedamageoroperatorerrors.
Donotmakeanyalterationsormodificationswhichcouldimpairthe safetyofthemachine.AllmodificationsandchangesmustbeapprovedbyBucyrusAmerica,Inc.andanyappropriateregulatory agency.
UseonlyoriginalsparepartsfromBucyrusAmerica,Inc.Notethatthe useofpartsfromothermanufacturerswillvoidthewarranty.
Inadditiontothisoperatingmanualbesuretoalsoobservetherespectivelegalprovisionsandregulationsinyourcountry.
Observethesafetyandaccidentpreventionregulations
■ ofthemine,
■ ofthemineinspector,and
■ oftheminingsupervisoryauthorities.
Readtheoperatingmanualsofthecomponentsrequiredforoperation, e.g.ofgearboxes,electricmotors,radioremotes,etc.,carefullyand thoroughly.Clarifyanyquestions before startingwork.
training
Personnel Operation Themachinemayonlybeoperatedbyqualified,trainedpersonnel. Themachineisonlyallowedtobeoperatedbyqualifiedpersonnelwho canprovideproofofhavingbeentrainedonthisunit.
Readingoftheoperationmanual,especiallythechapteronsafety,shall constituteapartofthistraining.
Youmusthaveadequateknowledgeofthe
■ mechanics,
■ hydraulics,and
■ controlengineering andmustbeabletoprovethisknowledge.
Installationandrepair Asafundamentalrule,installationandrepairworkmayonlybecarried outbypersonnelwhohavebeenadequatelytrainedfortheseparticular requirements.
Installationandrepairworkon:
■ safetycomponents(pressurereliefvalves,extinguishers,etc.)
■ theelectrics(motors,controllers,etc.)
■ thehydraulics(controls,cylinders,etc.)
mayonlybecarriedoutbyserviceengineersfromBucyrusAmerica, Inc.orbyspeciallyqualifiedpersonnelofthemine.
Operatingconditions Intendeduse TheContinuousMinerhasbeendesignedandmanufacturedforthe extractionofcoal,phosphate,potash,salt,tronaandothermedium hardnessminerals.
Intendedusesinclude:
■ extractionofcoal,phosphate,potash,salt,tronaandothermedium hardnessminerals
■ loadingthematerialslistedaboveontoahaulagesystemorshuttle car,ordumpingitontothegroundforloadingatalatertime
■ operationongradesoflessthan10degrees
Unauthorizeduse Applicationsnotexpresslylistedasintendedusesareunauthorized usesandarenotallowedtobeperformedwiththemachine.
■ thetransportofpersons
■ stonedevelopmentorextraction
BucyrusAmerica,Inc.acceptsnoliabilityforanydamageresulting fromanysuchunauthorizeduse.
Safetyinstructions Generalrules:
Alwaysworkwithfullconcentration.
Familiarizeyourselfwithyourworkingenvironment.
Alwayswearyourpersonalprotectiveequipment.Thisalsoincludes earprotectorsasthenoiseemittedbyotherequipmentintheareamay attimesexceed85db(A).
Informyourcolleaguesof
■ yourexactlocation,
■ theworkyouareperforming,and
■ thetimethatyouwillprobablyrequire.
Startthemachineonlywhenitisinagoodandsafeoperatingcondition andallprotectivedevices,e.g.EMERGENCYSTOPdevices,cover plates,etc.arecorrectlyinstalled.
Observetheacousticandopticalstart-upwarningsofthemachine.
Observethesymbolplatesonthemachine.
PresstheEMERGENCYSTOPbuttonimmediatelyintheeventoffault orirregularitiesinoperation.Reportanypeculiaritytoyoursuperiorso thatnecessarymeasurescanbetakenimmediately.
Lock-out,tag-outanddisconnectthepowersystemwhileperforming:
■ maintenancework
■ inspectionwork
■ repairwork
Cordonoffyourworkingareawidelyforthemachine.
Neverallowpartsofyourbodytocomebetweenpartswhichcould move,suchase.g.:
■ chains,flights,andchainsprockets
■ pivotpoints
■ cutterheadandloadinghead
■ crawlerassembliesandconveyors
■ cutterandgatheringheadassemblies
Safetyinstructions Storageandtransport Maintaintheprescribedstorageperiodsandobservetheinstructions forstorage.
Donotstorematerialsorpartsinthetravelwayorinyourworking area.
Informthepersonsinvolvedabouttheintendedtransportrouteandthe anticipateddurationofthetransport.
Ensurethatthetransportsafetydevicesarecorrectlyfitted. Fixallmovingpartswithtransportlocks.
Neverstandunderunsupportedpartsorsuspendedloads.
Connecttheliftingequipmentonlytothepointsofattachmentprovided forthatpurpose.Observethedifferentloadlimitsoftheattachment points.Alsoobservetheinstructionsonthetransportsheet.
Onlyusemeansofattachmentwhichareingoodconditionandhave beendesignedfortheloadstobehandled.
Forroundcomponentsusetransportstraps,only.Neverusechainsor steelcablesforthispurpose.
Donotdamagethetreatedorpolishedsurfacesofshafts,sealingsurfaces,etc.
Whenusingmobilehandlingsystemsfortransportmakesurethatthe centerofgravityisaslowaspossible.
Pre-startinspection Readthisentiremanualbeforeattemptingtooperatethismachine.
Inspectthemachineandhaveanymalfunctioning,brokenormissing partscorrectedorreplacedbeforeuse.
Verifythatallmaintenancehasbeenperformed.
Verifythatallinstructionandsafetytagsareinplaceandreadable. Theseareasimportantasanyotherequipmentonthemachine.
Cleananyforeignmaterialfromtheoperator’scompartment.
Thismachinemaybeshippedfromthefactoryequippedwithaprotectivecab/canopy.Thecab/canopymustbesecurelyinplacebeforeoperatingtheunit.
Safetyinstructions Installationandstart-up Oninclinedfacessecureallcomponentpartsbychains,e.g.tothe support.
Whenworkingwithoils,greasesandotherchemicalsubstances,observethesafetyregulationsapplicabletotheproduct.
Disposeofcleaningrags,etc.whichhavebeensoiledwithoil,grease orotherchemicalsubstancesinanenvironmentallysafemanner.
Whenstartingupmachine,donotoperateanycontrolslocatedinside theoperator’scompartment(optional)fromoutsidethecompartment.
Followthestartingprocedureinstructionsintheoperationsmanual.
Donotoperateanylevers,pedalsorcontrolsifanyoneisinthered zone.(SeeRedZoneinChapter5ofthismanual)
Operation Operatethemachineonlyifyouhaveaprofoundknowledgeofthe controlelementsandtheirfunctions.Itisnecessarythatyouhave beentasktrainedontherespectiveContinuousMiner.
Beforestart-up,ensurethattherearenopersonsorobstructionsin yourlineoftravelorinthearticulationareawhensteeringtheunit.
Checkthatallprotectivedevicesareinstalledonthemachineandfunctionproperly.
Cleantheoperator’scompartmentatregularintervals.Ensurethatthe operatingsymbolsarelegibleinordertoavoidanyoperatorerrorsand resultingaccidents.
Neverclimbonto,orclimboutofthemachinewhileitisinmotion.
Donotoperatethemachinewithanypartofyourbodyoutsideofthe operator’scompartmentinordertopreventbodypartsfrombeing crushedbetweenthemachineandoutsideobjects.
Useextremecautionwhentravelinginclosequartersorincongested orblind-travelareas.
Nevercarrypassengers.Passengersmaybethrownoffthemachine orcrushedbetweenthemachineandoutsideobjects.
Alwaysfollowallsafetyrulesofeachparticularminewhenoperating themachine.
Ifproblemsormalfunctionsareencounteredwhileoperatingtheunit,it mustbeproperlyshutdownandtheproblemcorrectedimmediately.
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Safetyinstructions Stopping Donotleavetheoperator’scompartmentwiththeunitrunning.Always properlyshutdowntheunitbeforeleavingtheoperator’scompartment.
Alwaysparktheunitonsolid,levelground.Ifthisisnotpossible,park theunitatarightangletotheslopetopreventaccidentalmovementof themachine.
Useproperflags,warningsorbarrierswhenparkinginareasoftraffic.
Thereisauniquecodeswitchsetupwhichpermitseachoperatorto activateonlyhisdesignatedminer,allowingseveralremote-controlled minerstooperateinthesameareawithoutgettingtheirradiosignals crossed.Inaddition,animproperlydecodedradiosignalwillautomaticallyshut-offtheminer.Followthegeneralsafetynoticesandsafety recommendationslistedintheremotecontrolsystemtroubleshooting guide.
Maintenanceandrepair Besuretoobservetheprescribedmaintenanceandinspectionintervals.
Informthesupervisorypersonnelandthefacecrewofanymaintenance andrepairoperations.Givetheminformationontheintendedoperationsandtheanticipatedduration.
Beforeattemptinganyrepairs,a DANGER signmustbeattachedtothe appropriatecircuitatthepowerdistributionbox.Itismandatoryunder theUnitedStatesFederalLaw,thatthetrailingcablebeuncoupledand locked-outandtagged-outfromthepowersourcetoprovidevisual evidencethattheminerisde-energized.
Secureyourworkingareaoverawiderange,inordertoavoidendangeringotherpersons.
Disconnectthepowerfromthemachinetopreventunauthorizedand unintentionalrestarting.
Protectyourworkareaagainstfallingrocks.
Disconnectthepowerfrommachinetopreventfromrestartingbefore replacinganydefectivecomponents.
Passdefectivecomponentsremovedonforservicingwithoutdelayin ordertopreventthesepartsbeingreinstalledelsewhere.
Useonlysparepartswhichsatisfythespecifiedtechnicalrequirements. ThisisonlyensuredwithoriginalBucyrusAmerica,Inc.spareparts. Pleaserefertothesparepartslistsfortheordernumbers.
handlingofhydraulicfluids lifting
maintenance,repair
Safetyinstructions ForraisingtheContinuousMineruseonly:
■ cribblockswithadequateload-holdingcapacity.
■ hoists,jacksorcraneswithadequateload-carryingcapacity.
Avoiddirectcontactbetweentheskinandhydraulicfluids.Hydraulic fluidcanpenetratetheskinandcauseseriousinfection.
Neverusehydraulicfluidforrinsingorcleaning.Hydraulicfluidrepresentsaveryseriousdangertohealth.
Onlypersonswhohaveandcandemonstrateaspecialknowledgeof hydraulicsareallowedtoworkonthehydraulicsystem.
Avoid,wheneverpossible,servicing,cleaningorexaminingthemachineincongestedareas.
Avoid,wheneverpossible,servicingorprovidingmaintenancetothe unitunlesstheappropriatesafetydevicesareplacedwhererecommendedtopreventaccidentalmovementoftheunit.
Donotaltertheelectricalorhydraulicsettingsfromthatindicatedinthis manualorassetatthefactory.
Alwaysreplacedamagedorlostdecalsandmetalinstructionplates.
Disconnectthepowerwhenworkingwiththeelectricalsystem,orwhen weldingontheunittopreventelectricalshock.
Alwaysfollowallsafetyproceduresofeachparticularminewhenperformingmaintenance.
Itisimportantthatanyprocedurenotspecificallyrecommendedinthis guidebethoroughlyevaluatedfromthestandpointofsafetybeforeitis implemented.
Safetyinstructions ____________________________________________ Someillustrationsinthismanualshowguardsorcoverpanelsremoved forpurposesofclarity.Neveroperateunitwithoutguardsorcoverpanelsinplace.
Carryoutavisualinspectionofallthehydrauliccomponentsatregular intervals.Inparticularcheckthat:
■ thehosesarenotpinchedortrapped.
■ thehoseshavenobubblesorblisters.
■ thehoseoroutersheathesofthehosearenotabnormallyrigidor hard.
■ theoutersheathofthehosesisnotdamaged.
■ theconnectorsaresecurelyinsertedintothesockets.
■ theconnectionsareleak-tight.
Ensurethatnodirtentersthehydraulicsystemduringrepairwork.Dirt inthehydraulicsystemcancauseseriousdamageinthewholesystem! Flushoutthehydrauliclinesthoroughlybeforeconnecting.
permissiblehoses
Ifhydraulichosecouplersaredifficulttodisconnectorcannotbedisconnected,thehydrauliclinemaystillbepressurized.Besuretodepressurizethelinebeforedisconnectingcouplers.
Securetheconnectorsofthehydraulicelementsonlywiththeproper couplingclamps.Alwaysfastentheclampscompletelyandwithboth sides.Neverusenails,wireorsimilarmaterialsforsecuring.
Afterfinishingrepairwork,checkallconnectorsandconnectionsfor leaksbeforepressurizingthesystemagain.
Useonlyhydraulichosesapprovedfortheprevailingpressures.
Donotuseanyhydraulichoseswithdamagedconnectorsorwornorings.
Replacehydraulichosesonlywithhosesofthesameorahigherquality.
Nevertrytoholdajumpinghydraulichose.Depressurizethelinein questionimmediately.
Nevertrytorepairdamagedhydraulichoses.
Replacehydraulichosesatthefirstsuspicionofdamage.
Safetyinstructions installinghydraulichoses
Installthehydraulichosesproperlybehindthebracketsandclamps providedforthem.
Alwaysinstallhydraulichosessothey:
■ alwayshavealittleslack.
Fig.1:Installinghydraulichoses,slack Right Wrong
■ arenottwisted.
Fig.2:Installinghydraulichoses,twisting Right Wrong
■ arenotbentdirectlybehindtheconnections. (distancemin.1.5xnominaldiameter).
Fig.3:Installinghydraulichoses,bending Right Wrong
Safetyinstructions ■ alwayshavealittleslack.
■ arenotkinked.
■ donothavetowithstandtensilestrains.
■ areprotectedagainstthermalradiation.
■ areaccessibleatalltimes.
Screwhydraulichosesintothesocketsonlybyhandandfingertighten. Nevertrytodrivethehydraulichosesinwithatoolasthiswilldamage theconnections.Usetheappropriateamountoftorquetoensurea properhosefit.
Wheninstallingthehydraulichoses,ensurethattheycannotbe:
■ tornout,
■ kinked,
■ crushed,
■ drivenoveror
■ twistedbymovementofthemachine.
Fig.4:Installinghydraulichoses,connectionsonmovingparts
Right
Overviewofthesafetyinstructions Thisisasummaryofallthesafetyinstructionswhichhavetobeobservedinthefollowingchapters.Thissummaryisintendedonlytogive youanoverviewofalltheinstructions.Insomecases,thereisnologicalrelationshipbetweentheindividualinstructions.
Chapter3:Storageandtransport IMPORTANT!
Takecaretoinsurethatnewmaintenancesuppliesarestored separatelyfromexistingstockandthatremovaltakesplaceonthe “firstin,firstout”principle.
WARNING!
Useonlyloadhandlingdevicescomplyingwiththetechnicaland legalregulationsforthetransportofloads. Youcouldbeseriouslyinjuredorevenkilledbyfallingloads.
WARNING!
DonotusetheeyebolttoliftthecomponentANDitsrelatedassemblies.
Chapter4:Installation CAUTION!
SeriousdamagecanbecausedtotheContinuousMinerasaresultofincorrectinstallation.TheunitshouldthereforeonlybeinstalledundertheinstructionofspecialistsfromBucyrusAmerica, Inc.
IMPORTANT!
Thesequenceofoperationsduringinstallationmustbeadaptedto theindividualconditionsprevailingatthesite.Beforestartingthe workadetailedlistofstepstobetakenwithrespecttotransport andassemblyshouldbepreparedandacorrespondingplan established.
NOTICE!
Themachinewasinspectedpriortoshipmentfromthefactoryto ensureproperfunctioningandinstallationofallcomponents. However,toensurethatnotransitdamagehasoccurred,thefollowingpre-startupchecksshouldbeperformed:
NOTICE!
Theoperatormustbecomefamiliarwithallthesafetyfeaturesand theirlocationonthemachinepriortoinstallationoroperation.
WARNING!
Ifeitherofthefiresuppressionactuators(optional)isactuated, thesystemmustbecompletelyrechargedwithdrychemicalsand expellants.
DANGER!
Donotoperatethemachinewithanyoftheguardsorcoversremoved.Youorotherpersonnelcouldbeseriouslyinjuredfrom movingorrotatingparts.
Overviewofsafetyinstructions Chapter5:Operation DANGER!
Incorrectoperationendangersyourselfandothers!Incorrectoperationofthemachineisoftenthecauseofveryseriousaccidents!Operatetheunitonlywhenyouhavebeensufficiently trainedonthemachineandhavereadandunderstoodthisoperatingmanual.Shouldanythingbeunclear,pleasecontactyourimmediatesupervisorortheirdesignee.
NOTICE! Beforebeginningcuttingoperations,carefullyunloadthetrailing cableprovidingenoughslackandplacingitwhereitallowsadequateclearanceforsafemaneuverabilityoftheminer.
WARNING!
TheContinuousMinerisradioremotecontrolled.Manualoperationisgenerallyfortroubleshootingandmaintenanceunderroof support.OperatingtheContinuousMinermanualfromtheOperator’sstationmayresultinseriousinjuryordeath.
CAUTION! MANUALONLY:TheContinuousMiner’stramandsteeringspeed isvariable.Thismeansthatthefartherthetramhandleis actuatedthefastertheContinuousMinerwilltravelorturn.The tramlevermustbemovedslowly.Movingthetramleverstoo quicklymayresultinsevereinjuryorlossofcontrol.
IMPORTANT! Oncethetram/steeringcontrolleverisreleasedbytheoperator thecontrolleverautomaticallyreturnstothecentered(neutral) position.
WARNING!
ManualoperationoftheContinuousMinerisnotallowedforproductionoperationunlesstheminerhasanoperator’spitandcanopy.Manualoperationisgenerallyfortroubleshootingandmaintenanceunderroofsupport.OperatingtheContinuousMiner manuallyfromtheoperator’sstationmayresultinseriousinjury ordeath.
WARNING!
Themachinecircuitbreakerde-energizestheelectricalcontroller andmotors.However,electricalpowerisstillpresentinsidethe connectionboxtothecircuitbreaker.Ifthecircuitbreakerinside theconnectionboxrequiresservice,thetrailingcableshouldbe disconnectedfromthepowercenter.
WARNING!
Oncethebreakerhastripped,itwillnotstayinthe“ON”position withoutfirstbeingmovedtothe"RESET"position,andthento "ON".
WARNING!
Overviewofsafetyinstructions Ifeitherofthefiresuppressionactuatorareactuated,thesystem mustbecompletelyrechargedwithdrychemicalsandexpellants.
WARNING!
BepreparedforasuddenstopwhentheE-stopisactuatedduringnormaltrammingofthemachine.
IMPORTANT!
Refertotheradioremotecontroloperationmanualsuppliedwith yourmachineforinformationregardingtheoperationofyour specificremotecontrol.
WARNING!
Failuretoreadandunderstandalloperatinginstructionsbefore startingtheContinuousMinercouldresultinseriousinjuryor deathtotheoperatororpersonsaroundthemachineorcause damagetothemachine.
WARNING!
Readallinstructionscarefullybeforeattemptingtostartoroperatemachine.
WARNING!
UnderstandthefunctionsofallcontrolsbeforestartingtheContinuousMiner.Readandfollowtheinstructionsonallwarning tagsonthemachine,observeallregulationsandsafetyprecautions.
WARNING!
NeveroperateaContinuousMinerwhichhasbeendamagedoris notoperatingproperly.AnypartoftheContinuousMinerwhich doesnotfunctionproperlycanbeahazard.Reportitimmediately toyoursupervisor.
WARNING!
BeforestartingtheContinuousMiner,makesurethatnooneisin theredzone(Fig.22throughFig.26).
NOTICE!
Inextremelycoldweather,allowmotorsandgearcasestoidle. Thiswillwarmthehydraulicoilsandlubricants.Stilloilsand greasescouldimmobilizethemachine.
IMPORTANT!
Apump“growl”meansnotenoughoilisreachingthepumps throughthesuctionlines.Ensurethepumpgetsprimedbefore continuingoperation.Alwayschecktheoillevel.
DANGER!
Improperpositioncouldresultininjuryordeathtotheoperator bycrushinghimagainsttheriborroofsupports.Itmayalso causehimtorunoverthetrailingcableordislodgetheroofsupports.
Overviewofsafetyinstructions _________________________________ WARNING!
Turningonthewatersprayspriortocuttingpreventstheaccumulationofdustandthegenerationofexcessiveheatwhichcould causeanignitionorexplosion.
WARNING!
TheContinuousMineristypicallyoperatedbyradioremotecontrol.Manualoperationisnotallowedforproductionoperation unlesstheminerhasanoperator’spitandcanopy.Manualoperationgenerallyisfortroubleshootingandmaintenanceunderroof support.
IMPORTANT!
Beforestart-up,checkthatdailymaintenancehasbeenperformed onthemachine.
WARNING!
Visuallycheckforotherpersonnelandverballyshoutawarning beforestartingthismachine.Makesureallpersonnelarecompletelyclearofthemachineandit’scomponentsandcheckthat anyloosematerial,tools,oilcansorotherobjectsareclearfrom theareabeforestartingthemachine.
IMPORTANT!
The“PUMPON”keymustbereleasedbefore“SHIFT”.If“SHIFT” isreleasedfirst,thepumpmotorwillshutoff.
WARNING!
Afterturningoffthepowertothemachine,neverwalkawayand leavethetransmitterturnedon.Failuretoturnthetransmitteroff couldresultinanaccidentcausingseriousinjuryorlossoflife.
WARNING!
Trammingrequirescoolingwatertothetrammotors.Failureto coolthemotorswillresultinmotordamageandprematurefailure.
WARNING!
Adjustconveyorboomtoallowclearancefromroof,walls,and floor.Failuretodosowillresultindamagetotheconveyorboom.
WARNING!
Neverstartcutterheadmotorsunderaload.Startingmotorsunderloadmayresultinmotordamageorprematurefailure.
WARNING!
Warn“ALLCLEAR”beforestartingthecutterhead.Failuretodo somayresultinseriousinjuryordeath.
IMPORTANT!
Bothcuttermotorsdonotstartatthesametime.Thereisapreset timeddelaybetweentheleftcuttermotorstartingandtheright cuttermotorstarting.
IMPORTANT!
The“CUTTERON”keymustbereleasedbefore“SHIFT”.If “SHIFT”isreleasedfirst,thecuttermotorswillshutoff.
Overviewofsafetyinstructions WARNING!
Warn“ALLCLEAR”beforestartingtheconveyor.Failuretodoso mayresultinseriousinjuryordeath.
IMPORTANT!
The“CONVON”keymustbereleasedbefore“SHIFT”.If“SHIFT” isreleasedfirst,theconveyormotorswillshutoff.
IMPORTANT!
The“FANON”keymustbereleasedbefore“SHIFT”.If“SHIFT”is releasedfirst,thefanmotorwillshutoff.
CAUTION!
Alwaysensureoperatorsafetywhileoperatingthemachine.
CAUTION!
Alwaysbealerttohazardousconditionsandtakecorrectiveactionasnecessary.
IMPORTANT!
Careshouldbetakennottostallcuttersonconveyorduringcuttingoperations.Severedamagetomotorsandgearboxescould occurifcuttersorconveyorarerepeatedlystalled.
IMPORTANT!
Tramislimitedintheforwarddirectionwhilethecuttersarerunningwiththecutterheadfeedbackcircuit.Asthecuttersbeginto cutthematerialfromthefacethesumpspeedwillautomatically slowthetramdowntopreventoversumpingthemachine.
IMPORTANT!
Inspectionofthebitsandbitblocksbeforethestartofeachshift willreducelaterproblems.Miningwithdull,bentorbrokenbit blocksincreasesdustandnoiselevels,aswellasputtingexcessivestrainonbothcutterandtramdrives.
WARNING!
Failuretomaintainthehydraulicsystemwillresultindamageto itshydrauliccomponentswhichwillresultinincreasedwearand prematurefailure.
IMPORTANT!
Schematicsmayvaryfromoneunittothenext.ConsulttheBucyrusAmerica,Inc.partsbookfortheschematicforyourmachine.
IMPORTANT!
Duringdisassemblyofcontrolvalves,giveparticularattentionto identificationofpartsforreassembly.Spoolsareselectivelyfitted tovalvebodiesandmustbereturnedtothesamebodiesfrom whichtheywereremoved.SpoolsareNOTinterchangeablebetweenvalvebodies.
Overviewofsafetyinstructions _________________________________ WARNING!
Donotsalvagespoolsorvalvebodiesforlaterusein“new”combinations.Impropercomponentsusedduringassemblymayappearasinternalleakage,ora"sticking"or"hangingup"ofthe spoolinthevalvebody.Incorrectsetswillresultinimproperoperationofthevalvesection,possiblycausingunexpectedmachine operationthatcouldresultinmachinedamageorinjurytopersonnel.
WARNING!
Donotrelyontheloadholdingvalvewhenworkingunderthecutterheadortheconveyor.Alwaysblocktheconveyororthecutter headifitmustbeelevated.Seriousinjuryordeathmayresult fromnotblockingtheload.
WARNING!
Theloadholdingvalvesonthecutterheadandconveyorcylinders arepresetandDONOTrequireadjustment.Adjustmentofthese valvemayresultinveryseriousinjuryorevendeath.
DANGER!
Theareaunderandaroundtheraisedcutterheadisdangerous. Securelyblocktheheadbeforeperformingmaintenanceonor belowit.Failuretoblocktheraisedcutterheadcouldresultin seriousinjuryorevendeath.
DANGER!
Theloadholdingvalveispreset. DONOTADJUSTIT.Ifitmalfunctions,replaceitimmediately.
IMPORTANT!
Ensurethatthepowerfillsuctionhose istightlypluggedtopreventdirtandcontaminantsfromenteringthehydraulicsystem whennotinuse.
IMPORTANT!
Thepowerfillisactivatedbyengagingconveyordownfunction andopeningtheballvalve.
IMPORTANT!
Neverruntheconveyorwithouttheneedlevalveclosed.Injuryor deathmayoccur.
IMPORTANT!
Youmustmanuallyresetthe2-way,2-positionwatervalvetoreset thedelugefirespraycircuit.
IMPORTANT!
Thebackupaccumulatormustmaintainaminimumpressureof 500psifor12minutesafterthepumphasbeende-energized.For maintenanceonthecircuit,loosenthefittingSLOWLYuntilthe pressureisreleased.
Overviewofsafetyinstructions IMPORTANT!
Hangtrailingcablestopreventdamagefrommovingequipment!
WARNING!
Neverrunoveranunprotectedtrailingcable.Damagedcables shouldberepairedimmediately.
DANGER!
Neverhandleenergizedtrailingcablewithoutproperprotective equipment.Contactwithanenergizedtrailingcablewithcompromisedinsulationcouldresultindeathbyelectrocution.
WARNING!
Alwaysusecautionwhenstandingnearorcrossingtrailingcables.Thetrailingcablemaymoveasthemachinemoves.
IMPORTANT!
Ifthelowoilwarninglightcomesonwhenthecircuitbreakeris closed.Besuretofillthereservoirbeforestartingthemotors.
CAUTION!
Onlyqualifiedtechniciansshouldtroubleshoottheelectricalsystems.Touchingorshortingenergizedcomponentscancauseseriousinjuryordeath.
WARNING!
Beforeperformingmaintenanceonthemachinethecircuitbreaker mustbeinthe“OFF”positionandthepowershouldbedisconnectedatthemainpowersource.FollowallFederalandMine safetyregulationsforlockout/tagoutprocedures.Accidentalmachinemovementorelectricalshockcanresultinseriousinjuryor deathtoyouorotherpersonnel.
WARNING!
Donotmoveanyhydrauliccontrolleverunlessyouarecertain thateveryoneiscompletelyclearofanymachinemovement.Accidentalmachinemovementcancauseseriousinjuriesoreven deathtoyouorthemaintenanceperson.
WARNING!
Neverdisconnectahydraulichoseifthecircuitispressurizedorif thereisaloadonthecircuit.Ifahoseisdisconnectedwhilethe circuitispressurizedoraloadisonthecircuit,theloadwillfall causingdamagetothemachineorseriousinjuryordeathtoyou orotherworkers.
WARNING!
Youcouldbeseriouslyinjuredorevenkilledbyfallingloads.Observethesafeworkingloadlimitsofliftingorblockingdevices andkeepasafedistancefromsuspendedloads.
Overviewofsafetyinstructions _________________________________ NOTICE!
Ifthegearcaseisscheduledforoildrainandrefill,obtaintheoil samplepriortotheoilchange.
IMPORTANT!
Alwayscollectoilsamplesusingasiphonpump.Donotremove thedrainplugandcollectoilbyallowingittorunoutintothebottle.
IMPORTANT!
Alwaysusethecollectionhoseprovidedwitheachbottle.Always discardhoseimmediatelyfollowingcollectionoftheoilanddonot useitforthenextsample.Todosowillcontaminatethenext samplewithoilfromtheprevioussample.
NOTICE!
Incorrectgreaseorovergreasingoftheelectricmotormaycause seriousdamagetothemotor.FollowthegreasingprocedureoutlinedintheMaintenancesectionofChapter5.
WARNING!
Thehydraulicoilfillpumpwillbedamagedifitisrundry.
WARNING!
Useextremecautionwhenperformingtestproceduresandmaking adjustments.Unlessnotedintheprocedures,allcontrolsaretobe intheneutralposition.
IMPORTANT!
Alwaysusethepropertoolswhenadjustingvalvecartridges.
IMPORTANT!
Donotstartanymotors - CLA,cutterhead,pump,ortractionmotors - untilallpressuresareset.Startthepumpmotorasdirected.
WARNING!
Neverrelyontheloadholdingvalveasameansofsupportingthe cutterorconveyorboomwhilemakingrepairs.Severeinjuryor deathcouldresult.
WARNING!
Alwaysallowfunctiontobottomoutandstopmovingbeforeadjustinganypressure.
IMPORTANT!
ReferencetheHydraulicsectioninthischapterforgeneralinformationontheindividualcircuits.Alwaysrefertothehydraulic schematicinyourBucyrusAmerica,Inc.partsmanualforinformationthatisspecifictoyourminer.
WARNING!
Twopeoplearerequiredtoadjustpressuresettings.Oneperson willmaketheadjustmentswhilethesecondpersonmustremain atthe“Machinestop/E-STOP”atalltimesduringtheadjustment procedure.Failuretodosomayresultinseriousinjuryordeath.
Overviewofsafetyinstructions IMPORTANT!
Beforemakinganyfurtheradjustments,verifythatthehydraulic oilisatoperatingtemperature.
IMPORTANT!
Themainreliefissethigherthantheportreliefsandwillonlyrelieveifaspikeoccursinthesystemoriftheportreliefdoesnot functionproperly.Thisprovidesprotectionofthemainpumpsection,A1.
CAUTION!
Donotadjustthemainreliefover3,000psi.Destructionofthe valvebankandthemainpumpcouldresult.
CAUTION!
Alwaysbealertforanyunintendedmachinemovement.
IMPORTANT!
ReferencetheHydraulicsectioninChapter5forindividualcircuitinformation.Alwaysrefertothehydraulicschematicinyour BucyrusAmerica,Inc.partsmanualforyourminer.
WARNING!
Keepbodypartsclearofmachinewhileinraisedpositionorseriousinjurycouldresult.
WARNING!
Youcouldbeseriouslyinjuredorkilledbyfallingloads.Observe thesafeworkingloadofallblockingdevices.
WARNING!
FollowallFederalandminelockout/tagoutregulationsandprocedures.Failuretodosocouldresultinmachinedamageorserious injuryordeathtopersonnel.
CAUTION!
Shimsmustbeinsertedcompletelyintotheidlerslidechannel.A shimthatisnotcorrectlyseatedontheidlerslidechannel’sinside surfaceprovidesunevensupportthatcancauseidlerslant.A slantedidlercancauseunevenwearandstressonthetramtrack andcancauseimproperoperationofordamagetothetramsystem.
IMPORTANT!
Checkthattheshimsarecorrectlyseatedontheidlerslidechannel’sinsidesurfacebylookingatthechannel’sinsidesurface fromtheoppositesideoftheminerthroughthespacebetween thegatheringheadandtheidlerassembly.
IMPORTANT!
Leftandrighttake-uprodsshouldberotatedequally.Thismaintainssteady,equalpressureonthetailrollerassemblyandkeeps theconveyorchainfromdriftingoffcenter.
Overviewofsafetyinstructions _________________________________ WARNING!
Donottestthealignmentoftheshearcylinderrodendbearings andthecutterboomclevisusingyourfingers.Shiftingofthe alignedpiecescouldcauseseriousinjury.
IMPORTANT!
Thepinshouldbeinsertedsothatitsretainingchannelremains outsidethebushing.
IMPORTANT!
Inadditiontotheshearcylinders,thestabilizerandgathering headcanalsobeusedtoadjustthecutterboom’spositiontoalloweasierinsertionofthecutterboompivotpins.
IMPORTANT!
Pressurefromthecutterboomontothepivotpincanmakeitsremovalverydifficult.Theshearcylinderscanbeusedtofindthe boompositionthatputstheleastpressureonthepin.
CAUTION!
Whenthepivotpinpullpointisfound,blockthecutterboomto preventitfromdroppingormovingwhenthepivotpinisremoved.
IMPORTANT!
Pressurefromthecutterboomontotheboompivotpincanmake itsremovalverydifficult.Theshearcylinderscanbeusedtofind theboompositionthatputstheleastpressureontothepin.This positioncanbedeterminedbystrikingthepin,slightlycontracting orextendingtheshearcylinder,thenstrikingthepivotagainand comparingthe“ring”;asboompressureonthepindecreases,the “ring”ofthepinwhenitisstruckbecomeslower.Whenthe“ring” ofthepinbecomesshortandlow,pinremovalismucheasier.
CAUTION!
Useextremecautionwhenadjustingtheboomwiththeshear cylindertofindthepivotpin’spullpoint.
IMPORTANT!
Onthebackofthetractorframeclevisthereisaweldedstrapthat keepstheboompivotpinfromrotating.Oneoftheflatsofthe boompivotpinmustparallelthisstraporthepincannotbecompletelyinserted.
IMPORTANT!
Ifitisextremelydifficulttoinserttheboompivotpinthroughthe alignedtractorframeclevisandboompivotbushings,extendor contracttheshearcylinderstoimprovethealignmentbetweenthe clevisandboom.
CAUTION!
Useextremecautionwhenadjustingtheclevisandboomalignmentwiththeshearcylinders.
Overviewofsafetyinstructions WARNING!
FollowallFederalandminelockout/tagoutregulationsandprocedures.Failuretodosocouldresultinmachinedamageorserious injuryordeathtopersonnel.
CAUTION!
Theshearcylinderisveryheavy.Verifyitsweightcanbesupported.
WARNING!
Replacementoftheshearcylinderinvolvesworkingarounda raisedcutterheadassembly.Neverworkunderanyraisedassemblywithoutproperblocking.Alwaysblockbetweentheraisedassemblyandthetractorframeinadditiontobetweentheraisedassemblyandthefloor.
WARNING!
Thisprocedureinvolvesdisconnectingthehydraulichoses.Alwaysusecautionwhenworkingwithoraroundhydraulicsystems theycanbeunderextremelyhighpressures.
WARNING!
Standclearoftheblockedcutterheadassemblyduringshearcylindercontraction.
WARNING!
FollowallFederalandminelockout/tagoutregulationsandprocedures.Failuretodosocouldresultinmachinedamageorserious injuryordeathtopersonnel.
WARNING!
Thenextstepsdisconnecttheshearcylinderfromthetractor frame.Theshearcylinderisextremelyheavy.Bepreparedtosupportitsweightbeforeperformingthefollowingsteps.
WARNING!
Neverdisconnectahydraulichoseifthecircuitispressurizedorif thereisaloadonthecircuit.Ifahoseisdisconnectedwhilethe circuitispressurizedoraloadisonit,theloadwillfall,causing damagetothemachineorseriousinjuryordeathtopersonnel.
WARNING!
Standclearoftheshearcylinderandtheblockedcutterheadassemblyduringextensionoftheshearcylinder.
WARNING!
Replacementofthecutterheadcenterdruminvolvesworking aroundaraisedcutterheadassembly.Neverworkunderany raisedassemblywithoutproperblocking.Alwaysblockbetween theraisedassemblyandthetractorframeinadditiontobetween theraisedassemblyandthefloor.
WARNING!
Thisprocedureinvolvesdisconnectingandreconnectingthe miner’strailingcable.Alwaysbeawareofwhetherornottheminer isenergized.Neverperformmaintenanceonanenergizedminer.
Overviewofsafetyinstructions _________________________________ WARNING!
Standclearofthecutterheadassemblyandtheunsecuredupper halfofthecenterdrumwhileloweringit.
WARNING!
Whilethispowercableisdetachedfromthemotor,thetrailing cableshouldnotbereconnectedtoenergizetheminer.Damageto theminer,personalinjuryordeathcouldresult.
WARNING!
Federallawrequiresthatminingequipmentelectricalconnections mustbeinspectedbyacertifiedelectricianbeforetheequipment canbeoperated.
WARNING!
Thisprocedureinvolvesattachinganelectricalpowercabletothe cutterheaddrumdrivemotor.Thetrailingcablemustbedisconnectedtosafelyperformthisoperationorseriousinjuryordeath willresult.
WARNING!
Thecutterheadgearcaseisextremelyheavy.Keepbodyparts andotherobjectsfromunderneathituntilitiscompletelysecured.
WARNING!
Useextremecautionwhentrammingtheminerforwardtoposition theboomfaceagainstthegearcase.
WARNING!
Standclearoftheblockedcutterheadandgatheringheadassembliesduringthecontractionofthegatheringheadliftcylinders.
CAUTION!
Whenseparatingthegatheringheadfromthetractorframe,ensurethatthedisconnectedendsoftheconveyorchainsmoothly slideoutofthegatheringhead.
CAUTION!
Whentrammingtheminertowardthegatheringhead,becareful thattheconveyorchainandgatheringheadliftcylindersdonot becomepinchedbetweenthetractorframeandthegathering head.
CAUTION!
Usecautionwhenusingtheliftcylindersandstabilizertoadjust thealignmentoftheclevisandpivotpins.
WARNING!
Thenextstepsdisconnectthegatheringheaddrivemotorfrom theadapterthatlinksittothegatheringheadgearcase.Thegatheringheaddrivemotorisextremelyheavy.Bepreparedtosupport thisweightbeforeperformingthefollowingsteps.
Overviewofsafetyinstructions IMPORTANT!
Thebottomportsonthehighspeedinputcasesarethefilllines. Thetopportsonthehighspeedinputcasesarethechecklines.
IMPORTANT!
Improperconveyorchaintensioncanleadtoexcessivewear,mechanicalproblems,andminerdowntime.Alwayskeeptheconveyorchainatpropertension.
IMPORTANT!
Positionthefootshaftsoitssprocketwillengagetheconveyor chainlinkswhenthechainisreconnected.
IMPORTANT!
Hogringsshouldbeinstalledsothattheirsharppointsare directedclockwise.
WARNING!
Thenextstepremovesthesecondaryplanetarygearringfromthe secondaryplanetarygearassembly.Thesecondaryplanetary gearringisextremelyheavy.Bepreparedtosupportitsweight beforeremovingitfromthesecondaryplanetaryassembly.
IMPORTANT!
Theflatedgeofthecoverlocatedadjacenttothelubricationfitting isthetopofthecover.Orientthecoversothatthelubricantlevel checkplugisonthemotorsideofthecoverandthedrainplugis onthebottom.
WARNING!
Thenextstepremovesthetramcasefromthetractorframe.The tramcase(withsprocketandreachgears)isextremelyheavy.Be preparedtosupportthetramcasebeforeremovingitfromthe tractorframe.
WARNING!
Ensurethattheelectricalcablesandcoolingwaterhosesforthe trammotorarefreefromthetramcasesbeforeattemptingtoremovethetramcasefromthetractorframe.
IMPORTANT!
Theguidewireswillbeusedtopullthetramtracklinksontothe tramcasesprocketafterthetramcaseisinstalled.
WARNING!
Beforeattemptingtoslidethetramcaseintothetractorframe, ensurethatthetrammotorelectricalandwaterconnectionsare outoftheway.Failuretodosomayresultindamagetotheelectricalandwaterconnections.
IMPORTANT!
There-installationprocedureforthetramcaseincludesreinstallationoftheprimaryandsecondaryplanetarygearsandthe trammotor,andreconnectionofthetramtrack.
Overviewofsafetyinstructions _________________________________ WARNING!
Thenextstepremovesthesprocketfromthetramcase.The sprocketisextremelyheavy.Bepreparedtosupportitsweight beforeremovingitfromthetramcase.
IMPORTANT!
Whenthebearingsleeveisinsertedintoposition,theo-ringforms asealbetweenthesleeveandthepiecethatholdsit.
WARNING!
Standclearoftheminerwhenusingthemotortopullthetram trackthroughthetramcase.
WARNING!
Doublecheckthatthelinksofthetramtrackarecorrectlyseated ontothetramdrivesprocket.Improperengaugementofthetram tracklinksontothesprocketcancauseseriousmechanicaldamage.
WARNING!
Thehydraulicpumpmotorisnowdetachedfromthetractorframe andcanberemoved.Thehydraulicpumpmotorisextremely heavy.Preparetosupportitsweightbeforeremovingitfromthe tractorframe.
WARNING!
Thescrubberfan/motorisnowdetachedfromthetractorframe andcanberemoved.Thehydraulicpumpmotorisextremely heavy.Preparetosupportitsweightbeforeremovingitfromthe tractorframe.
WARNING!
Standclearoftheblockedtractorframeduringcontractionofthe stabilizercylinder.
WARNING!
Followallfederalandminelockout/tagoutregulations.Failureto dosocouldresultinmachinedamageorseriousinjuryordeathto personnel.
WARNING!
Thenextstepsrequirecrawlingundertheblocksupportedconveyortailsection.Verifythatthistailsectionisadequatelysecuredbeforeproceeding.
IMPORTANT!
Machinepowermustbedisconnectedduringinstallationofthe currentgenerator.Cuttermotorfeedbackadjustmentisnormally setwiththecrawlertracksofftheminefloor,stabilizerandcutter headdown(machinejack-knifed).Tojack-knifethemachineyou shouldbefamiliarwiththehydrauliccircuitsontheminer,andin particular,thecutterheadcylinderandthesheardown/ maintenancevalve(anti-chatter)operationasdescribedinthehydraulicsectionofthischapter.(Chapter5)
Overviewofsafetyinstructions WARNING!
Eachstabilizercylinderisextremelyheavy.Thenextstepswill removethecylinderfromitstractorframemounting.Beprepared tosupporttheweightfromitstractorframemounting.Bepreparedtosupporttheweightofthecylinderwhenitbecomesfree fromthemounting.
IMPORTANT!
Toobtainmaximumperformance,theduoconesealsmustbeinstalledaccuratelytoinsureuniformloadingatthematingfaces andachieveastablerunningposition.Misalignmentorcockingof sealringsduringassemblycanproducenon-uniformloadingand wobblingofthesealsintheirhousingsresultinginleakagedueto scoringand/orpumpingofdebrispastthetoricrings.Improper installationcanalsoresultinbreakageofthemetalsealrings.
NOTICE!
Impropercareandinstallationofduoconesealscanresultinimmediateleakageorreducedservicelife.
IMPORTANT!
Thetoricmustlieuniformlyinthesealwiththesealingringand paralleltotheseatface.Besurethatthetoricisnottwistedand thatitrestsuniformlyagainsttheretaininglipornotdeeperinone sideoftheseatthantheother.
IMPORTANT!
Donotgetanyoilontotherubbertorics!
IMPORTANT!
Evenasmallpieceoflintcanholdthefacesapartandcauseleakage!
IMPORTANT!
Amixtureofmarkingcompoundandspindleoilisgoodlubefor thegearsunderlightloadsfor2-3revolutionsonly.Checktooth patternsallroundtomakesurethepattern/markingsareuniform.
CAUTION!
Becarefulnottosetfiretoanygreaseorlubricantwhenheating bearings!
IMPORTANT!
Observeallapplicablefireandsafetyregulationswhenheating bearings!
Overviewofsafetyinstructions _________________________________ CAUTION!
Becausegearmaintenancetechniquesarespecialized,they shouldbeperformedonlybyqualifiedpersonnel.
CAUTION!
Donotpowerwrenchtheleadthreadofthelockringinsertuntilit isengagedbyhandturning.Thentightennormally
IMPORTANT!
Anti-seizingcompoundsmaybeusedwiththistypeoflocknut. Washersarenotnormallyrequiredhere,butifassemblydoes,includethemastheyareneededduetohighstresstorque.
WARNING!
Componentsnotmeetingspecificationscanfail,causeserious injury,anddamageequipment.
WARNING!
Donotsubstitutematerialsorcompoundsnotcomplyingwiththe OEMspecifications.Useofnon-OEMsuppliesmayvoidwarranties.
IMPORTANT!
Whenperformingmaintenanceonthemachine,rememberthat fabrication,installation,modificationsoradjustmentsmustbeaccordingtoOEMspecifications.
IMPORTANT!
Airorelectricpowerwrenchesoftheappropriatesizemaybe usedforrunningupjackbolts.Attempttotightenasconsistently aspossibleandremovethepowerwrenchfrequently;donot tightenallatonce.Useastandardtorquewrenchtoverifyfinal torquevalues.
WARNING!
Sometroubleshootingproceduresmustbecarriedoutwiththe coveroftheelectricalcontrollerremovedandsomeprocedures requirethecontrollertobeenergizedduringthetests.Itisextremelyimportantthatyoutakeallnecessaryprecautionstopreventaccidentalelectricalshockwhileworkingwithinthecontroller.AnMSHA-certifiedelectricianmustsuperviseandinspectall workperformed.
IMPORTANT!
Ifbreakerresetoptionisused,seewarningtag(Fig.13).
Overviewofsafetyinstructions Chapter6:Technicaldata IMPORTANT!
Thetechnicaldatalistedinthischapterisforstockmachines only.Customerspecialsmaynotbelisted.
IMPORTANT!
Duetotheapplicationoffastenersbeingsubjecttogreatstresses andheavyorextremevibration,itisimperativethatallboltsbe appliedwithanadequateamountoftorque.Forthisreasonthis listofrecommendedtorquesettingsfordifferenttypesandsizes offastenersusedhasbeencompiled.Thetighteningtorques statedinthesparepartslistshavetobeobserved,aswell,forinstallationandmaintenance.
IMPORTANT!
Useacalibratedtorquewrenchforaccuracy!
NOTICE!
UseonlylubricationfluidsandgreasesapprovedbyBucyrus America,Inc.!ThesefluidsandgreaseshavebeentestedatBucyrusAmerica,Inc.andguaranteereliableoperationofthemechanicalandhydraulicfunctionsofthemachine.
IMPORTANT!
Thelubricationfluidsandgreaseslistedinthesametablecanbe mixed.Otherproductsmayonlybeusedifthesuppliercanguaranteethattheyareequivalent.
Differentlycomposedfluidsandgreasesmustnotbemixedas thismaychangetheconsistency,i.e.themixturecanbecome thinnersothatthelubricationeffectisnotsufficient.Itmayalso bedangeroustouselubricatinggreasesandfluidshavingthe samespecificationbasebutdifferentorigins.
Incaseofdoubt,themanufacturerofthelubricationtobeused shouldbecontactedastothecompatibilityofthelubricationin question.
IMPORTANT!
BucyrusAmerica,Inc.expresslypointoutthattheapprovalofthe listedproductsrelatesonlytothepuretechnicaluseinourmechanicalandhydraulicsystems.Theresponsibilityfortheconstituentsusedinthehydraulicconcentratesliessolelywiththe respectivemanufacturer.
IMPORTANT!
Besuretousethemanufacturer’sinstructionsforuse.
NOTICE!
Whenperformingmaintenanceonthemachine,allusedoiland lubricantsshouldbestoredanddisposedofperyourlocalEPA standards.
Overviewofsafetyinstructions _________________________________ IMPORTANT! Aslubricationtechnologyevolves,manufacturerscontinuetoreformulatetheirproductstoobtainimprovedcharacteristicsregardingwear,waterdispersion,waterabsorption,environmental impactandavarietyofotherperformancecriteria.Whenanapprovedlubricantonthislisthasbeensupersededbyanewformulation,itisrecommendedthatthenewformulationbetestedto ensurecompliancewiththeappropriateBucyrusspecification.At aminimum,astatementofconformancefromthelubricantsuppliershouldbeobtained.
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Storageandtransport Storageandtransport Thischaptercontainsimportantinformationonthecorrectstorageand transportoftheContinuousMiner.Storageproceduresaregeneral. Forspecificproceduresforyourenvironment,contactBucyrusAmerica,Inc.Engineering.
Observanceoftheinstructionsandtipswillincreasetheservicelifeand availabilityofthemachine.Youwillalsobeabletocarryoutthetransportworkquickerandmoresafely.Carefulattentiontothepointsin thischapterwillhelpyoutosimplifyyourday-to-daywork.
Storage Componentscoatedwithtemporarycorrosioninhibitorareprotectedfor approximatelysixmonths.
Beforedelivery,thehydraulicfunctionsaretestedandthehydraulic pressuresarepresettoOEMspecifications.
Storageofthemachineandspareparts Storetheequipmentindoorsorcoverwithatarpaulintoprotectagainst directexposuretosunlight.
Protecttheequipmentandallsparepartsstoredoutdoorsagainst moistureanddirt,e.g.usingtarpaulins.
Protectthehydraulicplugconnectorsandtheconnectorsofthe electricalcableswiththecapsandplugssupplied.
Duringshort-termstorage(approximately4weeks)ofequipment outdoors,butattemperaturesabovefreezing,electricalcomponents neednotberemoved.Suchcomponentsmustbeparticularlyprotectedagainstexcessivetemperatures,dirt,andmoisture.
Iftheequipmentistobestoredmorethansixmonths,thefollowing lubricationandcorrosioninhibitingproceduresmustbefollowed:
■ Ifthecylinderrodsareexposed,therodsmustbecoatedwitha corrosioninhibitingfluid.
■ Completelyfillthehydraulicoiltankwithoil.
■ Fillallgearcase(s)tothemaximumfilllevel.Thegearcase(s) mustberotatedmonthlytoensurethattheinteriorofthegearcase remainslubricated.
■ Lubricateallgreasepoints(seetheMaintenancesectionin Chapter5ofthismanual).
■ Completelydrainthewatersystemandrefillwitha50/50antifreeze/watersolution.Pumptheantifreezemixthroughthesystem untiltheantifreezemixcomesoutthewatersprays.ENSURE THATTHESYSTEMISCOMPLETELYPURGEDANDNO WATERORAIRPOCKETSEXIST.
■ Theequipmentmustbestoredinawellventilated,dryroom.Do notstoreoutdoors.
Storageandtransport ForcedPotatoelectroniccomponentshavethefollowingstorage requirements:
■ Graphicdisplaysmustbestoredattemperaturesabove14°F (-10°C)
■ Powersuppliesmustbestoredattemperaturesabove -3°F(-20° C)
■ Othercomponentsmustbestoredattemperaturesabove -13°F (-25°C)
Thetractiondrivesshouldbestoredat -10to50°C(14to122°F).
Majorproblemswithcondensationcanoccurifadriveisstoredin acoldenvironmentandisthentakenintoadeepminewherethe temperatureismuchhigher.Eventhoughthehumiditymaybeat anacceptablelevel,condensationwilloccuronthecolddrive.Slight exposuretoacondensingenvironmentisnotharmfulprovidedthe driveiscompletelydrybeforeelectricalpowerisapplied.
Afterastorageperiodofapproximatelytwoyears,arandomsample inspectionmustbeperformedtodeterminewhetherthemeasures takenandthemethodofstoragehaspreventeddamage. Onrequest,theinspectioncanbecarriedoutbyBucyrusAmerica,Inc.
Evenwithproperstorage,sealsandhosesaresubjecttonatural ageing.Donotusethesepartsiftheyhavebeenstoredformorethan twoyears.
Instructionsonthestorageofconcentratesforhydraulicfluidscanbe found,ifrequired,inchapter6inthisoperatingmanual.
IMPORTANT! Takecaretoinsurethatnewmaintenancesuppliesarestored separatelyfromexistingstockandthatremovaltakesplaceonthe “firstin,firstout”principle.
Long-termstorageofsparecomponents Ifacomponentistobestoredmorethansixmonths,thehydraulic componentmustbecompletelyfilledwithacorrosioninhibitingfluid. Fillthehollowareasofhydrauliccomponents(e.g.thepistonchambers)inhorizontalposition(portsfacingupwards)untiltheystartto overflowthensealtheportswithplasticorsteelplugs.
Storetheelectricalequipment,electroniccomponents,sparepartsof rubberorplastic – suchassealsandhoses – andhydraulicfluidsonly inclosedroomsattemperaturesof60°F(15°C)to77°F(25°C).
Refertothemotormanufacturer’sstorageprocedureguideinyour BucyrusAmerica,Inc.partsmanual.
Rotatetheimpeller1-1/4turnoncepermonthtopreventdimplingofthe motorbearingsrollers.
Inordertopreventplasticdeformationofthesealelements,cylinders mustbestoredinanuprightposition.Somecylindersmustberemoved sothattheycanbestoredupright.
Transport Loadunits:dimensionsandweights
Observethetransportsheetsforthemachineandspareparts.They containinformationon:
■ dimensions,
■ weights,
■ liftingpoints,etc.
Additionalinformationonthedimensionsandweightscanbefoundin chapter6andintheliftingweightguide(Table1)inthisoperatingsection.
WARNING!
Useonlyloadhandlingdevicescomplyingwiththetechnicaland legalregulationsforthetransportofloads.Youcouldbeseriouslyinjuredorevenkilledbyfallingloads. Useonlysuitableloadhandlingdevices.
Table1:LiftingweightsofContinuousMinerAssemblies
Wheneverpossible,allremovalsshouldbeaccomplishedusingan adjustableliftingbeam.Allsupportingmembers(chainsandcables) shouldbeparalleltoeachotherandasnearlyperpendicularaspossibletothetopoftheobjectbeinglifted.
Whenitisnecessarytoremoveacomponentonanangle,remember thatthecapacityofaneyeboltdiminishesastheanglebetweenthe supportingmembersandtheobjectincreases.Eyeboltsandbrackets shouldneverbebent.
Whenaneyeboltisprovidedtoliftacomponent,useittoliftonlythat component.
Youcouldbeseriouslyinjuredorkilledasaresultoffallingloads. Donotusetheeyebolttoliftthecomponent and itsrelatedassemblies. removalandinstallationof heavycomponents
WARNING!
Storageandtransport Transportenvironment Beforetransportingtheequipmentattemperaturesbelowfreezing,all hydrauliccomponentsoperatedwithemulsion(HFAEorHFAS)must becompletelydrainedandthenfilledwithacorrosioninhibitor/frostproofingfluid.
Transportofequipmentattemperaturesbetween -6°F(-21°C)and40° F(-40°C)isonlypermissiblewhencertainmeasuresweretakento meettheseconditionsatthedesignandmanufacturestages.Nevertheless,theindividualpartsanddevicesofthisequipmentmustnotbe subjectedtosuddenimpactloadsatsuchlowtemperaturesandmay onlybeloadedstaticallyorquasi-statically.
Duringtransportofthisequipmentwithfloor-mountedvehiclesatsuch lowtemperatures,measuresmustalsobetakentoensurethatthe partsanddevicesarenotsubjectedtosuddenimpactloads.Atvery lowtemperaturesandonpoorroads,thetransportvehiclespeedmust thereforebelimitedtoamaximumof15mph(25kph)fortrucktransport.
Electricalandelectroniccomponentsmustbeprotectedagainstharmful environmentalinfluencesbyasuitablepackaging.Theelectricalcables remainintheequipment.Theymustbecarefullyprotectedagainst transportdamageandsoilingoftheconnections. temperaturesbelowfreezing
Installation Installation Pointstoobservepriortoinstallation
Whoisallowedtocarryoutinstallation?
Installationisonlyallowedtobecarriedoutbypersonnelhaving receivedadequatetrainingtoperformthistask.
Workon:
■ thesafetycomponents(pressurereliefvalves,fireextinguishing equipmentetc.)
■ theelectricalequipment(controlunits,signalingdevices,etc.)
■ thehydraulicequipment(cylinders,directionalcontrolvalves, hosesetc.)
shouldonlybecarriedoutbyBucyrusAmerica,Inc.serviceengineers orbyspeciallytrainedpersonnel.
Whichtoolsarerequiredforinstallation? NospecialtoolsarerequiredtoputtheContinuousMinerintoservice. Variousitemsofauxiliaryequipmentandmachinesmayberequiredat thepointofinstallation.
Theseinclude:
■ hoistswithadequateliftingcapacity
■ meansofattachmentwithadequateliftingcapacity
■ unloadingdockandcribblocks
■ jackswithadequateliftingcapacity
■ impactwrenches,includingaccessories
toolbox
installationplan
Notesoninstallation CAUTION! SeriousdamagecanbecausedtotheContinuousMinerasa resultofincorrectinstallation.Theunitshouldthereforeonlybe installedundertheinstructionofspecialistsfromBucyrus America,Inc.
BucyrusAmerica,Inc.ContinuousMinersareshippedtothecustomer sitepercustomerpreference.TheContinuousMiner canbeshippedto thecustomersiteasacompletemachineorincomponentsections. Thisdependsonmineconditions,transportationweightrestrictions/ requirements,orsize/weightrestrictionsatthemine.
reassemblyinstructions
IMPORTANT! Thesequenceofoperationsduringinstallationmustbeadaptedto theindividualconditionsprevailingatthesite.Beforestartingthe workadetailedlistofstepstobetakenwithrespecttotransport andassemblyshouldbepreparedandacorrespondingplanestablished.
Whenassemblyisrequiredaftershipmentofthemachine,theassistanceofspecialistsfromBucyrusAmerica,Inc.isrecommended.This willinsurethatthecorrectinstallation,safetyandmaintenanceproceduresarefollowed.
Pre-installationchecklist NOTICE! Themachinewasinspectedpriortoshipmentfromthefactoryto ensureproperfunctioningandinstallationofallcomponents. However,toensurethatnotransitdamagehasoccurred,the followingpre-startupchecksshouldbeperformed:
■ visuallyinspectallcylinders,gearboxes,tanks,andhydraulic componentsforleaksordamage.
■ visuallyinspectallelectricmotorsandelectricalcomponentsfor signsofdamage.
■ checkthefulllengthofthetrailingcablefordamage
■ ensurethatthetrailingcableisproperlysuspendedacrossintersectionsandthatthetrailingcableclampattheContinuousMiner issecure
■ cleananyforeignmaterialfromtheoptionaloperator’s compartment,conveyor,andgatheringpan
■ startupthemachineandcheckforcorrectoperationofallstop switches.
■ performdailymaintenance
■ visuallyinspectallhydraulichosesandelectricalcablesfor damage
■ checksafetyprovisionsforoperationalconditiononfire suppressionsystem
■ startupthemachineandcheckforcorrectoperationofE-stopand machinestopbuttons
■ checkthatallcoversandguardsareinplaceandsecure
■ checkthatalltagsandinstructionlabelsareinplaceandsecure
■ checkthatoperator’scanopy(optional)issecureandinplace
■ startthemachineandallowthehydraulicsystemtowarmupfor five(5)toten(10)minutes
■ checkhydraulicsystempressures(refertothehydraulicschematic suppliedforyourparticularmachineforpressuresettings)
■ checkandoperateallcontrolhandlesandremoteswitchesto ensureallmachinefunctionsareoperatingproperlyandarein neutralposition
■ checkthetensionoftheconveyorchainandcrawlerchain
machinestopbutton
Safetyfeatures NOTICE!
Theoperatormustbecomefamiliarwithallthesafetyfeaturesand theirlocationonthemachinepriortoinstallationoroperation.
Safetyfeaturesinclude:(ReferenceFig.6)
Themachineisequippedwithamachinestopbuttonlocatedonboth sidesoftheminer.Themachinestopbutton(s)areusedtobreakthe controlcircuitonlyinemergencysituations,stoppingallmotors.Strikingwithasmallamountofforcewillactuatethemachinestopbutton.
canopy/cab(optional)
firesuppression
firesprays
Themachinemaybeshippedfromthefactorywithaprotectivecanopy/ cab(optional).Ensurethatthecanopy/cabisinplaceandsecureatall timestoprotecttheoperatorfromfallingdebris.
Themachinemaybeequippedwithfiresuppression(remote)actuators.Ifequipped,thelocationmayvary.Thisparticularsuppression systemispneumaticallyactuatedandextinguisheswithdrychemicals. Toactuatethesystemfromtheactuators,pullthesafetypinandstrike downwardontheplunger.Immediatelyaftertheplungerisstruck,dry chemicalwillbedispensedthroughoutthemachine.Thefiresuppressionsystemmustbecompletelyrechargedwithdrychemicalsand expellantsafterithasbeenactuated.
WARNING! Ifeitherofthefiresuppressionactuatorsisactuated,thesystem mustbecompletelyrechargedwithdrychemicalsandexpellants.
Watercanbedirectedtothefirespraynozzles manuallyfromthe firesprayvalveabove theswitchboxintheoperator'scompartment or bythefiresprayvalveonthelefthandside ofthemachine.
Onradiounits,anelectronicallyactuated solenoidisusedtoactuate thefirespraysystem fromtheremoteposition.
IMPORTANT!
Thefiresprayvalvemustbemanuallysettothenormalposition beforethedustsuppressionwaterspraysystemcanbe operated.
CAUTION!
Theminesupplywaterpressureatthemachineshouldnot exceed500psiandshouldsupply20gpmminimumforcooling.
Theremotefiresprayactuatorlocatedonthe mainfeedbehindthe minerisusedtoactivate thefirespraywhenthereisafireand powerhas beenturnedoff. Simplyturningthevalveallows'pilot'oil to feedintothesmallhosesecuredwithinthevalve assemblyand throughthemainfeedlineintothe miner,whereitcontactsa solenoidthatactivatesthefirespraysystem.
TheContinuousMinermaybeequippedwithanoptionaldustsuppressionpackage(scrubber).ThedustsuppressorallowstheMineroperatortousefaninducedventilationattheface.Thefansuctiondrawsin thedustandliberatedmethanefromtheintakeduct(s).Thedustladen airisthendrawnthroughthescrubberscreen,whichisconstantly floodedwithwaterspray.Thedirtywateristhenremovedfromtheair streambyade-misterwhichislocateddirectlybehindthescrubber screen.Thedirtywaterflowsdowntoasumptankwhereawaterpoweredjetpumpemptiesthesumpanddumpsthedirtywaterontothe conveyororgatheringpan.Theclean,dryairexitsthede-misterandis dischargedintothemineatmosphereattherearoftheminer,diffused downwardandtowardstheribtopreventcoalfinesfrombeingblown ontheoffsideshuttlecaroperator.
Themachineisequippedwithguardsandcoverstoreducethepossibilityofpersonnelcomingincontactwithrotatingormovingparts.All guardsandcoversmustbeinstalledandsecurelyfastenedduringoperation.
DANGER! Donotoperatethemachinewithanyoftheguardsorcovers removed.Youorotherpersonnelcouldbeseriouslyinjuredfrom movingorrotatingparts.
Everyswitchontheoperator’scontrollercasethatengagesafunction (pumpstart,cutterstart,etc.)isprotectedfromaccidentalactivationby acover.
Themachineisequippedwithamethanemonitorthatdetectsthepresenceofmethaneinthemineatmosphere.Whentheminerisbeing poweredup,themonitorlooksformethanebeforeanyotherfunctionis energized.Ifthemethanemonitordetectsalevelofmethanewithina presettolerance,themethanemonitorrelaywillcloseandpowerwillbe suppliedtotheotherfunctionsonthemachine.(Themachinecanhave anoptionaldualsnifferheadordualreadout.)
Fig.6:SafetyfeaturesontheContinuousMiner
Machinestop (locationtypical)
Safety covers
Methane monitor display
Manualcircuit breakerreset (optional)
Panicbar/ machinestop
Operator’s station
Fig.7:OverviewoftheContinuousMiner
Cutter boom
Conveyor boom
Crawler assembly
Gatheringhead assembly
Operation Operation Thischaptercontainsimportantinformationontheoperationand maintenanceofthemachine.Italsoincludesinstructionsonthe replacementofwearparts.
Readthischaptercarefullyandthoroughly.Inparticular,observethe safetyinstructionsinchapter2“Yoursafety”.
HowtooperatetheContinuousMiner DANGER! Incorrectoperationendangersyourselfandothers!Incorrect operationofthemachineisoftenthecauseofveryserious accidents!Operatetheunitonlywhenyouhavebeensufficiently trainedonthemachineandhavereadandunderstoodthis operatingmanual.Shouldanythingbeunclear,pleasecontact yourimmediatesupervisor.
WhoisallowedtooperatetheContinuousMiner?
TheContinuousMinerisonlyallowedtobeoperatedbypersonswith adequateknowledgeofthecompletemachine.
Thisalsoincludes:
■ whatsafetydevicesareinstalledonthemachine.
■ wherethesesafetydevicesarelocated.
■ howthesesafetydevicesaretobeoperated.
Whencanoperationbestarted? Operationmustnotbestarteduntilthesafeconditionandproper functionofthecompletemachinehasbeencheckedandthedaily maintenanceoperationshavebeencarriedout.
NOTICE! Beforebeginningcuttingoperations,carefullyunloadthetrailing cableprovidingenoughslackandplacingitwhereitallows adequateclearanceforsafemaneuverabilityoftheminer.
TheBucyrus25M0ContinuousMinerisanelectricallypowered,drum type,radioremotecontrolledminer.
TheMinerismountedoncrawlertracksthatprovidefullmobilityanda sharpturningradiusinbothroomandpillarandlongwalldevelopment miningplans.Thecuttingheadsupportframeminesmaterialfromthe solidfaceusingachainlessrotatingdrum,andaCLA-typegathering head.Thehighspeedconveyorefficientlymovesminedmaterialtoa haulagesystembehindtheMiner.
Controlsandindicators Operator’sstation
WARNING!
TheContinuousMinerisradioremotecontrolled.Manualoperationisgenerallyfortroubleshootingandmaintenanceunderroof support.OperatingtheContinuousMinermanuallyfromtheOperator’scasemayresultinseriousinjuryordeath.
Theprimarycontrolsforthemachinearenormallylocatedatthe operator’sstation(Fig.8)ontherighthandsideofthemachinenear therearbumper.
Theexplosionproofoperator’sstationhousesthecontrolsandindicatorsusedinthenormaloperationofthemachine.Mountedinsidethe casearethemaincircuitbreaker,auxiliarycircuitbreaker,control transformer,methanemonitorrelay,electricalmeteringpackage,controlbreakers,headlightswitch,radio/manualswitches,manualstart/ stopswitches,andbridgerectifiers.Allcontrolbreakersarelocated withinthiscase,behindthesmallaccesscoverlocatedabovethetrailingcableentrance.Thetrailingcableentersintothisenclosureatthe bottomleftcornerfacingthecase.Themachinestopismountedonthe enclosureandoperatesthepumpstopswitchtoshutthemachine down.
Themanualcircuitbreakerresetlevers(optional)arelocatedatthe frontbottomofthecase.
Fig.8:Operator’sstation
tramcontrollevers(optional)
Theoptionaltramcontrollevers(Fig.9)controlthespeedanddirection ofeach(leftandright)crawlerdrive.Thetramcontrolleverscanbe usedtogether(totramstraightforwardorstraightbackwards),inoppositedirections(forfastturns),orindividually(forslowturns).Whenin manualmode,the“TRAMDEADMAN”switchmustbedepressedand thetramcontrolleversinthecenter(neutral)position,priortostarting thepumportrammotors.
NOTICE! TheContinuousMinerhasskidtypesteering:itiscapableofturningwithinitsownlimits.
CAUTION! MANUALONLY:TheContinuousMiner’stramandsteeringspeed isvariable.Thismeansthatthefartherthetramhandleis actuatedthefastertheContinuousMinerwilltravelorturn.The tramlevermustbemovedslowly.Movingthetramleverstoo quicklymayresultinsevereinjuryorlossofcontrol.
IMPORTANT! Oncethetram/steeringcontrolleverisreleasedbytheoperatorthe controlleverautomaticallyreturnstothecentered(neutral)position.
Totramforward,pushthetramleverslowlyforward,awayfromtheoperator.Totraminreverse,pulltheleverslowlyback,towardtheoperator.Thefurthertheleverispushedorpulled,thefasterthetramming. Whenreleased,thetramleverreturnstothecentered(neutral)position.
Totramstraightforward,pushbothleversforwardatthesametime.To tramstraightback,pullbothleversbackatthesametime.
Toturnleft,pulltheleftcrawlerleverbackandpushtherightcrawler leverforward.Toturnright,pushtheleftcrawlerleverforwardandpull therightcrawlerleverback.Thespeedoftheturnisdeterminedby whethertheleversareoperatedatthesametimeorseparately.
Fig.9:Tramcontrollevers(optional)
Pressingthemachinestop(Fig.10)willshutdownthepump,causing theminertoshutdown.Torestartthemachineafterstrikingthemachinestop,follownormalpumpstartupprocedure(seeStartprocedure inthischapter).
Fig.10:Machinestop
Electricalswitches Theelectricalswitches(Fig.11)thatcontrolthemachineoperationare agroupofpushbuttonswitcheslocatedonthecontrolcase.
WARNING! ManualoperationoftheContinuousMinerisnotallowedfor productionoperationunlesstheminerhasanoperator’spitand canopy.Manualoperationisgenerallyfortroubleshootingand maintenanceunderroofsupport.OperatingtheContinuousMiner manuallyfromtheoperator’sstationmayresultinseriousinjury ordeath.
The“PUMPSTART”switchstartsthepumpmotor.Tostartthemotor, depresstheswitch.
The“PUMPSTOP”switchstopsthepumpmotor.Tostopthemotor, depresstheswitch.
Startingthecuttermotorisatwo-handstart:pushthe“PUMPSTART” andthe“CUTTERSTART”switchatthesametime.Theleftcutter motorwillstartfirstand,afterapresettime,therightcuttermotorwill start.
The“CUTTERSTOP”switchshutsdownbothcuttermotors.Both motorsstopwhenthe“CUTTERSTOP”switchisdepressed.
Theconveyormotorscannotbestarteduntilthepumpmotorisstarted. Depressingthe“CONVEYORFWD”switchstartstheconveyormotors. Theforwarddirectionoftheconveyorchainisalwaysawayfromthe cutterhead.
Theconveyormotorscannotbestarteduntilthepumpmotorisstarted. Depressandholdthe“CONVEYORREV”switchtostarttheconveyor motors.Whentheconveyormotorsarerunninginreverse,theconveyorchainismovinginthedirectionofthecutterhead.Theconveyor willcontinuetoruninreverseuntilthe“CONVEYORREV”switchis released.Theconveyorcannotbestartedintheforwarddirectionuntil apresetamountoftimehaselapsedfromrunningtheconveyorinreverse.
“CONVEYORSTOP” Depressingthe“CONVEYORSTOP”switchwillstoptheconveyormotorswhentheconveyorisrunningforward(awayfromthecutterhead).
Thepumpmotormustberunningbeforethescrubbermotorwillstart. Depressandholdthe“SCRUBBER”switchtostartthescrubbermotors andtoenergizethescreensprays.Tostopthescrubbermotor,release the‘SCRUBBER”switch.
The“TRAMDEADMAN”switchmustbedepressedandheldtotram. Releasingthe“TRAMDEADMAN”switchwillstoptrammingfunctions.
The“LIGHTS”switchhasthreepositions:“MANUAL”,“OFF”,AND “RADIO”.The“OFF”positionturnsalllights,arealightsandheadlights, off.Whenthelightswitchisturnedtothe“MANUAL”position,the headlightsandthearealightswillbothturnon.whenthelightswitchis turnedtothe“RADIO”position,thearealightsareilluminatedandthe headlightscanbeturnedonandoffwiththeradioremote.
The“RADIO/MANUALSW.1”switchputsthemachineundermanualor radiocontrol.
The“RADIO/MANUALSW.2”switchconnectsmotorcontroltothe manualpushbuttonsandisolatescontrolfromtheradioreceiver.Inthe radioposition,“RADIO/MANUALSW.2”isolatesthepushbuttonsand connectsmotorcontroltotheradioreceiver.
Thecontrolbreakerswitchesturnthebreakersonandoffandarealso usedtoresetabreakerthathastripped.Allcontrolbreakersareturned onbypushingthebuttoninandareturnedoffbypullingthebuttonout. Ifabreakertrips,thebuttonmustbepulledouttoresetthebreaker, thenpushedintoturniton.Thecontrolbreakersmayvaryandcanbe identifiedbythelabelsonthefrontoftheoperator’scase.
Fig.11:Electricalcontrolswitches
“PUMP START” “CUTTER START” “CONVEYOR FWD”
“CUTTER STOP”
“PUMP STOP”
Circuit breaker resetpanel
“RADIO/ MANUALSW.1”
“RADIO/ MANUALSW.2”
“SCRUBBER”
“CONVEYOR STOP”
“LIGHTS”
“TRAM DEADMAN”
“CONVEYOR REV”
“LEFTCUTTERMOTOR” and “RIGHTCUTTERMOTOR” “LEFTCONVEYORMOTOR” and “RIGHTCONVEYORMOTOR”
Electricalmeteringpackage(optional)
Theoptionalelectricalmeteringpackage(Fig.12)consistsofagroupof metersthatmonitorcurrentdrawonthemotors,machinevoltage,and cutterandconveyorhoursofoperation.
The“LEFTCUTTERMOTOR”and“RIGHTCUTTERMOTOR” ammetersmonitorthecurrentdrawbythecuttermotors.Duringnormal operation,thetwometersshouldindicateapproximatelythesame currentdraw.Ifonemeterconsistentlyreadshigherthantheother meter,shutdownthemachine(seeShutdownprocedureinthischapter) andcontactMaintenance.
The“LEFTCONVEYORMOTOR”and“RIGHTCONVEYORMOTOR” ammetersmonitorthecurrentdrawbytheconveyormotors.During normaloperation,thetwometersshouldindicateapproximatelythe samecurrentdraw.Ifonemeterconsistentlyreadshigherthanthe othermeter,shutdownthemachine(seeShutdownprocedureinthis chapter)andcontactMaintenance.
The“MACHINEVOLTAGE”voltmeterindicatesthecontrolcircuitvoltage.Duringnormaloperation,theindicatorshouldstaybetween855 and1,045volts(950V±10%).Shouldthemeterindicatehighorlow voltage,shutdownthemachine(seeShutdownprocedureinthis chapter)andcontactMaintenance.
The“CUTTERHOURS”meterindicatesthehoursofrunningtimefor thecutterheadmotors.
The“CONVEYORHOURS”meterindicatesthehoursofrunningtime fortheconveyormotors.
Fig.12:Electricalmeteringpackage(optional)
“LEFTCUTTER MOTOR”ammeter
“LEFTCONVEYOR MOTOR”ammeter
“MACHINEVOLTAGE” voltmeter
“RIGHTCUTTER MOTOR”ammeter
“RIGHTCONVEYOR MOTOR”ammeter
“CUTTER HOURS”meter
“CONVEYOR HOURS”meter
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circuitbreaker
Thecircuitbreakeristhemaincircuitbreakerforthemachine.The circuitbreakerhastwo(2)positions:"OFF,"tode-energizethemachine'selectricalsystemsand"ON,"fornormaloperation.Thecircuit breakershouldbeinthe"OFF"positionbeforethemachineisserviced orshutdown.
manualcircuitbreakerreset (optional)
WARNING!
Themachinecircuitbreakerde-energizestheelectricalcontroller andmotors.However,electricalpowerisstillpresentinsidethe connectionboxtothecircuitbreaker.Ifthecircuitbreakerinside theconnectionboxrequiresservice,thetrailingcableshouldbe disconnectedfromthepowercenter.
Themanualcircuitbreakerresetlevers(Fig.13)arelocatedbelowthe electricalswitchesattheoperator’scontrolstation.Thecircuitbreaker tripswhentheelectricalsystemisoverloadedorshorted.
WARNING!
Oncethebreakerhastripped,itwillnotstayinthe“ON”position withoutfirstbeingmovedtothe"RESET"position,andthento "ON".
Toresetthecircuitbreakermanuallyproceedasfollows:
Movetheselectorto“RESET”positionandmovethecircuit breakertofull“OFF”position.
Movetheselectortothe“ON”positionfornormaloperation.
Fig.13:Manualcircuitbreakerreset
“MAINBREAKER”reset (shownwithpinout)
“AUXILIARYBREAKER” reset(notshown)
machinestop/e-stop
methanemonitor
TheContinuousMinerisequippedwithanmachinestop/e-stopbutton (Fig.14)locatedontheleftandrightsidesofthemachine.Themachinestop/e-stopbuttonisusedtobreakthecontrolcircuitinemergencysituations,stoppingallmotors.Strikingwithasmallamountof forcewillactuatethemachinestop/e-stop.
WARNING!
Bepreparedforasuddenstopwhenthemachinestop/e-stopis actuatedduringnormaltrammingofthemachine.
Machinestop/ e-stop(2) (locationtypical)
Themachineisequippedwithamethanemonitoringsystem(Fig.15) which,whenenergized,maintainsacontinuouscheckonmethanegas concentration.ThismachinehastwoLEDindicatordisplayswhich showthepercentageofmethanegasinlargernumerals.
Consultthemanufacturer’smanualandliteratureintheBucyrusparts bookforyourmachineforthesetup,operation,andmaintenanceofthe methanemonitoringsystem.
IMPORTANT! Itistheresponsibilityofthecontinuousminerowner/operatorto knowandfollowallregulationsregardingmethanemonitoring requirements,including,butnotlimitedto,dailyoperation,maintenanceandtesting.
Fig.15:Methanemonitordisplay
Methanemonitor display
Fig.14:Machinestop/e-stop
radioremotecontrol
Whenoperatedbyaradio(Fig.16),aportablewirelesstransmitter withauniquecodefeaturesendsradiocommandstoareceiverinthe switchconsoleviaawhipantennasetup.Thesmallwhipantennae intercepttheradiosignalswhichthereceivertranslatesintoelectrical commandstovariouselectricalcircuitstoperformthefunctionselected.Thesecircuitsenergizesolenoidswhichactuatepilot-valves, switches,orrelayscontrollingaspecificmechanical,hydraulic,orelectricalfunction.
Thereareeightselectablefrequencieswhichpermitseachoperatorto activateonlyhisdesignatedminer,allowingseveralremote-controlled minerstooperateinthesameareawithoutgettingtheirradiosignals crossed.Inaddition,animproperlydecodedradiosignalwillautomaticallyshutdowntheminer.
Alwaysrefertothespecificradioremotecontroloperationmanualsuppliedwithyourspecificmachinefordetailsandoptionsontheradio remotecontrol.
IMPORTANT! Refertotheradioremotecontroloperationmanualsuppliedwith yourmachineforinformationregardingtheoperationofyourspecificremotecontrol.
Topview
Fig.16:Radioremotecontrol(typical)
Theoptional“LOWOIL”light(Fig.17)illuminateswhenthehydraulicoil levelinthemachineislow.Ifthe“LOWOIL”lightcomeson,shutdown themachine(seeShutdownprocedureinthischapter)andcheckthe hydraulicoillevel.Ifoilisneeded,addoil(seeprocedureinMaintenancesectionofthischapter).
Fig.17:“LOWOIL”light(optional)
“LOWOIL”light(optional)
“LOWOIL”
Valvebank Themanuallyoperatedvalvebank(Fig.18)islocatedonthenearthe operator’sstationandisusedtooperatetheminerduringmaintenance andtroubleshootingfunctionswhileundersupportedroof.
NOTICE! Onceahydrauliccontrolvalvehandleisreleasedbytheoperator, theleverwillautomaticallyreturntothecentered(“HOLD”)position.
Thefirstleverfromtheoperator’sleft,“STABILIZER”,controlsthecylinderthatraisesandlowersthestabilizershoe.Toraisethestabilizer shoeoffofthefloor,pullthelevertowardtheoperator.Tolowerthe stabilizershoetothefloor,pushtheleverawayfromtheoperator.
Thesecondleverfromtheoperator’sleft,“CONVEYOR”-RAISE/ LOWER”,controlsthecylindersthatraiseandlowertheconveyor boom.Toraisetheconveyor,pullthelevertowardtheoperator.To lowertheconveyor,pushtheleverawayfromtheoperator.
Thethirdleverfromtheoperator’sleft,“CONVEYOR”-LEFT/RIGHT, controlstheconveyorswingcylinders.Toswingtheconveyorboomto theleft,pushtheleverawayfromtheoperator.Toswingtheconveyor boomtotheright,pullthelevertowardtheoperator.
Thefourthleverfromtheoperator’sleft,“GATHHD”,controlsthecylindersthatpositionthegatheringhead.Toraisethegatheringhead, pushtheleverawayfromtheoperator.Tofloatthegatheringhead, pullthelevertowardtheoperator.
Thefifthleverfromtheoperator’sleft,“CUTTINGHD”,controlsthecylindersthatraiseandlowerthecuttinghead.Toraisethecuttinghead, pullthelevertowardtheoperator.Tolowerthecuttinghead,pushthe leverawayfromtheoperator.
Gaugepanel(optional)
Theoptionalgaugepanel(Fig.19)consistsofgaugesusedtomonitor waterandhydraulicpressurethroughouttheminer.
The“MINERWATERPRESSURE”gaugemonitorsthepressureatthe maindistributionmanifoldforthewatersystemontheminer.Seethe minerwaterpressurecircuitinthehydraulicsectionofthischapterfor furtherinformation.
The“MAINPRESSURE”gaugeisusedtomeasurethepressurein mainflow - primarypressurecircuit.Seethemainflow - primarypressurecircuitinthehydraulicsectionofthischapterforfurtherinformation.
The“PILOTCIRCUITPRESSURE”gaugeisusedtomonitorthesupplypressureforallpilotfunctions.Seethepilotpressurecircuitinthe hydraulicsectionofthischapterforfurtherinformation.
The“GHFLOATPRESSURE”gaugemonitorsthepressureoftheextendportofthegatheringheadfloatcylinders.Thispressuregauge displaysdifferentreadingsdependingontheoperatingconditionofthe cylinders:
■ Withthegatheringheadworkingsectionofthemaincontrolvalve intheGatheringHeadUp(GHU)positionandthecylinderfullyextended,thegaugewilldisplaythesettingofthereliefvalve“CR” andthevalvecanbeadjustedusingthegauge.
■ Withthegatheringheadworkingsectionofthemaincontrolvalve intheGatheringHeadFloat(GHD/F)position,thegaugecanbe usedtoadjustthepressureinthegatheringheadfloatcounterbalancevalve“VR”andthevalvecanbeadjustedusingthegauge.
■ Withthegatheringheadworkingsectionofthemaincontrolvalve inthecenterposition,thegaugedisplaysthepilotpressureatthe valvemanifold.
■ Thegaugewillalsodisplayhighpressuresseenbythegathering headcylindersduringnormaloperation.
The“ACCUMULATORPRESSURE”gaugeisusedtomonitoraccumulatorpressure.Thepurposeoftheaccumulatoristostorethenecessarypilotpressuretoallowremoteoperationofthefiresuppression andbreakeron/offcontrolvalveswhenthepumpisnotoperational. Theaccumulatorpressureshouldcloselytrackthepilotcircuitpressure.Iftheaccumulatordoesnotholdpressurewhenthepumpis shutdown,callmaintenance.Seetheaccumulatorpressurecircuitin thehydraulicsectionofthischapterforfurtherinformation.
The“SHEARDOWNPRESSURE”gaugeisusedtomonitorthepressureofthecuttingheadcylindercircuitduringsheardownoperations. Seethesheardown/maintenance(anti-chatter)valveinthecutterhead cylindercircuitinthehydraulicsectionofthischapterforfurtherinformation.
Fig.19:Gaugepanel
“MINERWATER PRESSURE”
“MAIN PRESSURE”
“PILOTCIRCUIT PRESSURE”
“ACCUMULATOR PRESSURE”
“GHFLOAT PRESSURE” “SHEARDOWN PRESSURE”
waterregulatorassemblyscrubberspraygauge andjetpumpgauge
Thewaterregulatorassembly(Fig.20)islocatedinthelefthandrear ofthemachinenearthescrubber.Thewaterregulatorassemblyincludesthescrubberspraygaugeandthejetpumpgauge.Thescrubberspraygaugemonitorsthewaterpressureofthescrubbersprays. Thejetpumpgaugemonitorsthewaterpressureofthejetpump.ConsulttheschematicintheBucyrusAmerica,Inc.partsmanualsupplied withyourmachine.
Fig.20:Waterregulatorassembly
firesuppressionsprayvalvepilotoperated (optional)
Thepilotoperatedfiresuppressionsprayvalve(Fig.21)istypicallylocatedonthelefthandsideofthemachine.Thispilotoperated,2-way, 2-positionvalvecanalsobeoperatedmanually.Thespoolisdetented sothatitstaysintheopenpositionuntilitismanuallyclosedbypulling ontheknob.
Fig.21:Firesuppressionsprayvalve-pilotoperated
Firesuppression sprayvalvepilotoperated
Jetpump pressuregauge
Scrubberspray pressuregauge
firesuppressionsprayvalvemanuallyoperated
Themanualfiresuppressionsprayvalve(Fig.22)islocatedontheoppositesideofthemachineasthepilotoperatedvalve.This2-way,2positionballvalveisoperatedbyturningthehandle90degrees.
Fig.22:Firesuppressionsprayvalve-manuallyoperated
Firesuppression sprayvalvemanuallyoperated
Machinecontrolsystem Amulti-componentsystemisusedtocontrolandmonitorthefunctions ofthemachine.Thissystemconsistsofthefollowingmaincomponents:
■ Receivercontrolunit
■ Powersupply
■ Input/Output(I/O)modules
■ Remotecontroltransmitter
■ Graphicsdisplay
Thefollowinginformationispresentedasageneralguidetothecapabilitiesandfunctionsofthecontrolsystem.Beforeattemptingtooperate,service,ortroubleshootthecontinuousminer,trainingmustbe completed.
receivercontrolunit
powersupply
Input/Outputmodules
Thereceivercontrolunitisthemaincontrolunitofthesystem.Itincludestheradiodatareceiverwhichisusedtoreceiveanddecode commandsfromtheremotecontroltransmitter.
Thecontrolsystemhasitsownpowersupply,withtheoptionofhaving batterybackupforthepowersupply,whichprovidespowertothereceivercontrolandI/Omodules.
Input/Outputmodulesareusedtoreaddatafromand/orsendcommandstothefollowingmachinefunctions:
■ Cuttermotors(leftandright)
■ Gatheringheadmotors(leftandright)
■ Tractionmotors(leftandright)
■ Pumpmotor
■ Hydraulicoillevel
■ Methanemonitoring
Basedontheparametersettingsandtheinputreceivedfromdifferent components,thecontrolsystemshastheabilitytoissueerrormessages,faultmessages,and/orshutdownthemachine.
radiocontroltransmitter
Theradiocontroltransmitter(Fig.16)isabatterypoweredremoteused tocontrolthecontinuousminerduringnormaloperations.
WARNING!
Radioremotecontrolsystemsaredangerous.Thecontinuous mineroperatorcannotoperatearemotesystemuntilheisproperlytrainedintheoperationofthesystem.Remotecontrolsystemssometimeshaveautomaticfeaturesofwhichuntrainedoperatorsandworkersmaynotbeaware.
Fig.16Radiocontroltransmitter(typical)
Theremotecontroltransmittershownmayvaryfromthetransmitter thatshippedwithyourmachine.
IMPORTANT! Refertotheradioremotecontroloperationmanualsuppliedwith yourmachineforinformationregardingtheoperationofyourspecificremotecontrol.
Therearetwodisplayslocatedonthemachine:agraphicsdisplaylocatedattheoperator’scaseandatextdisplaylocatedneartheback righthandsideofthemachine(Fig.17).Bothscreensareusedtodisplaydiagnosticinformationontheminer.
Fig.17:Controlsystemdisplaylocations(typical)
displays Thegraphicsdisplay,locatedontheoperator’scase,isusedtomonitor machineoperatingparameters,fordiagnosingerrorandfaultcodes, andforinputofoperatingparameters.
Thetextdisplay,locatedonthenearthebackrighthandsideofthe machine,hasthesamefunctionsasthegraphicsdisplay.Ifthecontrol systemlosespower,thetextdisplaywillremainpoweredthroughthe batterybackup.
NOTICE! Informationpriorityisgiventothegraphicsdisplayunlessthe graphicsdisplaybecomesunhealthy.Thetwomonitorswillnot necessarilydisplaythesameinformationatthesametime.
Therearedifferentscreensthatcanbedisplayed:productionmonitoring,functionmonitoring,diagnostic,motorhours,andfaultpages.A systemhaltmessagecanappearasapop-updialogboxinthemiddle ofanyscreen.Amessagewillappearwhenacriticalconditionshas occurredthatpreventscontinuedoperationofthemachineinasafe manner.Themessageboxcannotbeclearedanditisnecessaryto recyclepowertothecontrolsystemtorestoremachineoperation.
Normaldisplaypages Themaindiagnosticscreen(Fig.18)isdisplayedduringnormalremote controloperationofthemachine.Thescreenpresentsrealtimediagnosticandperformanceinformation.
Fig.18:Mainpage,example
Graphicsdisplay
Textdisplay
SystemMenu Thecontrolsystemprovidesinformation,diagnostic,andsetupscreens thataregroupedtogetherinthesystemmenu(Fig.19).Thesystem menuisaccessedbyusingeitherdisplaymoduleandaremotecontrol handset.
Toaccessandnavigatethesystemmenuusingtheradioremote:
PresstheSHIFTandMENUkeytoaccessthesystemmenu screen.
IMPORTANT! Allfunctionsandmotorsareshutdownanddisablewhenthesystemmenuisselected.
PressCONVUPorCONVDOWNtomovethecursorupanddown thelist.
PressSHIFTandMENUtoselectthehighlighteditem
Toleavethemenuandreturntoremotemode,pressSHIFTand REMOTE.
Fig.19:Systemmenu,example
Fig.19:Systemmenu,example,continued
Textdisplay
DiagnosticMode Diagnosticmodeallowsalargenumberofmonitoringscreenstobe selectedanddisplayedwhilethemachineisoperating.Eachscreen provideshelpfultroubleshootinginformationsuchasmachineinformation,softwarerevision,andmachineconfiguration.Italsoprovidesthe statusofthemotors,digitalandanaloginputs,etc.Diagnosticmodeis forinformationalpurposesonly.Noconfigurationchangescanbe madewithinthismode.
Tonavigatethroughthescreens,holdtheSHIFTswitchwhilepressing aconveyorswitch.Toreturntothemainmenu,pressSHIFTand MENU
Graphicsdiagnosticsincludesthefollowingpages:
■ Mainmonitor
■ Productionmonitor
■ Pumpmonitor
■ Cuttermonitor
■ Conveyormonitor
■ I/Omonitor - relayoutputs
■ I/Omonitor - digitalinputs
■ I/Omonitor - analogoutputs
■ Solenoid6 - breakerresetmonitor
■ Solenoid5 - dustsprayandfiresuppression
■ Solenoid4 - stabliftmonitor
■ Solenoid3 - gatheringheadmonitor
■ Solenoid2 - conveyorliftmonitor
■ Solenoid1 - conveyorswingmonitor
■ Solenoid0 - cutterliftmonitor
■ Inverterrightmonitor
■ Inverterleftmonitor
■ Rectifiermonitor
■ Smartslicemonitor
■ Thermistormonitor
■ Motormatenetworkmonitor
■ CANnetworkmonitor
SeeFig.20forexamplescreenshotsofvariousdiagnosticpages.
Fig.20:Graphicsdisplaydiagnosticpages,examples
Fig.20:Graphicsdisplaydiagnosticpages,examples,continued
Textdiagnosticsincludesthefollowingpages:
■ Mainmonitor
■ Machineinformation
■ Pumpdiagnostics
■ Cutterdiagnostics
■ Conveyordiagnostics
■ Fandiagnostics
■ Tramdiagnostics
■ 24VDCdigitalinput
■ I/Omonitor - relayboard
■ I/Omonitor - solenoidboard
■ I/Omonitor - analogoutputs
■ Solenoidboarddiagnostics
■ Relayboardstatus
■ Powersupplystatus
■ Thermistormodulestatus
Fig.21:Textdisplaydiagnosticpages,examples
Faultlog Thefaultlog(Fig.22)allowstheusertoviewthelast100faultsthat haveoccurredsincethelogwaslastcleared.
Tonavigatethefaultlogpage:
PresstheCONVUPorCONVDOWNkeytomovethecursorupor downthepage.
PressSHIFTandCONVUPorCONVDOWNmoveupordown onepage.
ItispossibletoclearthefaultlogundertheEngineeringSetupMenu, whichispasswordprotected.
IMPORTANT! Itisnotrecommendedthatthefaultlogbeclearedunlessthereceiverhasbeenreplaced.Retainingthefaultsisveryhelpfulin troubleshootingaproblemwhenareceiverissentforservice. Faultscannotberetrievedoncetheyhavebeencleared.Usecautionandonlyclearthelogifitisabsolutelynecessary.
Onceafaulthasbeenselected,theSHIFTandMENUkeyscanbe usedtoaccessmoreinformationonthefault(Fig.23).
Fig22:Faultlog,example
Graphicsdisplay
Fig.22:Faultlog,examples,continued
Textdisplay
Onceafaulthasbeenselected,theSHIFTandMENUkeyscanbe usedtoaccessmoreinformationonthefault(Fig.20).
Fig.23:Faultdetailedinformation,example
Foracompletelistoffaults,seethetroubleshootingsectionofthis chapter.
Hourmeters Selectinghourmeters(Fig.24)fromtheMainMenuwilldisplayruntime forthefollowingmotors:pump,fan,leftcutter,rightcutter,andconveyor.Timeisdisplayedinhours:minutes:secondsformat.Thisruntimeonlyreflectsaccumulatedtimesincethereceiverhasbeeninstalledorsincethecounterwaslastreset.Thehourmeterscanbe clearedundertheEngineeringSetupMenu,whichispasswordprotected.
IMPORTANT! Thehoursmetersshouldonlybeclearedwhenamotorisreplaced orwhenthereceiverisinstalled.Tokeepanaccuratelogofamotor’stotalhours,theinformationshouldberecordedanytimedata iscleared.
Fig.24:Hourmeters,examples
Trampendant
Themachinecanbeoperatedusingapendantcontrol(Fig.25)connectedtotheminerbyanumbilicalcable.Thiscontrolisusedinthe eventthattheoperatorlosesradiolinkwiththeminetosafelyrecover theminerfromthefacetoanareaundersupportedrooffortroubleshootingandmaintenance.
Thependantcontrollerallowslimitedoperationofthemachine:trammingandpumpmotoractivationtoprovidehydraulicpowertoraiseor lowerthecuttinghead.
Inordertousethependant,itmustbeconnectedtothemachineviaa pigtail.Afterpluggingintheumbilicalcord,the“MACHINE”modeof operationswitchmustberotatedtothe“E-TRAM”.
IMPORTANT! Thependantcontrolleranditsumbilicalcordshouldbestoredina protectedlocationontheworkingsection,awayfromtheminer,to preventdamage.
Fig.25:Trampendant
Redzone Remotecontrolledcontinuousminers
Theremotecontrolofminersintroducescertainpotentialsafetyhazards whichthemineroperatormustwatchforandbeawareof.Whilethe operatorisnowfreetopositionhimselfforconvenientvisibilityofmining operationsattheface,hecaneasilyexposehimselftothedangerof beingnearmobileheavyequipment.
Mostsignificantly,theoperator’sgreatestdangerisfromhisContinuous Miner,especiallywhenheismaneuveringitduringminingoperations. Themineriscapableofslewingwhenturning,especiallywhenthe crawlersaresplit.Thedischargeconveyorcanalsoswing.Ineachof thesecases,themineroperatorisindangerofbeinghit,orworseyet, runoverbyhisownmachine.Equallydangerousisthepossibilityof theoperatorbeingpinnedagainsttheribbyhisownminer.
Mineroperatordangerareas,orRedzones Sometypicalsituationsdangeroustothemineroperatorareillustrated onthefollowingpages.Thedangerarea,orredzone(Fig.30)is indicatedbyalternatingredandwhitediagonalstripes.
Fig.30:Redzone
Trammingtheminer (Fig.31)fromoneplacetoanother,especially maneuveringaroundintersections.Thisillustratesthattheoperator shouldnotplacehimselfbetweenhisminerandtherib.
Beginningthefirstsump (Fig.31)inanewcut.Theminerisagainst theleftribandthedischargeconveyorisswungtowardthecenterof theentryreadyforthehaulagecar.Theoperatormuststayclearofthe dischargeconveyorandtherearoftheminer.
Fig.31:Redzones
Trammingtheminerredzone Beginning1stsumpredzone
Sumpinginthelefthandside ofthecut(Fig.32).Astheminer penetratestheface,newunsupportedroofisbeingexposed,andthe operatornowhasanadditionalconstrainttohismovements.Hemust alsostayclearofthehaulagevehicleattherearoftheminerasit approachestheminerandwhileitisloading.
Repositioningtheminerfortherighthandcut (Fig.32).Because theminerisbackingoutandturninginclosequarters,theoperator muststaybehindtheminertobesafe.
Sumpingintherighthandcut (Fig.32).Again,theoperatormust stayawayfromthefacewherethenewly-exposedroofisunsupported, aswellasstayingclearofthehaulagevehiclewhileitapproachesand loads.
Sumpingonthelefthand sideredzone
Sumpingintherighthand cutredzone
Repositioningminerforright handcutredzone
Fig.32:Redzones
Crosscutredzones (Fig.33). Beginningandcompletingcrosscuts requiresalotofmaneuveringoftheminerandloadingthehaulage vehiclewhileatawkwardpositions.Crosscutsalsoresultinnewly exposedunsupportedroof.Respectingareddangerzoneisimportant tooperatorsafetyintheseconditions.
Whentheminerbeginningarighthandcrosscutitisnearlyagainstthe opposite(lefthand)rib,whilethedischargeconveyorisswungtoits maximum45o rightpositionforloadingthehaulagevehicle.Hence,the entirerearofthemineristreatedasaredzone.Therearetwoother dangerareas.Ontherighthandside,theminerformsapinchpointat theribwhichmustbeavoided.Also,onthelefthandsideoftheminer, astheminerprogressesintotherib,asharp-angledfenderwillbe formedwhichwillbesusceptibletosloughingandfallingoff.Hence, thatribmustbeconsideredaredzone.
Theredzonesurroundstheminerasthedischargeconveyorisfreeto swingeitherwayandmoreunsupportedroofisexposedduringthe furtherdevelopmentoftherighthandcrosscut.
Beginningarighthand crosscutredzone
Righthandcrosscut development
Fig.33:Crosscutredzones
Pillaringredzones (Fig.34) Remotecontroloffersasignificantsafety advantageinpartialorcompleteremovalofthepillarsinretreatmining becauseitplacestheoperatorfurtherawayfrompotentialcollapsing roof.
Muchoftheareaaroundtheminermustbeconsideredaredzone, mostlybecauseofextensiveunsupportedroofandtheneedfortemporarysupportsunderweakenedroof.Withremotecontrol,theoperator canpositionhimselfsafelyawayfromtheminerwhilestillretaininga goodviewoftheminingcycle.
Aredzonearoundtheminerisnolongerapplicablewhenworkingin theoppositerighthandpillar,astheoperatorisnowexcludedfromthe entireworkingareabecauseoffailingroofconsiderations,evenwiththe existenceoftemporaryroofsupports.
Whenmakinganadditionalendcutintothepillar,creatingafenderof coalbetweenthetwocuts,additionaltemporaryroofsupportsare installed.
Becauseofroofpressures,thefenderwilltendtosloughitsribsinthe processofeventuallycrushing.Hence,theoperatormuststayaway fromthisfenderaswellasavoidingtheentryandcrosscutareasas shown.
Fig.34:Pillaringredzones
Safetyprecautionsforundergroundoperation InadditiontotheprecedinginstructionsforoperatingtheContinuous Miner,observethefollowingspecialprecautionsaftertheContinuous Mineristakenunderground.
■ Communicationisakeyelementinmaintainingsafety.Exactinstructionsandwarningsshouldbegivento,andthoroughlyunderstoodbyeachworkman.Goodcommunicationsbetweentheentire crewmustbemaintainedthroughouttheshift.
■ Checktheconditionofthetrailingcablebeforeturningpoweronat thepowersource.
■ Thismachinemustbemaintainedinapermissiblecondition,followingallstateandfederallaws.
■ MakeavisualcheckoftheContinuousMinerbeforeenergizing. Lookforloosebolts,covers,lockingdevices,damagedparts,and crackedorbrokenlenses.Anypartofthemachinewhichdoesnot functionproperlyisahazard.Reportitimmediatelytoyourimmediatesupervisorortheirdesignee.
■ Priortooperation,makesuretheworkingareaissafe.Makea visualinspectionofroofandribsandtakeallstepsnecessaryto insuresafety.
Trammingsafetyrules ■ Communicateyourintentionstotheemployeesaffectedbythe movementoftheContinuousMiner.
■ Checkthepositionofthewaterhoseandtrailingcabletobe sure thereissufficientslacktofinishtheoperation.
■ Notetheconditionoftheroadwaysandphysicalsurroundingsof theroute.
■ Positionthecutterandgatheringheadfortramming.
■ Positionthestabilizershoeandboomsfortramming.
■ Positionyourbodycompletelyinsidetheoperator'scompartment (optional),facingtheintendeddirectionoftravel.
■ PositiontheContinuousMinerinthecenteroftheroadwaytoallowmaximumsafeclearance.Consistentlymaintainclearance, whichiscriticaltothesafemovementoftheContinuousMiner.
Startingprocedure WARNING!
Failuretoreadandunderstandalloperatinginstructionsbefore startingtheContinuousMinercouldresultinseriousinjuryor deathtotheoperatororpersonsaroundthemachineorcause damagetothemachine.
WARNING!
Readallinstructionscarefullybeforeattemptingtostartor operatemachine.
WARNING!
Understandthefunctionsofallcontrolsbeforestartingthe ContinuousMiner.Readandfollowtheinstructionsonallwarningtagsonthemachine,observeallregulationsandsafetyprecautions.
WARNING!
NeveroperateaContinuousMinerwhichhasbeendamagedoris notoperatingproperly.AnypartoftheContinuousMinerwhich doesnotfunctionproperlycanbeahazard.Reportitimmediately toyoursupervisorortheirdesignee.
WARNING!
BeforestartingtheContinuousMiner,makesurethatnooneisin theredzone(Fig.30throughFig.34).
NOTICE!
Inextremelycoldweather,allowmotorsandgearcasestoidle. Thiswillwarmthehydraulicoilsandlubricants.Stilloilsand greasescouldimmobilizethemachine.
IMPORTANT! Apump“growl”meansnotenoughoilisreachingthepumps throughthesuctionlines.Ensurethepumpgetsprimedbefore continuingoperation.Alwayschecktheoillevel.
DANGER! Improperpositioncouldresultininjuryordeathtotheoperator bycrushinghimagainsttheriborroofsupports.Itmayalso causehimtorunoverthetrailingcableordislodgetheroof supports.
WARNING!
Turningonthewatersprayspriortocuttingpreventstheaccumulationofdustandthegenerationofexcessiveheatwhichcould causeanignitionorexplosion.
Afterreadingthepreviousdescriptionsandlocatingeachcontrol,the operatorisreadytooperatetheContinuousMiner.Anexperienced operatorshouldmonitoranewoperator’sindoctrinationtothestarting procedure.
WARNING!
TheContinuousMineristypicallyoperatedbyradioremote control.Manualoperationisnotallowedforproductionoperation unlesstheminerhasanoperator’spitandcanopy.Manualoperationgenerallyisfortroubleshootingandmaintenanceunderroof support.
Theoperatingprocedureslistedinthefollowingsectionsareforradio operation.
IMPORTANT!
Beforestart-up,checkthatdailymaintenancehasbeenperformed onthemachine.
WARNING!
Visuallycheckforotherpersonnelandverballyshoutawarning beforestartingthismachine.Makesureallpersonnelarecompletelyclearofthemachineandit’scomponentsandcheckthat anyloosematerial,tools,oilcansorotherobjectsareclearfrom theareabeforestartingthemachine.
ReferenceFig.16.
Turnthemaincircuitbreakertothe“ON”position.
Select“RADIO”onthe“RADIO/MANUALSW.1”
Turnthepowerswitchonradiotransmittertotheonposition.
Press“SHIFT”andwait1/4second.
Whilepressing“SHIFT”,press“PUMPON”.Holdbothkeysinuntil thepumpstarts.
Releasethe“PUMPON”key.
IMPORTANT!
The“PUMPON”keymustbereleasedbefore“SHIFT”.If“SHIFT” isreleasedfirst,thepumpmotorwillshutoff.
Releasethe“SHIFT”key.
Shutdownprocedure TheContinuousMinermustbeproperlyshutdownbeforeleavingthe areaorbeforeperforminganymaintenanceorservice.Somemaintenanceorserviceproceduresmayrequireadditionalstepstoinsurethe safetyofthemaintenancepersonnelworkingonoraroundthemachine andwillbelistedinthemaintenancesectionofthisguide.
Backthemineraboutonefootfromthefaceprovidingsufficient clearanceandshutoffthecutterheadmotors(seeCutteroperation inthissection).
Tramtheminertoanareaofwellsupportedroof.Parkthemachine initsdesignatedparkingareaoutoftraffic,onflat,solidground.Ifit isnotpossibletoparkthemachineonflatground,parkthemachine atarightangletotheslope.
WARNING! Afterturningoffthepowertothemachine,neverwalkawayand leavethetransmitterturnedon.Failuretoturnthetransmitteroff couldresultinanaccidentcausingseriousinjuryorlossoflife.
Emptytheconveyorandshutitoff(seeConveyoroperationin thischapter).
Lowerthecutterheadtothefloor.
Lowertheconveyorandgatheringhead.
Pressandholdthe“PUMPOFF”key.Thepumpmotorshould shutdownimmediately.
Releasethe“PUMPOFF”key.
Turnoffthewatersprays.
PositionallleversandcontrolstoNeutralorOff.
Shutoffthemainpowersupply.
Shutofftheminewatersupply.
Trammingtheminer Trammingrequirescoolingwatertopreventdamage.
NOTICE!
TheContinuousMinerhasskidtypesteering:itiscapableof turningwithinitsownlimits.
WARNING!
Trammingrequirescoolingwatertothetrammotors.Failureto coolthemotorswillresultinmotordamageandprematurefailure.
Ensurethatthestabilizershoeisawayfromtheminefloor.
Raisecutterboomtobestpossiblepositiontoallowclearancefrom roof,ribs,andfloor.
Raisegatheringheadawayfromtheminefloor.
Adjustconveyorboomtobestpossiblepositiontoallowclearance fromroof,walls,andfloor.
WARNING!
Adjustconveyorboomtoallowclearancefromroof,walls,and floor.Failuretodosowillresultindamagetotheconveyorboom.
Ensureadequateclearanceatalltimeswhiletrammingmachine. Beawardofpeople,equipment,andcables.
Remotecontrol - tramenable:
Toenablemachinetramming,pressandreleasethe“TRAM2-3” key.
Onceenabled,thetramleverscanbeusedtodriveleftandright trammingtracksforwardsandbackwards.Ifthetramleversare releasedforacontinuousperiodoffive(5)seconds,thetram becomesdisabled.
Tore-enablethetramfunction,pressandreleasethe“TRAM2-3” key.
Remotecontrol - tramtrackconsole:
Pressthe“LEFTFWD”tramkeytoturnthelefttrammingtrack forward.
Pressthe“LEFTREV”tramkeytoturnthelefttrammingtrack backwards.
Pressthe“RIGHTFWD”tramkeytoturntherighttrammingtrack forward.
Pressthe“RIGHTREV”tramkeytoturntherighttrammingtrack backwards.
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