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Operation Manual Bucyrus - Continuous Miner Model - 25M0 Doc. No.: A6474X332

Bucyrus America, Inc. ________________________________________ 2045 West Pike Street Houston, PA 15342

Telephone: 724-743-1200 Fax: 724-743-1201

Internet: www.bucyrus.com

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This manual is intended to provide GENERAL product information for the Model 25M0 Continuous Miner. The illustrations, descriptions and procedures contained in this publication apply only to THIS machine.

Bucyrus America, Inc. reserves the right to revise models and designs without prior notice.

This Continuous Miner was manufactured under the guidelines, procedures and requirements of the U. S. Federal Coal Mine Health and Safety Act, Code of Federal Regulations, Title 30, Chapter 1, Subpart 0, Part 75 for underground coal mines, and other applicable non-U.S. regulatory agency standards.

At the completion of the manufacturing process, this unit was issued the appropriate approval numbers and nameplates indicating it met the technical requirements of these regulatory agencies. Any change to the design or structure of this unit, without the consent of Bucyrus America, Inc. and these regulatory agencies, or any repair or replacement of parts contrary to Bucyrus America, Inc.’s instructions, may invalidate these approvals and render this unit unsafe to operate.

Strict compliance with all Federal and State Mining laws, regulations and practices regarding the safe operation and maintenance of underground mining equipment and strict adherence to the instructions in this manual is necessary for the personal safety of those working on or around this unit.

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

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

© BUCYRUS AMERICA, INC.

ALL RIGHTS RESERVED

________________________________________________ Table of contents

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

2. Your safety

© BUCYRUS AMERICA, INC.

Your safety .............................................................................. 2.3 Personnel............................................................................. 2.4 Operation ........................................................................ 2.4 Installation and repair...................................................... 2.4 Operating conditions ............................................................ 2.5 Intended use ................................................................... 2.5 Unauthorized use............................................................ 2.5 Safety instructions................................................................ 2.7 General rules: ................................................................. 2.7 Storage and transport ..................................................... 2.8 Pre-start inspection ......................................................... 2.8 Installation and start-up................................................... 2.9 Operation ........................................................................ 2.9 Stopping .........................................................................2.10 Maintenance and repair .................................................2.10 Overview of the safety instructions .....................................2.15 Chapter 3: Storage and transport ..................................2.15 Chapter 4: Installation ....................................................2.15 Chapter 5: Operation .....................................................2.16 Chapter 6: Technical data..............................................2.31

3. Storage and transport Storage and transport ............................................................ 3.3 Storage ................................................................................ 3.3 Storage of the machine and spare parts......................... 3.3 Long-term storage of spare components........................ 3.4 Transport.............................................................................. 3.5 Load units: dimensions and weights ............................... 3.5 Transport environment.................................................... 3.6

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

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Table of contents _________________________________________________

Operation ................................................................................. 5.3 How to operate the Continuous Miner ................................. 5.3 Who is allowed to operate the Continuous Miner ........... 5.3 When can operation be started?..................................... 5.3 Machine description ............................................................. 5.4 Controls and indicators ........................................................ 5.4 Machine control system ....................................................... 5.19 Red zone.............................................................................5.26 Safety precautions for underground operation ...................5.31 Tramming safety rules ........................................................5.31 Starting procedure ..............................................................5.32 Shutdown procedure...........................................................5.34 Tramming the miner............................................................5.35 Cutter head operation .........................................................5.37 Conveyor operation.............................................................5.38 Scrubber motor operation ...................................................5.39 Area and headlight operation..............................................5.32 Fire suppression in radio remote operation ........................5.40 Conveyor raise/lower/left/right in radio remote operation ...5.40 Stabilizer cylinder raise/lower in radio remote operation ....5.41 Shear up/down in radio remote operation...........................5.41 Gathering head raise/float in radio remote operation .........5.41 Breaker on/off in radio remote operation ............................5.42 Typical cutting sequence ....................................................5.43 Mining operations................................................................5.45 Mechanical assemblies.......................................................5.50 Hydraulic system.................................................................5.57 Water system ......................................................................5.89 Electrical system .................................................................5.99 Instructions on the maintenance....................................... 5.135 Important notes ............................................................ 5.135 Before maintenance..................................................... 5.135 Torque values .............................................................. 5.136 Lubricants, fluids and capacities .................................. 5.137 Specific lubrication and maintenance instructions ............ 5.141 Every shift .................................................................... 5.141 Every third shift (daily) ................................................. 5.143 Weekly ......................................................................... 5.148 Monthly......................................................................... 5.152 Every three months ...................................................... 5.158 Every six months.......................................................... 5.161 Adjustment procedures ..................................................... 5.164 Setting hydraulic pressures .......................................... 5.164 Load holding valve ....................................................... 5.165 Pilot pump circuit relief................................................. 5.166 Main control valve ........................................................ 5.168 Port relief...................................................................... 5.169 Tram track .................................................................... 5.171 Tail shim....................................................................... 5.176 Chain tension ............................................................... 5.179 Mechanical........................................................... 5.179 Grease take-up .................................................... 5.181 Cutter motor feedback ................................................. 5.183

_________________________________________________________________ Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

5. Operation

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© BUCYRUS AMERICA, INC.

Instructions on replacement of wear parts........................ 5.186 Cutter head (boom) assembly ..................................... 5.186 Boom pivot pin ............................................................. 5.190 Shear cylinder .............................................................. 5.193 Center cutter drum ....................................................... 5.198 End cutter drum ........................................................... 5.202 Drum drive motor ......................................................... 5.204 Drum drive gear case................................................... 5.210 Gathering head assembly ............................................ 5.212 Gathering head drive motor ......................................... 5.218 Gathering head gear case ........................................... 5.223 Gathering head foot shaft ............................................ 5.229 Gathering head lift cylinder .......................................... 5.232 CLA .............................................................................. 5.235 CLA tip replacement .................................................... 5.238 Tram motor................................................................... 5.239 Tram primary planetary gear........................................ 5.244 Tram secondary planetary gear ................................... 5.247 Tram case .................................................................... 5.252 Tram reach gear set..................................................... 5.257 Tram sprocket .............................................................. 5.265 Tram track front idler.................................................... 5.272 Front idler take-up cylinder .......................................... 5.276 Hydraulic pump ............................................................ 5.278 Hydraulic pump motor.................................................. 5.281 Scrubber fan/motor ...................................................... 5.284 Stabilizer cylinder......................................................... 5.287 Swivel pin assembly..................................................... 5.290 Tail roller ...................................................................... 5.292 Conveyor chain replacement ....................................... 5.294 Duo-cone seals ............................................................ 5.395 Bearings ....................................................................... 5.301 Bevel gears .................................................................. 5.307 Gears and gear failures ............................................... 5.308 Lock wire fasteners ...................................................... 5.310 Special fasteners ......................................................... 5.310 Self-locking screws ...................................................... 5.310 Locknuts....................................................................... 5.311 Component substitution ............................................... 5.312 Troubleshooting procedures ............................................. 5.313 Typical hydraulic problems .......................................... 5.314 Contaminants in hydraulic systems ............................. 5.315 Specific hydraulic circuits............................................. 5.316 Multi-function failure............................................. 5.316 Oil tank fill ............................................................ 5.317 Cutter head raise ................................................. 5.317 Cutter head lower ................................................ 5.317 Gathering head raise ........................................... 5.318 Gathering head float ............................................ 5.318 Conveyor raise..................................................... 5.318 Conveyor lower .................................................... 5.319 Conveyor swing ................................................... 5.319 Stabilizer raise ..................................................... 5.319 Stabilizer lower..................................................... 5.319 ........................................................................................

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Table of contents _________________________________________________ General safety procedure for shutdown .......................5.320 Excessive noise............................................................5.321 Excessive heat .............................................................5.322 Incorrect flow ................................................................5.323 Incorrect pressure ........................................................5.324 Faulty operation............................................................5.325 Restarting checklist ......................................................5.326 Water system ...............................................................5.327 Bearings .......................................................................5.329 Electrical system ..........................................................5.330

6. Technical data Technical data ......................................................................... 6.3 Tightening torques................................................................ 6.5 Permissible media ................................................................ 6.7 Lubrication fluids and greases......................................... 6.7

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

_________________________________________________________________ Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

7. For your information

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About this manual

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________________________________________Before starting to work

About this manual This chapter provides important information making it easier for you to use this manual. You will also be given information on the structure of the manual and the symbols and characters used.

Before starting to work applicable operating manual machine type

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

This operating manual is intended for: Bucyrus Model 25M0 Continuous Miner Serial No.: N/A and is only permitted to be used for equipment of this type.

© BUCYRUS AMERICA, INC.

new operation manual

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

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

Who is this operating manual intended for?

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

This includes persons who: ■

are in charge of transport

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perform assembly / disassembly work

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operate the machine

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eliminate faults

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perform daily routine work on the face or in the entry

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perform maintenance work

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perform repair work

supervisory personnel who: ■

initiate and/or supervise the activities just indicated.

______________________________________________________________ A6474X332 VSSV/00 1.3

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

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

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

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

safety

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

© BUCYRUS AMERICA, INC.

service

_________________________________________________________________ 1.4 Bucyrus – Model 25M0 Continuous Miner

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

Try to memorize the symbols and their meanings.

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

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

© BUCYRUS AMERICA, INC.

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

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

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

■

Items in lists are marked with bullets.

–

Points in sub-lists are marked with a long dash at the start of the line.

 Points in text marked in this way describe individual operations.

Follow these instructions step by step. They will help you carry out your work faster and more importantly, safer.

______________________________________________________________ A6474X332 VSSV/00 1.5

© BUCYRUS AMERICA, INC.

Before starting to work ________________________________________

_________________________________________________________________ 1.6 Bucyrus – Model 25M0 Continuous Miner

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Your safety

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__________________________________________________ Personnel

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

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

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

Do not make any alterations or modifications which could impair the safety of the machine. All modifications and changes must be approved by Bucyrus America, Inc. and any appropriate regulatory agency.

© BUCYRUS AMERICA, INC.

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

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

Observe the safety and accident prevention regulations

further operating manuals

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of the mine,

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of the mine inspector, and

■

of the mining supervisory authorities.

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

______________________________________________________________ A6474X332 VSSV/00 2.3

Personnel ___________________________________________________ Personnel Operation training

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

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

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

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mechanics,

■

hydraulics, and

■

control engineering

and must be able to prove this knowledge.

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

Installation and repair work on: ■

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

■

the electrics (motors, controllers, etc.)

■

the hydraulics (controls, cylinders, etc.)

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

_________________________________________________________________ 2.4 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

You must have adequate knowledge of the

_________________________________________ Operating conditions Operating conditions Intended use The Continuous Miner has been designed and manufactured for the extraction of coal, phosphate, potash, salt, trona and other medium hardness minerals.

Intended uses include: ■

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

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

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operation on grades of less than 10 degrees

© BUCYRUS AMERICA, INC.

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

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the transport of persons

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stone development or extraction

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

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© BUCYRUS AMERICA, INC.

Operating conditions __________________________________________

_________________________________________________________________ 2.6 Bucyrus – Model 25M0 Continuous Miner

___________________________________________ Safety instructions Safety instructions General rules: general

Always work with full concentration.

Familiarize yourself with your working environment.

noise emissions

Always wear your personal protective equipment. This also includes ear protectors as the noise emitted by other equipment in the area may at times exceed 85 db(A).

© BUCYRUS AMERICA, INC.

Inform your colleagues of

safety equipment

■

your exact location,

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the work you are performing, and

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the time that you will probably require.

Start the machine only when it is in a good and safe operating condition and all protective devices, e.g. MACHINE STOP devices, cover plates, etc. are correctly installed.

Observe the acoustic and optical start-up warnings of the machine.

symbol plates

Observe the symbol plates on the machine.

machine stop

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

lock-out and tag-out

Lock-out, tag-out and disconnect the power system while performing:

cordon off working area moving parts

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maintenance work

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inspection work

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repair work

Cordon off your working area widely for the machine.

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

chains, flights, and chain sprockets

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pivot points

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cutter head and loading head

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crawler assemblies and conveyors

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cutter and gathering head assemblies

______________________________________________________________ A6474X332 VSSV/00 2.7

Safety instructions ____________________________________________ Storage and transport Maintain the prescribed storage periods and observe the instructions for storage.

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

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

Ensure that the transport safety devices are correctly fitted.

Fix all moving parts with transport locks.

Never stand under unsupported parts or suspended loads.

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

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

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

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

mobile handling equipment

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

Pre-start inspection operation

Read this entire manual before attempting to operate this machine.

inspection

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

maintenance instruction and safety tags operator’s compartment (optional) cab/canopy (optional)

Verify that all maintenance has been performed.

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

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

Clean any foreign material from the operator’s compartment.

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

_________________________________________________________________ 2.8 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

means of attachment

___________________________________________ Safety instructions Installation and start-up inclined face

environmental acceptability

On inclined faces secure all component parts by chains, e.g. to the support.

When working with oils, greases and other chemical substances, observe the safety regulations applicable to the product.

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

controls

When starting up machine, do not operate any controls located inside the operator’s compartment (optional) from outside the compartment.

starting procedures

Follow the starting procedure instructions in the operations manual.

red zone

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

© BUCYRUS AMERICA, INC.

Operation training

Operate the machine only if you have a profound knowledge of the control elements and their functions. It is necessary that you have been task trained on the respective Continuous Miner.

before start-up

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

protective devices

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

operator’s compartment (optional)

Clean the operator’s compartment at regular intervals. Ensure that the operating symbols are legible in order to avoid any operator errors and resulting accidents.

Never climb onto, or climb out of the machine while it is in motion.

Do not operate the machine with any part of your body outside of the operator’s compartment in order to prevent body parts from being crushed between the machine and outside objects .

traveling

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

passengers

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

safety rules

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

problems and malfunctions

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

______________________________________________________________ A6474X332 VSSV/00 2.9

Safety instructions ____________________________________________ Stopping operator’s compartment (optional)

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

parking

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

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

radio

There is a unique code switch setup which permits each operator to activate only his designated miner, allowing several remote-controlled miners to operate in the same area without getting their radio signals crossed. In addition, an improperly decoded radio signal will automatically shut-off the miner. Follow the general safety notices and safety recommendations listed in the remote control system troubleshooting guide.

trailing cable uncoupled and locked-out

Be sure to observe the prescribed maintenance and inspection intervals.

signage

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

securing

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

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

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

Protect your work area against falling rocks.

replacing components

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

original parts

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

methane monitoring

Use only spare parts which satisfy the specified technical requirements.

This is only ensured with original Bucyrus America, Inc. spare parts.

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

_________________________________________________________________ 2.10 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

Maintenance and repair

___________________________________________ Safety instructions lifting

handling of hydraulic fluids

For raising the Continuous Miner use only: ■

crib blocks with adequate load-holding capacity.

■

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

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

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

maintenance, repair

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

© BUCYRUS AMERICA, INC.

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

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

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

Always replace damaged or lost decals and metal instruction plates.

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

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

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

______________________________________________________________ A6474X332 VSSV/00 2.11

Safety instructions ____________________________________________ Some illustrations in this manual show guards or cover panels removed for purposes of clarity. Never operate unit without guards or cover panels in place.

■

the hoses are not pinched or trapped.

■

the hoses have no bubbles or blisters.

■

the hose or outer sheathes of the hose are not abnormally rigid or hard.

■

the outer sheath of the hoses is not damaged.

■

the connectors are securely inserted into the sockets.

■

the connections are leak-tight.

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

Flush out the hydraulic lines thoroughly before connecting. permissible hoses

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

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

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

Use only hydraulic hoses approved for the prevailing pressures.

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

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

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

Never try to repair damaged hydraulic hoses.

Replace hydraulic hoses at the first suspicion of damage.

_________________________________________________________________ 2.12 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

Carry out a visual inspection of all the hydraulic components at regular intervals. In particular check that:

___________________________________________ Safety instructions installing hydraulic hoses

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

Always install hydraulic hoses so they: ■

always have a little slack.

Fig. 1: Installing hydraulic hoses, slack Right

■

Wrong

are not twisted.

© BUCYRUS AMERICA, INC.

Fig. 2: Installing hydraulic hoses, twisting Right

■

Wrong

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

Fig. 3: Installing hydraulic hoses, bending Right

Wrong

______________________________________________________________ A6474X332 VSSV/00 2.13

Safety instructions ____________________________________________ ■

always have a little slack.

■

are not kinked.

■

do not have to withstand tensile strains.

■

are protected against thermal radiation.

■

are accessible at all times.

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

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

■

torn out,

■

kinked,

■

crushed,

■

driven over or

■

twisted by movement of the machine.

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

Wrong

_________________________________________________________________ 2.14 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

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

________________________________ Overview of safety instructions Overview of the safety instructions This is a summary of all the safety instructions which have to be observed in the following chapters. This summary is intended only to give you an overview of all the instructions. In some cases, there is no logical relationship between the individual instructions.

Chapter 3: Storage and transport IMPORTANT! Take care to insure that new maintenance supplies are stored separately from existing stock and that removal takes place on the “first in, first out” principle.

© BUCYRUS AMERICA, INC.

WARNING! Use only load handling devices complying with the technical and legal regulations for the transport of loads.

You could be seriously injured or even killed by falling loads.

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

Chapter 4: Installation CAUTION! Serious damage can be caused to the Continuous Miner as a result of incorrect installation. The unit should therefore only be installed under the instruction of specialists from Bucyrus America, Inc. IMPORTANT! The sequence of operations during installation must be adapted to the individual conditions prevailing at the site. Before starting the work a detailed list of steps to be taken with respect to transport and assembly should be prepared and a corresponding plan established.

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

However, to ensure that no transit damage has occurred, the following pre-startup checks should be performed: NOTICE! The operator must become familiar with all the safety features and their location on the machine prior to installation or operation.

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

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

______________________________________________________________ A6474X332 VSSV/00 2.15

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

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

CAUTION! MANUAL ONLY: The Continuous Miner’s tram and steering speed is variable. This means that the farther the tram handle is actuated the faster the Continuous Miner will travel or turn. The tram lever must be moved slowly. Moving the tram levers too quickly may result in severe injury or loss of control.

IMPORTANT! Once the tram/steering control lever is released by the operator the control lever automatically returns to the centered (neutral) position.

WARNING! Manual operation of the Continuous Miner is not allowed for production operation unless the miner has an operator’s pit and canopy. Manual operation is generally for troubleshooting and maintenance under roof support. Operating the Continuous Miner manually from the operator’s station may result in serious injury or death.

WARNING! The machine circuit breaker de-energizes the electrical controller and motors. However, electrical power is still present inside the connection box to the circuit breaker. If the circuit breaker inside the connection box requires service, the trailing cable should be disconnected from the power center.

WARNING! Once the breaker has tripped, it will not stay in the “ON” position without first being moved to the "RESET" position, and then to "ON".

_________________________________________________________________ 2.16 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

WARNING! The Continuous Miner is radio remote controlled. Manual operation is generally for troubleshooting and maintenance under roof support. Operating the Continuous Miner manual from the Operator’s station may result in serious injury or death.

________________________________ Overview of safety instructions WARNING! If either of the fire suppression actuator are actuated, the system must be completely recharged with dry chemicals and expellants.

WARNING! Be prepared for a sudden stop when the E-stop is actuated during normal tramming of the machine.

IMPORTANT! Refer to the radio remote control operation manual supplied with your machine for information regarding the operation of your specific remote control.

© BUCYRUS AMERICA, INC.

WARNING! Failure to read and understand all operating instructions before starting the Continuous Miner could result in serious injury or death to the operator or persons around the machine or cause damage to the machine.

WARNING! Read all instructions carefully before attempting to start or operate machine.

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

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

WARNING! Before starting the Continuous Miner, make sure that no one is in the red zone (Fig. 22 through Fig. 26).

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

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

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

DANGER! Improper position could result in injury or death to the operator by crushing him against the rib or roof supports. It may also cause him to run over the trailing cable or dislodge the roof supports.

______________________________________________________________ A6474X332 VSSV/00 2.17

Overview of safety instructions _________________________________ WARNING! Turning on the water sprays prior to cutting prevents the accumulation of dust and the generation of excessive heat which could cause an ignition or explosion.

WARNING! The Continuous Miner is typically operated by radio remote control. Manual operation is not allowed for production operation unless the miner has an operator’s pit and canopy. Manual operation generally is for troubleshooting and maintenance under roof support.

WARNING! Visually check for other personnel and verbally shout a warning before starting this machine. Make sure all personnel are completely clear of the machine and it’s components and check that any loose material, tools, oil cans or other objects are clear from the area before starting the machine.

IMPORTANT! The “PUMP ON” key must be released before “SHIFT”. If “SHIFT” is released first, the pump motor will shut off.

WARNING! After turning off the power to the machine, never walk away and leave the radio remote turned on. Failure to turn the remote off could result in an accident causing serious injury or loss of life.

WARNING! Tramming requires cooling water to the tram motors. Failure to cool the motors will result in motor damage and premature failure.  WARNING! Adjust conveyor boom to allow clearance from roof, walls, and floor. Failure to do so will result in damage to the conveyor boom.

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

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

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

IMPORTANT! The “CUTTER ON” key must be released before “SHIFT”. If “SHIFT” is released first, the cutter motors will shut off. _________________________________________________________________

2.18

Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

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

________________________________ Overview of safety instructions WARNING! Warn “ALL CLEAR” before starting the conveyor. Failure to do so may result in serious injury or death.

IMPORTANT! The “CONV ON” key must be released before “SHIFT”. If “SHIFT” is released first, the conveyor motors will shut off.

IMPORTANT! The “FAN ON” key must be released before “SHIFT”. If “SHIFT” is released first, the fan motor will shut off.

CAUTION! Always ensure operator safety while operating the machine.

© BUCYRUS AMERICA, INC.

CAUTION! Always be alert to hazardous conditions and take corrective action as necessary.

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

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

IMPORTANT! Inspection of the bits and bit blocks before the start of each shift will reduce later problems. Mining with dull, bent or broken bit blocks increases dust and noise levels, as well as putting excessive strain on both cutter and tram drives.

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

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

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

______________________________________________________________ A6474X332 VSSV/00 2.19

Overview of safety instructions _________________________________ WARNING! Do not salvage spools or valve bodies for later use in “new” combinations. Improper components used during assembly may appear as internal leakage, or a "sticking" or "hanging up" of the spool in the valve body. Incorrect sets will result in improper operation of the valve section, possibly causing unexpected machine operation that could result in machine damage or injury to personnel.

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

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

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

DANGER! The load holding valve is preset. DO NOT ADJUST IT. If it malfunctions, replace it immediately.

IMPORTANT! When not in use, ensure that the power fill suction hose is tightly plugged to prevent dirt and contaminants from entering the hydraulic system when not in use.

IMPORTANT! The power fill is activated by opening the ball valve and then engaging conveyor down function.

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

IMPORTANT! You must manually reset the 2-way, 2-position water valve to reset the deluge fire spray circuit.

IMPORTANT! The backup accumulator must maintain a minimum pressure of 500 psi for 12 minutes after the pump has been de-energized. For maintenance on the circuit, loosen the fitting SLOWLY until the pressure is released.

_________________________________________________________________ 2.20 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

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

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

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

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

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

© BUCYRUS AMERICA, INC.

IMPORTANT! If the low oil warning light comes on when the circuit breaker is closed. Be sure to fill the reservoir before starting the motors.

CAUTION! Only qualified technicians should troubleshoot the electrical systems. Touching or shorting energized components can cause serious injury or death.

WARNING! Before performing maintenance on the machine the circuit breaker must be in the “OFF” position and the power should be disconnected at the main power source. Follow all Federal and Mine safety regulations for lockout/tagout procedures. Accidental machine movement or electrical shock can result in serious injury or death to you or other personnel.

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

WARNING! Never disconnect a hydraulic hose if the circuit is pressurized or if there is a load on the circuit. If a hose is disconnected while the circuit is pressurized or a load is on the circuit, the load will fall causing damage to the machine or serious injury or death to you or other workers.

WARNING! You could be seriously injured or even killed by falling loads. Observe the safe working load limits of lifting or blocking devices and keep a safe distance from suspended loads.

______________________________________________________________ A6474X332 VSSV/00 2.21

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

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

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

WARNING! The hydraulic oil fill pump will be damaged if it is run dry.

WARNING! Use extreme caution when performing test procedures and making adjustments. Unless noted in the procedures, all controls are to be in the neutral position.

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

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

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

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

IMPORTANT! Reference the Hydraulic section in this chapter for general information on the individual circuits. Always refer to the hydraulic schematic in your Bucyrus America, Inc. parts manual for information that is specific to your miner.

WARNING! Two people are required to adjust pressure settings. One person will make the adjustments while the second person must remain at the “Machine stop/E-STOP” at all times during the adjustment procedure. Failure to do so may result in serious injury or death.

_________________________________________________________________ 2.22 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

NOTICE! Incorrect grease or over greasing of the electric motor may cause serious damage to the motor. Follow the greasing procedure outlined in the Maintenance section of Chapter 5.

________________________________ Overview of safety instructions IMPORTANT! Before making any further adjustments, verify that the hydraulic oil is at operating temperature.

IMPORTANT! The main relief is set higher than the port reliefs and will only relieve if a spike occurs in the system or if the port relief does not function properly. This provides protection of the main pump section, A1.

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

© BUCYRUS AMERICA, INC.

CAUTION! Always be alert for any unintended machine movement.

IMPORTANT! Reference the Hydraulic section in Chapter 5 for individual circuit information. Always refer to the hydraulic schematic in your Bucyrus America, Inc. parts manual for your miner.

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

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

WARNING! Follow all Federal and mine lockout/tagout regulations and procedures. Failure to do so could result in machine damage or serious injury or death to personnel.

CAUTION! Shims must be inserted completely into the idler slide channel. A shim that is not correctly seated on the idler slide channel’s inside surface provides uneven support that can cause idler slant. A slanted idler can cause uneven wear and stress on the tram track and can cause improper operation of or damage to the tram system.

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

IMPORTANT! Left and right take-up rods should be rotated equally. This maintains steady, equal pressure on the tail roller assembly and keeps the conveyor chain from drifting off center.

______________________________________________________________ A6474X332 VSSV/00 2.23

Overview of safety instructions _________________________________ WARNING! Do not test the alignment of the shear cylinder rod end bearings and the cutter boom clevis using your fingers. Shifting of the aligned pieces could cause serious injury.  IMPORTANT! The pin should be inserted so that its retaining channel remains outside the bushing.

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

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

IMPORTANT! Pressure from the cutter boom onto the boom pivot pin can make its removal very difficult. The shear cylinders can be used to find the boom position that puts the least pressure onto the pin. This position can be determined by striking the pin, slightly contracting or extending the shear cylinder, then striking the pivot again and comparing the “ring”; as boom pressure on the pin decreases, the “ring” of the pin when it is struck becomes lower. When the “ring” of the pin becomes short and low, pin removal is much easier.

CAUTION! Use extreme caution when adjusting the boom with the shear cylinder to find the pivot pin’s pull point.

IMPORTANT! On the back of the tractor frame clevis there is a welded strap that keeps the boom pivot pin from rotating. One of the flats of the boom pivot pin must parallel this strap or the pin cannot be completely inserted.

IMPORTANT! If it is extremely difficult to insert the boom pivot pin through the aligned tractor frame clevis and boom pivot bushings, extend or contract the shear cylinders to improve the alignment between the clevis and boom.

CAUTION! Use extreme caution when adjusting the clevis and boom alignment with the shear cylinders.

_________________________________________________________________ 2.24 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

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

________________________________ Overview of safety instructions WARNING! Follow all Federal and mine lockout/tagout regulations and procedures. Failure to do so could result in machine damage or serious injury or death to personnel.

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

WARNING! Replacement of the shear cylinder involves working around a raised cutter head assembly. Never work under any raised assembly without proper blocking. Always block between the raised assembly and the tractor frame in addition to between the raised assembly and the floor.

© BUCYRUS AMERICA, INC.

WARNING! This procedure involves disconnecting the hydraulic hoses. Always use caution when working with or around hydraulic systems—they can be under extremely high pressures.

WARNING! Stand clear of the blocked cutter head assembly during shear cylinder contraction.

WARNING! Follow all Federal and mine lockout/tagout regulations and procedures. Failure to do so could result in machine damage or serious injury or death to personnel.

WARNING! The next steps disconnect the shear cylinder from the tractor frame. The shear cylinder is extremely heavy. Be prepared to support its weight before performing the following steps.

WARNING! Never disconnect a hydraulic hose if the circuit is pressurized or if there is a load on the circuit. If a hose is disconnected while the circuit is pressurized or a load is on it, the load will fall, causing damage to the machine or serious injury or death to personnel.

WARNING! Stand clear of the shear cylinder and the blocked cutter head assembly during extension of the shear cylinder.

WARNING! Replacement of the cutter head center drum involves working around a raised cutter head assembly. Never work under any raised assembly without proper blocking. Always block between the raised assembly and the tractor frame in addition to between the raised assembly and the floor.

WARNING! This procedure involves disconnecting and reconnecting the miner’s trailing cable. Always be aware of whether or not the miner is energized. Never perform maintenance on an energized miner. ______________________________________________________________ A6474X332

VSSV/00

2.25

Overview of safety instructions _________________________________ WARNING! Stand clear of the cutter head assembly and the unsecured upper half of the center drum while lowering it.

WARNING! While this power cable is detached from the motor, the trailing cable should not be reconnected to energize the miner. Damage to the miner, personal injury or death could result.

WARNING! Federal law requires that mining equipment electrical connections must be inspected by a certified electrician before the equipment can be operated.

WARNING! The cutter head gear case is extremely heavy. Keep body parts and other objects from underneath it until it is completely secured.

WARNING! Use extreme caution when tramming the miner forward to position the boom face against the gear case.

WARNING! Stand clear of the blocked cutter head and gathering head assemblies during the contraction of the gathering head lift cylinders.

CAUTION! When separating the gathering head from the tractor frame, ensure that the disconnected ends of the conveyor chain smoothly slide out of the gathering head.

CAUTION! When tramming the miner toward the gathering head, be careful that the conveyor chain and gathering head lift cylinders do not become pinched between the tractor frame and the gathering head.

CAUTION! Use caution when using the lift cylinders and stabilizer to adjust the alignment of the clevis and pivot pins.

WARNING! The next steps disconnect the gathering head drive motor from the adapter that links it to the gathering head gear case. The gathering head drive motor is extremely heavy. Be prepared to support this weight before performing the following steps.

_________________________________________________________________ 2.26 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

WARNING! This procedure involves attaching an electrical power cable to the cutter head drum drive motor. The trailing cable must be disconnected to safely perform this operation or serious injury or death will result.

________________________________ Overview of safety instructions IMPORTANT! The bottom ports on the high speed input cases are the fill lines.

The top ports on the high speed input cases are the check lines.

IMPORTANT! Improper conveyor chain tension can lead to excessive wear, mechanical problems, and miner downtime. Always keep the conveyor chain at proper tension.

IMPORTANT! Position the foot shaft so its sprocket will engage the conveyor chain links when the chain is reconnected.

© BUCYRUS AMERICA, INC.

IMPORTANT! Hog rings should be installed so that their sharp points are directed clockwise.

WARNING! The next step removes the secondary planetary gear ring from the secondary planetary gear assembly. The secondary planetary gear ring is extremely heavy. Be prepared to support its weight before removing it from the secondary planetary assembly.

IMPORTANT! The flat edge of the cover located adjacent to the lubrication fitting is the top of the cover. Orient the cover so that the lubricant level check plug is on the motor side of the cover and the drain plug is on the bottom.

WARNING! The next step removes the tram case from the tractor frame. The tram case (with sprocket and reach gears) is extremely heavy. Be prepared to support the tram case before removing it from the tractor frame.

WARNING! Ensure that the electrical cables and cooling water hoses for the tram motor are free from the tram cases before attempting to remove the tram case from the tractor frame.

IMPORTANT! The guide wires will be used to pull the tram track links onto the tram case sprocket after the tram case is installed.

WARNING! Before attempting to slide the tram case into the tractor frame, ensure that the tram motor electrical and water connections are out of the way. Failure to do so may result in damage to the electrical and water connections.

IMPORTANT! The re-installation procedure for the tram case includes reinstallation of the primary and secondary planetary gears and the tram motor, and reconnection of the tram track.

______________________________________________________________ A6474X332 VSSV/00 2.27

Overview of safety instructions _________________________________

WARNING! The next step removes the sprocket from the tram case. The sprocket is extremely heavy. Be prepared to support its weight before removing it from the tram case.

IMPORTANT! When the bearing sleeve is inserted into position, the o-ring forms a seal between the sleeve and the piece that holds it.

WARNING! Stand clear of the miner when using the motor to pull the tram track through the tram case.

WARNING! The hydraulic pump motor is now detached from the tractor frame and can be removed. The hydraulic pump motor is extremely heavy. Prepare to support its weight before removing it from the tractor frame.

WARNING! The scrubber fan/motor is now detached from the tractor frame and can be removed. The hydraulic pump motor is extremely heavy. Prepare to support its weight before removing it from the tractor frame.

WARNING! Stand clear of the blocked tractor frame during contraction of the stabilizer cylinder.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.

WARNING! The next steps require crawling under the block supported conveyor tail section. Verify that this tail section is adequately secured before proceeding.

IMPORTANT! Machine power must be disconnected during installation of the current generator. Cutter motor feedback adjustment is normally set with the crawler tracks off the mine floor, stabilizer and cutter head down (machine jack-knifed). To jack-knife the machine you should be familiar with the hydraulic circuits on the miner, and in particular, the cutter head cylinder and the shear down/ maintenance valve (anti-chatter) operation as described in the hydraulic section of this chapter. (Chapter 5)

_________________________________________________________________ 2.28 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

WARNING! Double check that the links of the tram track are correctly seated onto the tram drive sprocket. Improper engaugement of the tram track links onto the sprocket can cause serious mechanical damage.

________________________________ Overview of safety instructions WARNING! Each stabilizer cylinder is extremely heavy. The next steps will remove the cylinder from its tractor frame mounting. Be prepared to support the weight from its tractor frame mounting. Be prepared to support the weight of the cylinder when it becomes free from the mounting.

IMPORTANT! To obtain maximum performance, the duocone seals must be installed accurately to insure uniform loading at the mating faces and achieve a stable running position. Misalignment or cocking of seal rings during assembly can produce non-uniform loading and wobbling of the seals in their housings resulting in leakage due to scoring and/or pumping of debris past the toric rings. Improper installation can also result in breakage of the metal seal rings.

© BUCYRUS AMERICA, INC.

NOTICE! Improper care and installation of duocone seals can result in immediate leakage or reduced service life.

IMPORTANT! The toric must lie uniformly in the seal with the sealing ring and parallel to the seat face. Be sure that the toric is not twisted and that it rests uniformly against the retaining lip or not deeper in one side of the seat than the other.

IMPORTANT! Do not get any oil onto the rubber torics!

IMPORTANT! Even a small piece of lint can hold the faces apart and cause leakage!

IMPORTANT! A mixture of marking compound and spindle oil is good lube for the gears under light loads for 2-3 revolutions only. Check tooth patterns all round to make sure the pattern/markings are uniform.

CAUTION! Be careful not to set fire to any grease or lubricant when heating bearings!

IMPORTANT! Observe all applicable fire and safety regulations when heating bearings!

______________________________________________________________ A6474X332 VSSV/00 2.29

Overview of safety instructions _________________________________ CAUTION! Because gear maintenance techniques are specialized, they should be performed only by qualified personnel.

CAUTION! Do not power wrench the lead thread of the lock ring insert until it is engaged by hand turning. Then tighten normally.

IMPORTANT! Anti-seizing compounds may be used with this type of locknut.

Washers are not normally required here, but if assembly does, include them as they are needed due to high stress torque.

WARNING! Do not substitute materials or compounds not complying with the OEM specifications. Use of non-OEM supplies may void warranties.

IMPORTANT! When performing maintenance on the machine, remember that fabrication, installation, modifications or adjustments must be according to OEM specifications.

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

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

IMPORTANT! If breaker reset option is used, see warning tag (Fig. 13).

_________________________________________________________________ 2.30 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

WARNING! Components not meeting specifications can fail, cause serious injury, and damage equipment.

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

IMPORTANT! Due to the application of fasteners being subject to great stresses and heavy or extreme vibration, it is imperative that all bolts be applied with an adequate amount of torque. For this reason this list of recommended torque settings for different types and sizes of fasteners used has been compiled. The tightening torques stated in the spare parts lists have to be observed, as well, for installation and maintenance.

© BUCYRUS AMERICA, INC.

IMPORTANT! Use a calibrated torque wrench for accuracy!

NOTICE! Use only lubrication fluids and greases approved by Bucyrus America, Inc. ! These fluids and greases have been tested at Bucyrus America, Inc. and guarantee reliable operation of the mechanical and hydraulic functions of the machine.

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

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

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

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

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

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

______________________________________________________________ A6474X332 VSSV/00 2.31

Overview of safety instructions _________________________________

© BUCYRUS AMERICA, INC.

IMPORTANT! As lubrication technology evolves, manufacturers continue to reformulate their products to obtain improved characteristics regarding wear, water dispersion, water absorption, environmental impact and a variety of other performance criteria. When an approved lubricant on this list has been superseded by a new formulation, it is recommended that the new formulation be tested to ensure compliance with the appropriate Bucyrus specification. At a minimum, a statement of conformance from the lubricant supplier should be obtained.

_________________________________________________________________ 2.32 Bucyrus – Model 25M0 Continuous Miner

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Storage and transport

________________________________________________________________

________________________________________________________________

_________________________________________________________________

________________________________________ Storage and transport

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

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

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

Storage corrosion protection

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

© BUCYRUS AMERICA, INC.

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

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

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

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

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

short-term storage

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

long-term storage

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

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

■ Completely fill the hydraulic oil tank with oil.

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

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

■ Completely drain the water system and refill with a 50/50 antifreeze/water solution. Pump the antifreeze mix through the system until the antifreeze mix comes out the water sprays. ENSURE THAT THE SYSTEM IS COMPLETELY PURGED AND NO WATER OR AIR POCKETS EXIST. ■ The equipment must be stored in a well ventilated, dry room. Do not store outdoors. ______________________________________________________________ A6474X332

VSSV/00

3.3

Storage and transport _________________________________________ machine electrical components

Forced Potato electronic components have the following storage requirements: ■ ■ ■

traction drives

Graphic displays must be stored at temperatures above 14 °F (-10 °C) Power supplies must be stored at temperatures above -3 °F (-20 ° C) Other components must be stored at temperatures above -13 °F (-25 °C)

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

random sample inspection

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

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

natural aging

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

HFA fluids

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

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

Long-term storage of spare components hydraulic components

miscellaneous components

motors fan assembly

If a component is to be stored more than six months, the hydraulic component must be completely filled with a corrosion inhibiting fluid.

Fill the hollow areas of hydraulic components (e.g. the piston chambers) in horizontal position (ports facing upwards) until they start to overflow then seal the ports with plastic or steel plugs.

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

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

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

plastic deformation

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

3.4

Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

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

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

dimensions,

■

weights,

■

lifting points, etc.

Additional information on the dimensions and weights can be found in chapter 6 and in the lifting weight guide (Table 1) in this operating section.

© BUCYRUS AMERICA, INC.

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

Use only suitable load handling devices.

Table 1: Lifting weights of Continuous Miner Assemblies

removal and installation of heavy components

Description

Approximate Weight

Complete Machine

105,000 lbs.

Tractor Frame Assembly

43,000 lbs.

Gathering Head Assembly

18,000 lbs.

Conveyor Assembly

12,000 lbs.

Cutter Head Assembly

32,000 lbs.

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

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

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

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

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

______________________________________________________________ A6474X332 VSSV/00 3.5

Storage and transport _________________________________________ Transport environment temperatures below freezing

Before transporting the equipment at temperatures below freezing, all hydraulic components operated with emulsion (HFAE or HFAS) must be completely drained and then filled with a corrosion inhibitor/frostproofing fluid.

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

electronic components

Electrical and electronic components must be protected against harmful environmental influences by a suitable packaging. The electrical cables remain in the equipment. They must be carefully protected against transport damage and soiling of the connections.

_________________________________________________________________ 3.6 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

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

_______________________________________________________________

Installation

________________________________________________________________

________________________________________________________________

_________________________________________________________________

__________________________________________________ Installation

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

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

© BUCYRUS AMERICA, INC.

Work on: ■

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

■

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

■

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

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

Which tools are required for installation? tool box

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

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

These include: ■

hoists with adequate lifting capacity

■

means of attachment with adequate lifting capacity

■

unloading dock and crib blocks

■

jacks with adequate lifting capacity

■

impact wrenches, including accessories

______________________________________________________________ A6474X332 VSSV/00 4.3

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

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

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

reassembly instructions

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

_________________________________________________________________ 4.4 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

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

__________________________________________________ Installation Pre-installation check list NOTICE! The machine was inspected prior to shipment from the factory to ensure proper functioning and installation of all components.

However, to ensure that no transit damage has occurred, the following pre-startup checks should be performed: 1. visually inspect all cylinders, gear boxes, tanks, and hydraulic components for leaks or damage.

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

3. check the full length of the trailing cable for damage

© BUCYRUS AMERICA, INC.

4. ensure that the trailing cable is properly suspended across intersections and that the trailing cable clamp at the Continuous Miner is secure 5. visually inspect all hydraulic hoses and electrical cables for damage 6. check that all covers and guards are in place and secure 7. check that all tags and instruction labels are in place and secure 8. check that operator’s canopy (optional) is secure and in place clean any foreign material from the optional operator’s compartment, conveyor, and gathering pan 9. clean any foreign material from the operator’s compartment (if equipped), conveyor and gathering pan.

10. perform daily maintenance 11. check safety provisions for operational condition on fire suppression system 12. start up the machine and check for correct operation of all stop switches.

13. start the machine and allow the hydraulic system to warm up for five (5) to ten (10) minutes 14. check hydraulic system pressures (refer to the hydraulic schematic supplied for your particular machine for pressure settings) 15. check and operate all control handles and remote switches to ensure all machine functions are operating properly and are in neutral position 16. check the tension of the conveyor chain and crawler chain

______________________________________________________________ A6474X332 VSSV/00 4.5

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

machine stop button

The machine is equipped with a machine stop button located on both sides of the miner. The machine stop button (s) are used to break the control circuit only in emergency situations, stopping all motors. Striking with a small amount of force will actuate the machine stop button.

canopy/cab (optional)

The machine may be shipped from the factory with a protective canopy/ cab (optional). Ensure that the canopy/cab is in place and secure at all times to protect the operator from falling debris.

fire suppression

The machine may be equipped with fire suppression (remote) actuators. If equipped, the location may vary. This particular suppression system is pneumatically actuated and extinguishes with dry chemicals.

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

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

fire sprays

Water can be directed to the fire spray nozzles manually from the fire spray valve by the fire spray valve on the left hand side of the machine.

On radio units, an electronically actuated solenoid is used to actuate the fire spray system from the remote position.

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

CAUTION! The mine supply water pressure at the machine should not exceed 500 psi and should supply 20 gpm minimum for cooling.

The remote fire spray actuator located on the main feed behind the miner is used to activate the fire spray when there is a fire and power has been turned off. Simply turning the valve allows 'pilot' oil to feed into the small hose secured within the valve assembly and through the main feed line into the miner, where it contacts a solenoid that activates the fire spray system.

_________________________________________________________________ 4.6 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

Safety features include: (Reference Fig. 6)

__________________________________________________ Installation scrubber/dust suppression (optional)

© BUCYRUS AMERICA, INC.

guards and covers

The Continuous Miner may be equipped with an optional dust suppression package (scrubber). The dust suppressor allows the Miner operator to use fan induced ventilation at the face. The fan suction draws in the dust and liberated methane from the intake duct(s). The dust laden air is then drawn through the scrubber screen, which is constantly flooded with water spray. The dirty water is then removed from the air stream by a de-mister which is located directly behind the scrubber screen. The dirty water flows down to a sump tank where a water powered jet pump empties the sump and dumps the dirty water onto the conveyor or gathering pan. The clean, dry air exits the de-mister and is discharged into the mine atmosphere at the rear of the miner, diffused downward and towards the rib to prevent coal fines from being blown on the offside shuttle car operator.

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

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

start switch safety covers

Every switch on the operator’s controller case that engages a function (pump start, cutter start, etc.) is protected from accidental activation by a cover.

methane monitor

The machine is equipped with a methane monitor that detects the presence of methane in the mine atmosphere. When the miner is being powered up, the monitor looks for methane before any other function is energized. If the methane monitor detects a level of methane within a preset tolerance, the methane monitor relay will close and power will be supplied to the other functions on the machine. (The machine can have an optional dual sniffer head or dual readout.)

______________________________________________________________ A6474X332 VSSV/00 4.7

Installation___________________________________________________ Fig. 6: Safety features on the Continuous Miner

Machine stop (location typical)

© BUCYRUS AMERICA, INC.

Methane monitor display

Safety covers

Manual circuit breaker reset (optional)

Panic bar/ machine stop

_________________________________________________________________ 4.8 Bucyrus – Model 25M0 Continuous Miner

Installation___________________________________________________ Fig. 7: Overview of the Continuous Miner Conveyor boom

Cutter boom

Crawler assembly

Gathering head assembly

_________________________________________________________________ 4.9 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

Operator’s station

_______________________________________________________________

Operation

________________________________________________________________

__________________________________________________________

___________________________________________________Operation

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

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

How to operate the Continuous Miner

© BUCYRUS AMERICA, INC.

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

Who is allowed to operate the Continuous Miner?

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

This also includes: ■

what safety devices are installed on the machine.

■

where these safety devices are located.

■

how these safety devices are to be operated.

When can operation be started?

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

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

______________________________________________________________ A6474X332 VSSV/00 5.3

___________________________________________________Operation Controls and indicators Operator’s station WARNING! The Continuous Miner is radio remote controlled. Manual operation is generally for troubleshooting and maintenance under roof support. Operating the Continuous Miner manually from the Operator’s case may result in serious injury or death.

© BUCYRUS AMERICA, INC.

The primary controls for the machine are normally located at the operator’s station (Fig. 8) on the right hand side of the machine near the rear bumper.

The explosion proof operator’s station houses the controls and indicators used in the normal operation of the machine. Mounted inside the case are the main circuit breaker, auxiliary circuit breaker, control transformer, methane monitor relay, electrical metering package, control breakers, headlight switch, radio/manual switches, manual start/ stop switches, and bridge rectifiers. All control breakers are located within this case, behind the small access cover located above the trailing cable entrance. The trailing cable enters into this enclosure at the bottom left corner facing the case. The machine stop is mounted on the enclosure and operates the pump stop switch to shut the machine down.

The manual circuit breaker reset levers (optional) are located at the front bottom of the case.

Fig. 8: Operator’s station “MACHINE STOP”

Electrical switches

Electrical metering package (optional)

Circuit breakers

Tram control levers

Main circuit breaker (pin out)

______________________________________________________________ A6474X332 VSSV/00 5.4

Operation____________________________________________________ tram control levers (optional)

The optional tram control levers (Fig. 9) control the speed and direction of each (left and right) crawler drive. The tram control levers can be used together (to tram straight forward or straight backwards), in opposite directions (for fast turns), or individually (for slow turns). When in manual mode, the “TRAM DEADMAN” switch must be depressed and the tram control levers in the center (neutral) position, prior to starting the pump or tram motors.

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

IMPORTANT! Once the tram/steering control lever is released by the operator the control lever automatically returns to the centered (neutral) position.

To tram forward, push the tram lever slowly forward, away from the operator. To tram in reverse, pull the lever slowly back, toward the operator. The further the lever is pushed or pulled, the faster the tramming.

When released, the tram lever returns to the centered (neutral) position.

To tram straight forward, push both levers forward at the same time. To tram straight back, pull both levers back at the same time.

To turn left, pull the left crawler lever back and push the right crawler lever forward. To turn right, push the left crawler lever forward and pull the right crawler lever back. The speed of the turn is determined by whether the levers are operated at the same time or separately.

Fig. 9: Tram control levers (optional)

Left tram control lever

Forward Reverse

Right tram control lever

_________________________________________________________________ 5.5 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

CAUTION! MANUAL ONLY: The Continuous Miner’s tram and steering speed is variable. This means that the farther the tram handle is actuated the faster the Continuous Miner will travel or turn. The tram lever must be moved slowly. Moving the tram levers too quickly may result in severe injury or loss of control.

___________________________________________________Operation machine stop/panic bar

Pressing the machine stop (Fig. 10) will shutdown the pump, causing the miner to shutdown. To restart the machine after striking the machine stop, follow normal pump start up procedure (see Start procedure in this chapter).

Fig. 10: Machine stop

Machine stop

Electrical switches

© BUCYRUS AMERICA, INC.

The electrical switches (Fig. 11) that control the machine operation are a group of push button switches located on the control case.

WARNING! Manual operation of the Continuous Miner is not allowed for production operation unless the miner has an operator’s pit and canopy. Manual operation is generally for troubleshooting and maintenance under roof support. Operating the Continuous Miner manually from the operator’s station may result in serious injury or death.

“PUMP START”

The “PUMP START” switch starts the pump motor. To start the motor, depress the switch.

“PUMP STOP”

The “PUMP STOP” switch stops the pump motor. To stop the motor, depress the switch.

“CUTTER START”

Starting the cutter motor is a two-hand start: push the “PUMP START” and the “CUTTER START” switch at the same time. The left cutter motor will start first and, after a preset time, the right cutter motor will start.

“CUTTER STOP”

The “CUTTER STOP” switch shuts down both cutter motors. Both motors stop when the “CUTTER STOP” switch is depressed.

“CONVEYOR FWD”

The conveyor motors cannot be started until the pump motor is started.

Depressing the “CONVEYOR FWD” switch starts the conveyor motors.

The forward direction of the conveyor chain is always away from the cutter head.

“CONVEYOR REV”

The conveyor motors cannot be started until the pump motor is started.

Depress and hold the “CONVEYOR REV” switch to start the conveyor motors. When the conveyor motors are running in reverse, the conveyor chain is moving in the direction of the cutter head. The conveyor will continue to run in reverse until the “CONVEYOR REV” switch is released. The conveyor cannot be started in the forward direction until a preset amount of time has elapsed from running the conveyor in reverse. ______________________________________________________________ A6474X332

VSSV/00

5.6

“CONVEYOR STOP”

Depressing the “CONVEYOR STOP” switch will stop the conveyor motors when the conveyor is running forward (away from the cutter head).

“SCRUBBER”

The pump motor must be running before the scrubber motor will start.

Depress and hold the “SCRUBBER” switch to start the scrubber motors and to energize the screen sprays. To stop the scrubber motor, release the ‘SCRUBBER” switch.

“TRAM DEADMAN”

The “TRAM DEADMAN” switch must be depressed and held to tram.

Releasing the “TRAM DEADMAN” switch will stop tramming functions.

“LIGHTS”

The “LIGHTS” switch has three positions: “MANUAL”, “OFF”, AND “RADIO”. The “OFF” position turns all lights, area lights and headlights, off. When the light switch is turned to the “MANUAL” position, the headlights and the area lights will both turn on. when the light switch is turned to the “RADIO” position, the area lights are illuminated and the headlights can be turned on and off with the radio remote.

“RADIO/MANUAL SW. 1”

The “RADIO/MANUAL SW. 1” switch puts the machine under manual or radio control.

“RADIO/MANUAL SW. 2”

The “RADIO/MANUAL SW. 2” switch connects motor control to the manual push buttons and isolates control from the machine controller.

In the radio position, “RADIO/MANUAL SW. 2” isolates the push buttons and connects motor control to the machine controller.

control breakers

The control breaker switches turn the breakers on and off and are also used to reset a breaker that has tripped. All control breakers are turned on by pushing the button in and are turned off by pulling the button out.

If a breaker trips, the button must be pulled out to reset the breaker, then pushed in to turn it on. The control breakers may vary and can be identified by the labels on the front of the operator’s case.

_________________________________________________________________ 5.7 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

Operation____________________________________________________

___________________________________________________Operation Fig. 11: Electrical control switches “PUMP START”

“CUTTER START”

“CONVEYOR FWD”

“SCRUBBER”

“CUTTER STOP”

“PUMP STOP” “CONVEYOR STOP”

© BUCYRUS AMERICA, INC.

Circuit breaker reset panel “TRAM DEADMAN”

“CONVEYOR REV”

“RADIO/ MANUAL SW. 1”

“RADIO/ MANUAL SW. 2”

“LIGHTS”

______________________________________________________________ A6474X332 VSSV/00 5.8

Operation____________________________________________________ Electrical metering package (optional)

“LEFT CUTTER MOTOR” and “RIGHT CUTTER MOTOR”

The “LEFT CUTTER MOTOR” and “RIGHT CUTTER MOTOR” ammeters monitor the current draw by the cutter motors. During normal operation, the two meters should indicate approximately the same current draw. If one meter consistently reads higher than the other meter, shutdown the machine (see Shutdown procedure in this chapter) and contact Maintenance.

“LEFT CONVEYOR MOTOR” and “RIGHT CONVEYOR MOTOR”

The “LEFT CONVEYOR MOTOR” and “RIGHT CONVEYOR MOTOR” ammeters monitor the current draw by the conveyor motors. During normal operation, the two meters should indicate approximately the same current draw. If one meter consistently reads higher than the other meter, shutdown the machine (see Shutdown procedure in this chapter) and contact Maintenance.

“MACHINE VOLTAGE”

The “MACHINE VOLTAGE” voltmeter indicates the control circuit voltage. During normal operation, the indicator should stay between 855 and 1,045 volts (950V ± 10%). Should the meter indicate high or low voltage, shutdown the machine (see Shutdown procedure in this chapter) and contact Maintenance.

“CUTTER HOURS”

The “CUTTER HOURS” meter indicates the hours of running time for the cutter head motors.

“CONVEYOR HOURS”

The “CONVEYOR HOURS” meter indicates the hours of running time for the conveyor motors.

Fig. 12: Electrical metering package (optional) “LEFT CUTTER MOTOR” ammeter

“RIGHT CUTTER MOTOR” ammeter

“LEFT CONVEYOR MOTOR” ammeter

“RIGHT CONVEYOR MOTOR” ammeter

“MACHINE VOLTAGE” volt meter

“CUTTER HOURS” meter

“CONVEYOR HOURS” meter

_________________________________________________________________ 5.9 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

The optional electrical metering package (Fig. 12) consists of a group of meters that monitor current draw on the motors, machine voltage, and cutter and conveyor hours of operation.

___________________________________________________Operation circuit breaker

The circuit breaker is the main circuit breaker for the machine. The circuit breaker has two (2) positions: "OFF," to de-energize the machine's electrical systems and "ON," for normal operation. The circuit breaker should be in the "OFF" position before the machine is serviced or shutdown.

WARNING! The machine circuit breaker de-energizes the electrical controller and motors. However, electrical power is still present inside the connection box to the circuit breaker. If the circuit breaker inside the connection box requires service, the trailing cable should be disconnected from the power center.

© BUCYRUS AMERICA, INC.

manual circuit breaker reset (optional)

The manual circuit breaker reset levers (Fig. 13) are located below the electrical switches at the operator’s control station. The circuit breaker trips when the electrical system is overloaded or shorted.

WARNING! Once the breaker has tripped, it will not stay in the “ON” position without first being moved to the "RESET" position, and then to "ON".

To reset the circuit breaker manually proceed as follows:  Move the selector to “RESET” position and move the circuit breaker to full “OFF” position.  Move the selector to the “ON” position for normal operation.

Fig. 13: Manual circuit breaker reset

“MAIN BREAKER” reset (shown with pin out)

“AUXILIARY BREAKER” reset (not shown)

______________________________________________________________ A6474X332 VSSV/00 5.10

Operation____________________________________________________ machine stop/e-stop

The Continuous Miner is equipped with a machine stop button (Fig. 14) located on the left and right sides of the machine. The machine stop/estop button is used to break the control circuit, stopping all motors.

Striking with a small amount of force will actuate the machine stop.

WARNING! Be prepared for a sudden stop when the machine stop/e-stop is actuated during normal tramming of the machine.

methane monitor

Machine stop (2) (location typical)

The machine is equipped with a methane monitoring system (Fig. 15) which, when energized, maintains a continuous check on methane gas concentration. This machine has an LED indicator displays which show the percentage of methane gas in larger numerals.

Consult the manufacturer’s manual and literature in the Bucyrus parts book for your machine for the setup, operation, and maintenance of the methane monitoring system.

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

Fig. 15: Methane monitor display

Methane monitor display

_________________________________________________________________ 5.11 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

Fig. 14: Machine stop/e-stop—right side

___________________________________________________Operation radio remote control

When operated by a radio (Fig. 16), a portable wireless remote with a unique code feature sends radio commands to a receiver in the switch console via a whip antenna setup. The small whip antennae intercept the radio signals which the receiver translates into electrical commands to various electrical circuits to perform the function selected.

These circuits energize solenoids which actuate pilot-valves, switches, or relays controlling a specific mechanical, hydraulic, or electrical function.

There are eight selectable frequencies which permits each operator to activate only his designated miner, allowing several remote-controlled miners to operate in the same area without getting their radio signals crossed. In addition, an improperly decoded radio signal will automatically shutdown the miner.

© BUCYRUS AMERICA, INC.

Always refer to the specific radio remote control operation manual supplied with your specific machine for details and options on the radio remote control.

IMPORTANT! Refer to the radio remote control operation manual supplied with your machine for information regarding the operation of your specific remote control.

Fig. 16: Radio remote control (typical)

Top view

______________________________________________________________ A6474X332 VSSV/00 5.12

Operation____________________________________________________ “LOW OIL” light (optional)

The optional “LOW OIL” light (Fig. 17) illuminates when the hydraulic oil level in the machine is low. If the “LOW OIL” light comes on, shutdown the machine (see Shutdown procedure in this chapter) and check the hydraulic oil level. If oil is needed, add oil (see procedure in Maintenance section of this chapter).

Fig. 17: “LOW OIL” light (optional)

© BUCYRUS AMERICA, INC.

“LOW OIL”

_________________________________________________________________ 5.13 Bucyrus – Model 25M0 Continuous Miner

___________________________________________________Operation Valve bank The manually operated valve bank (Fig. 18) is located on the near the operator’s station and is used to operate the miner during maintenance and troubleshooting functions while under supported roof.

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

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

“CONVEYOR RAISE/LOWER”

The second lever from the operator’s left, “CONVEYOR-RAISE/ LOWER”, controls the cylinders that raise and lower the conveyor boom. To raise the conveyor, pull the lever toward the operator. To lower the conveyor, push the lever away from the operator.

“CONVEYOR LEFT/RIGHT”

The third lever from the operator’s left, “CONVEYOR-LEFT/RIGHT”, controls the conveyor swing cylinders. To swing the conveyor boom to the left, push the lever away from the operator. To swing the conveyor boom to the right, pull the lever toward the operator.

“GATH HD”

The fourth lever from the operator’s left, “GATH HD”, controls the cylinders that position the gathering head. To raise the gathering head, push the lever away from the operator. To float the gathering head, pull the lever toward the operator.

“CUTTING HD”

The fifth lever from the operator’s left, “CUTTING HD”, controls the cylinders that raise and lower the cutting head. To raise the cutting head, pull the lever toward the operator. To lower the cutting head, push the lever away from the operator.

© BUCYRUS AMERICA, INC.

“STABILIZER”

Fig. 18: Valve bank

“STABILIZER”

“CONVEYOR RAISE/LOWER”

“CUTTING HD”

“GATH HD”

“CONVEYOR LEFT/RIGHT”

______________________________________________________________ A6474X332 VSSV/00 5.14

___________________________________________________Operation Gauge panel (optional) The optional gauge panel (Fig. 19) consists of gauges used to monitor water and hydraulic pressure throughout the miner.

The “MINER WATER PRESSURE” gauge monitors the pressure at the main distribution manifold for the water system on the miner. See the miner water pressure circuit in the hydraulic section of this chapter for further information.

“MAIN PRESSURE”

The “MAIN PRESSURE” gauge is used to measure the pressure in main flow - primary pressure circuit. See the main flow - primary pressure circuit in the hydraulic section of this chapter for further information.

“PILOT CIRCUIT PRESSURE”

The “PILOT CIRCUIT PRESSURE” gauge is used to monitor the supply pressure for all pilot functions. See the pilot pressure circuit in the hydraulic section of this chapter for further information.

“GH FLOAT PRESSURE”

The “GH FLOAT PRESSURE” gauge monitors the pressure of the extend port of the gathering head float cylinders. This pressure gauge displays different readings depending on the operating condition of the cylinders:

© BUCYRUS AMERICA, INC.

“MINER WATER PRESSURE”

■

With the gathering head working section of the main control valve in the Gathering Head Up (GHU) position and the cylinder fully extended, the gauge will display the setting of the relief valve “CR” and the valve can be adjusted using the gauge.

■

With the gathering head working section of the main control valve in the Gathering Head Float (GHD/F) position, the gauge can be used to adjust the pressure in the gathering head float counterbalance valve “VR” and the valve can be adjusted using the gauge.

■

With the gathering head working section of the main control valve in the center position, the gauge displays the pilot pressure at the valve manifold.

■

The gauge will also display high pressures seen by the gathering head cylinders during normal operation.

“ACCUMULATOR PRESSURE”

The “ACCUMULATOR PRESSURE” gauge is used to monitor accumulator pressure. The purpose of the accumulator is to store the necessary pilot pressure to allow remote operation of the fire suppression and breaker on/off control valves when the pump is not operational.

The accumulator pressure should closely track the pilot circuit pressure. If the accumulator does not hold pressure when the pump is shutdown, call maintenance. See the accumulator pressure circuit in the hydraulic section of this chapter for further information.

“SHEAR DOWN PRESSURE”

The “SHEAR DOWN PRESSURE” gauge is used to monitor the pressure of the cutting head cylinder circuit during shear down operations.

See the shear down/maintenance (anti-chatter) valve in the cutter head cylinder circuit in the hydraulic section of this chapter for further information.

______________________________________________________________ A6474X332 VSSV/00 5.15

Operation____________________________________________________ Fig. 19: Gauge panel “MINER WATER PRESSURE”

“PILOT CIRCUIT PRESSURE”

“GH FLOAT PRESSURE”

“SHEAR DOWN PRESSURE”

© BUCYRUS AMERICA, INC.

“MAIN PRESSURE”

“ACCUMULATOR PRESSURE”

_________________________________________________________________ 5.16 Bucyrus – Model 25M0 Continuous Miner

___________________________________________________Operation water regulator assemblyscrubber spray gauge and jet pump gauge

The water regulator assembly (Fig. 20) is located in the left hand rear of the machine near the scrubber. The water regulator assembly includes the scrubber spray gauge and the jet pump gauge. The scrubber spray gauge monitors the water pressure of the scrubber sprays.

The jet pump gauge monitors the water pressure of the jet pump. Consult the schematic in the Bucyrus America, Inc. parts manual supplied with your machine.

Fig. 20: Water regulator assembly

Scrubber spray pressure gauge

© BUCYRUS AMERICA, INC.

Jet pump pressure gauge

fire suppression spray valvepilot operated (optional)

The pilot operated fire suppression spray valve (Fig. 21) is typically located on the left hand side of the machine. This pilot operated, 2-way, 2-position valve can also be operated manually. The spool is detented so that it stays in the open position until it is manually closed by pulling on the knob.

Fig. 21: Fire suppression spray valve-pilot operated

Fire suppression spray valvepilot operated

______________________________________________________________ A6474X332 VSSV/00 5.17

Operation____________________________________________________ fire suppression spray valvemanually operated

The manual fire suppression spray valve (Fig. 22) is located on the opposite side of the machine as the pilot operated valve. This 2-way, 2position ball valve is operated by turning the handle 90 degrees.

Fig. 22: Fire suppression spray valve-manually operated

© BUCYRUS AMERICA, INC.

Fire suppression spray valvemanually operated

_________________________________________________________________ 5.18 Bucyrus – Model 25M0 Continuous Miner

___________________________________________________Operation Machine control system A multi-component system is used to control and monitor the functions of the machine. This system consists of the following main components: ■

Machine controller

■

Power supply

■

Input/Output (I/O) modules

■

Radio remote

■

Textdisplay

© BUCYRUS AMERICA, INC.

The following information is presented as a general guide to the capabilities and functions of the control system. Before attempting to operate, service, or troubleshoot the continuous miner, training must be completed. machine controller

The machine controller unit is the main control unit of the system. It includes the radio data controller which is used to receive and decode commands from the radio remote.

power supply

The control system has its own power supply, with the option of having battery backup for the power supply, which provides power to the machine controller and I/O modules.

input/output modules

Input/output modules are used to read data from and/or send commands to the following machine functions: ■

Cutter motors (left and right)

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Gathering head motors (left and right)

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Traction motors (left and right)

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Pump motor

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Hydraulic oil level

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Methane monitoring

Based on the parameter settings and the input received from different components, the control systems has the ability to issue error messages, fault messages, and/or shutdown the machine.

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Operation____________________________________________________ radio remote

The radio remote (Fig. 23) is a battery powered remote used to control the continuous miner during normal operations.

WARNING! Radio remote control systems are dangerous. The continuous miner operator cannot operate a remote system until he is properly trained in the operation of the system. Remote control systems sometimes have automatic features of which untrained operators and workers may not be aware.

The radio remote shown may vary from the remote that shipped with your machine.

_________________________________________________________________ 5.20 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

Fig. 23: Radio remote (typical)

___________________________________________________Operation Text display

There is a text display located near the back right hand side of the machine (Fig. 24) used to display diagnostic information on the miner.

Fig. 24: Control system display locations (typical)

Text display

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The text display will remain powered through the battery back up if the control system loses power.

Normal display pages The main diagnostic screen (Fig. 25) is displayed during normal remote control operation of the machine. The screen presents real time diagnostic and performance information.

Fig. 25: Main diagnostic screen, example

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___________________________________________________Operation System Menu The control system provides information, diagnostic, and setup screens that are grouped together in the system menu (Fig. 26). The system menu is accessed by using the display module and a remote control handset.

To access and navigate the system menu using the radio remote:  Press the SHIFT and MENU key to access the system menu screen.

IMPORTANT! All functions and motors are shut down and disabled when the system menu is selected.  Press CONV UP or CONV DOWN to move the cursor up and down the list.

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 Press SHIFT and MENU to select the highlighted item  To leave the menu and return to remote mode, press SHIFT and REMOTE. Fig. 26: System menu, example

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Operation____________________________________________________

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Fig. 26: System menu, example, continued

_________________________________________________________________ 5.23 Bucyrus – Model 25M0 Continuous Miner

___________________________________________________Operation Other functions The control system allows a large number of monitoring screens to be selected and displayed while the machine is operating. After accessing the selected screen, press SHIFT and MENU to return to the system menu.

Factory default settings may be restored to non-password-protected setup parameters.

The control system includes the following screens: ■ ■ ■ ■ ■ ■

Date/Time setting Module temperatures Solenoid self-test User setup options Engineering setup options Fault Log

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Fig. 27: Other control system functions

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___________________________________________________Operation Fault log The fault log (event monitor) (Fig. 28) allows the user to view the last 32 faults that have occurred since the log was last cleared.

To navigate the fault log page:  Press the CONV LEFT or CONV RIGHT keys to move the cursor up or down the page.  Press SHIFT and MENU keys together to return to the system menu.

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It is possible to clear the fault log under the Engineering Setup Menu, which is password protected.

IMPORTANT! It is not recommended that the fault log be cleared unless the machine controller has been replaced. Retaining the faults is very helpful in troubleshooting a problem when a machine controller is sent for service. Faults cannot be retrieved once they have been cleared. Use caution and only clear the log if it is absolutely necessary.

Once a fault has been selected, press and hold the SHIFT key to access more information on the fault.

Fig 28: Fault log, example

For a complete list of faults, see the troubleshooting section of this chapter.

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___________________________________________________Operation Red zone Remote controlled continuous miners The remote control of miners introduces certain potential safety hazards which the miner operator must watch for and be aware of. While the operator is now free to position himself for convenient visibility of mining operations at the face, he can easily expose himself to the danger of being near mobile heavy equipment.

Most significantly, the operator’s greatest danger is from his Continuous Miner, especially when he is maneuvering it during mining operations.

The miner is capable of slewing when turning, especially when the crawlers are split. The discharge conveyor can also swing. In each of these cases, the miner operator is in danger of being hit, or worse yet, run over by his own machine. Equally dangerous is the possibility of the operator being pinned against the rib by his own miner.

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Miner operator danger areas, or red zones Some typical situations dangerous to the miner operator are illustrated on the following pages. The danger area, or red zone (Fig. 29) is indicated by alternating red and white diagonal stripes.

Fig. 29: Red zone

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Operation____________________________________________________ Tramming the miner (Fig. 30) from one place to another, especially maneuvering around intersections. This illustrates that the operator should not place himself between his miner and the rib.

Beginning the first sump (Fig. 30) in a new cut. The miner is against the left rib and the discharge conveyor is swung toward the center of the entry ready for the haulage car. The operator must stay clear of the discharge conveyor and the rear of the miner.

Tramming the miner red zone

Beginning 1st sump red zone

Sumping in the left hand side of the cut (Fig. 31). As the miner penetrates the face, new unsupported roof is being exposed, and the operator now has an additional constraint to his movements. He must also stay clear of the haulage vehicle at the rear of the miner as it approaches the miner and while it is loading.

Repositioning the miner for the right hand cut (Fig. 31). Because the miner is backing out and turning in close quarters, the operator must stay behind the miner to be safe.

Sumping in the right hand cut (Fig. 31). Again, the operator must stay away from the face where the newly-exposed roof is unsupported, as well as staying clear of the haulage vehicle while it approaches and loads.

_________________________________________________________________ 5.27 Bucyrus – Model 25M0 Continuous Miner

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Fig. 30: Red zones

___________________________________________________Operation

Fig. 31: Red zones

Repositioning miner for right hand cut red zone

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Sumping on the left hand side red zone

Sumping in the right hand cut red zone

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Operation____________________________________________________ Crosscut red zones (Fig. 32). Beginning and completing crosscuts requires a lot of maneuvering of the miner and loading the haulage vehicle while at awkward positions. Crosscuts also result in newly exposed unsupported roof. Respecting a red danger zone is important to operator safety in these conditions.

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

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

Beginning a right hand crosscut red zone

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Fig. 32: Crosscut red zones

Right hand crosscut development

_________________________________________________________________ 5.29 Bucyrus – Model 25M0 Continuous Miner

___________________________________________________Operation Pillaring red zones (Fig. 33) Remote control offers a significant safety advantage in partial or complete removal of the pillars in retreat mining because it places the operator further away from potential collapsing roof.

Much of the area around the miner must be considered a red zone, mostly because of extensive unsupported roof and the need for temporary supports under weakened roof. With remote control, the operator can position himself safely away from the miner while still retaining a good view of the mining cycle.

A red zone around the miner is no longer applicable when working in the opposite right hand pillar, as the operator is now excluded from the entire working area because of failing roof considerations, even with the existence of temporary roof supports.

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When making an additional end cut into the pillar, creating a fender of coal between the two cuts, additional temporary roof supports are installed.

Because of roof pressures, the fender will tend to slough its ribs in the process of eventually crushing. Hence, the operator must stay away from this fender as well as avoiding the entry and crosscut areas as shown.

Fig. 33: Pillaring red zones

Pillaring in a left hand cut red zone

Pillaring in a end cut red zone

Pillaring in a right hand cut red zone

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Operation____________________________________________________ Safety precautions for underground operation

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

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

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This machine must be maintained in a permissible condition, following all state and federal laws.

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Make a visual check of the Continuous Miner before energizing.

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

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

Tramming safety rules ■

Communicate your intentions to the employees affected by the movement of the Continuous Miner.

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

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

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Position the cutter and gathering head for tramming.

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Position the stabilizer shoe and booms for tramming.

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Position your body completely inside the operator's compartment (optional), facing the intended direction of travel.

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

_________________________________________________________________ 5.31 Bucyrus – Model 25M0 Continuous Miner

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In addition to the preceding instructions for operating the Continuous Miner, observe the following special precautions after the Continuous Miner is taken underground.

___________________________________________________Operation Starting procedure WARNING! Failure to read and understand all operating instructions before starting the Continuous Miner could result in serious injury or death to the operator or persons around the machine or cause damage to the machine.

WARNING! Read all instructions carefully before attempting to start or operate machine.

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

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

WARNING! Before starting the Continuous Miner, make sure that no one is in the red zone (Fig. 30 through Fig. 34).

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

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

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

DANGER! Improper position could result in injury or death to the operator by crushing him against the rib or roof supports. It may also cause him to run over the trailing cable or dislodge the roof supports.

WARNING! Turning on the water sprays prior to cutting prevents the accumulation of dust and the generation of excessive heat which could cause an ignition or explosion.

After reading the previous descriptions and locating each control, the operator is ready to operate the Continuous Miner. An experienced operator should monitor a new operator’s indoctrination to the starting procedure.

______________________________________________________________ A6474X332 VSSV/00 5.32

Operation____________________________________________________ WARNING! The Continuous Miner is typically operated by radio remote control. Manual operation is not allowed for production operation unless the miner has an operator’s pit and canopy. Manual operation generally is for troubleshooting and maintenance under roof support.

The operating procedures listed in the following sections are for radio operation.

WARNING! Visually check for other personnel and verbally shout a warning before starting this machine. Make sure all personnel are completely clear of the machine and it’s components and check that any loose material, tools, oil cans or other objects are clear from the area before starting the machine.   Turn the main circuit breaker to the “ON” position.  Select “RADIO” on the “RADIO/MANUAL SW. 1”  Turn the power switch on radio remote to the on position.  Press “SHIFT” and wait 1/4 second.  While pressing “SHIFT”, press “PUMP ON”. Hold both keys in until the pump starts.  Release the “PUMP ON” key.

IMPORTANT! The “PUMP ON” key must be released before “SHIFT”. If “SHIFT” is released first, the pump motor will shut off.  Release the “SHIFT” key.

_________________________________________________________________ 5.33 Bucyrus – Model 25M0 Continuous Miner

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

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

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 Tram the miner to an area of well supported roof. Park the machine in its designated parking area out of traffic, on flat, solid ground. If it is not possible to park the machine on flat ground, park the machine at a right angle to the slope.

WARNING! After turning off the power to the machine, never walk away and leave the radio remote turned on. Failure to turn the radio remote off could result in an accident causing serious injury or loss of life.   Empty the conveyor and shut it off (see Conveyor operation in this chapter).  Lower the cutter head to the floor.  Lower the conveyor and gathering head.  Press and hold the “PUMP OFF” key. The pump motor should shutdown immediately.  Release the “PUMP OFF” key.  Turn off the water sprays.  Position all levers and controls to Neutral or Off.  Shut off the main power supply.  Shut off the mine water supply.

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Operation____________________________________________________ Tramming the miner Tramming requires cooling water to prevent damage.

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

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

 Ensure that the stabilizer shoe is away from the mine floor.  Raise cutter boom to best possible position to allow clearance from roof, ribs, and floor.  Raise gathering head away from the mine floor.

WARNING! Adjust conveyor boom to allow clearance from roof, walls, and floor. Failure to do so will result in damage to the conveyor boom.  Ensure adequate clearance at all times while tramming machine.

Be award of people, equipment, and cables.

Remote control - tram enable:  To enable machine tramming, press and release the “TRAM 2-3” key.  Once enabled, the tram levers can be used to drive left and right tramming tracks forwards and backwards. If the tram levers are released for a continuous period of five (5) seconds, the tram becomes disabled.  To re-enable the tram function, press and release the “TRAM 2-3” key.

Remote control - tram track console:  Press the “LEFT FWD” tram key to turn the left tramming track forward.  Press the “LEFT REV” tram key to turn the left tramming track backwards.  Press the “RIGHT FWD” tram key to turn the right tramming track forward.  Press the “RIGHT REV” tram key to turn the right tramming track backwards.

_________________________________________________________________ 5.35 Bucyrus – Model 25M0 Continuous Miner

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 Adjust conveyor boom to best possible position to allow clearance from roof, walls, and floor.

___________________________________________________Operation Remote console - tram speed control: The system allows the tramming to be driven in three discrete speeds (SPEED 1, SPEED 2, and SPEED 3). SPEED 1 is the default tramming speed.

To advance a speed:  Press the tram levers and “TRAM 2-3” keys together to move from SPEED 1 to SPEED 2.  Once in SPEED 2, press the tram levers and “TRAM 2-3” together to move from SPEED 2 to SPEED 3.

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The following tramming configurations are enforced by the control system for safety reasons: ■

Spilt track tramming is limited to SPEED 1 when cutter motors are not running.

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Single track tramming is normally limited to SPEED 1 when cutter motors are not running.

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It is possible to speed up a single track from SPEED 1 to SPEED 2 providing that tramming is started in SPEED 1.

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Tramming is limited to sump speed while the cutters are on.

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While the cutters are running, reverse speed can be incremented while the reverse tram keys are being pressed. Note that this option is used when the miner is retreating or pillar mining.

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

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

 Ensure that the pump motor is running. The cutter motors will not run if the pump motor is not running.   Press “SHIFT” and wait 1/4 second.  While holding in “SHIFT”, press “CUTTER ON”. Continue to hold both keys in until the cutter motors turn on.

IMPORTANT! Both cutter motors do not start at the same time. There is a preset timed delay between the left cutter motor starting and the right cutter motor starting.   Release the “CUTTER ON” key.

IMPORTANT! The “CUTTER ON” key must be released before “SHIFT”.

If “SHIFT” is released first, the cutter motors will shut off.  Release the “SHIFT” key.

To stop the cutter motors:   Press and hold the “CUTTER OFF” key. The cutter motors should shutdown immediately.  Release the “CUTTER OFF” key.

_________________________________________________________________ 5.37 Bucyrus – Model 25M0 Continuous Miner

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

___________________________________________________Operation

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

WARNING! Warn “ALL CLEAR” before starting the conveyor. Failure to do so may result in serious injury or death.  Ensure that the pump motor is running. The conveyor motors will not start if the pump motor is not running.   Press “SHIFT” and wait 1/4 second.  While holding in “SHIFT”, press “CONV ON”. Continue to hold until the conveyor motor turns on and the conveyor starts to run forward. © BUCYRUS AMERICA, INC.

 Release the “CONV ON” key.

IMPORTANT! The “CONV ON” key must be released before “SHIFT”. If “SHIFT” is released first, the conveyor motors will shut off.  Release the “SHIFT” key.

To stop the conveyor motors - conveyor forward  Press and hold the “CONV OFF” key. The conveyor motors should shutdown immediately.

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

WARNING! Warn “ALL CLEAR” before starting the conveyor. Failure to do so may result in serious injury or death.  Ensure that the pump motor is running. The conveyor motors will not start if the pump motor is not running.   Press “SHIFT” and wait 1/4 second.  While holding in “SHIFT”, press “CONV REV”. Continue to hold until the conveyor motor turns on and the conveyor starts to run in reverse.  The conveyor will continue to run in reverse until the “CONV REV” or the “SHIFT” key is released.

______________________________________________________________ A6474X332 VSSV/00 5.38

Operation____________________________________________________

 Scrubber motor To start the scrubber fan motor:  Ensure that the pump motor is running. The scrubber motor will not start if the pump motor is not running.  Press “SHIFT” and wait 1/4 second.  While holding shift, press “FAN ON”. Continue to hold until the scrubber fan motor turns on.  Release the “FAN ON” key.

IMPORTANT! The “FAN ON” key must be released before “SHIFT”. If “SHIFT” is released first, the fan motor will shut off.

To stop the scrubber fan motor:  Press and hold the “FAN OFF” key. The fan motor will shutdown immediately.  Release the “FAN OFF” key.

Control headlights and area lights The light switch has three positions: area lights only, all on and all off.

When the power is turned on to the continuous miner, the methane monitor relay is closed and the light switch is on. When the light switch is turned to the all on position, the headlights and the area lights (Fig. 29) will come on. When the light switch is turned to the area lights only position, the headlights only (not the area lights) can be turned on and off with the radio.

The headlights can be turned off and on from the remote console at any time that the light switch is in all on position and the remote console is on by: Reference Fig. 16.  Press the “SHIFT” and “LIGHTS” keys together to turn the lights on.  Press the “SHIFT” and “LIGHTS” keys together to turn the lights off. 

_________________________________________________________________ 5.39 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

 Release the “SHIFT” key.

___________________________________________________Operation Fire suppression in radio remote The control system uses a solenoid output to drive the fire suppression system on the continuous miner. The fire suppression can be activated at any time from the remote control console. If the machine is fitted with the battery backup version of the power supply, the fire suppression can also be activated in battery standby mode. The system will remain in battery standby mode for at least ten minutes after loss of main power to the machine.

When in radio mode, the fire suppression can be activated from the radio as follows:  Press the “SHIFT” and “FIRE” keys at the same time and hold for two (2) full seconds.

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 After two seconds, the fire suppression system will activate. At this time, the “SHIFT” and “FIRE” keys can be released.

See the operation manual for the radio remote that shipped with your machine for options.

Conveyor raise/lower and left/right in radio remote The pump motor must be running in order to control the conveyor raise, lower, and swing left/right.

To control the conveyor from the radio remote:  Press the “CONVEYOR LEFT” key to the left to swing the conveyor tail to the left. The solenoid controlling the left conveyor swing will remain energized until the key is released.  Press the “CONVEYOR RIGHT” key to the right to swing the conveyor tail to the left. The solenoid controlling the right conveyor swing will remain energized until the key is released.  Press the “CONVEYOR DWN” key to lower the conveyor boom.

The solenoid controlling the conveyor lower function will remain energized until the key is released.  Press the “CONVEYOR UP” key to raise the conveyor boom. The solenoid controlling the conveyor raise function will remain energized until the key is released.

Note: Conveyor left and right are described as viewed by the operator from the rear of the machine facing towards the conveyor discharge.

______________________________________________________________ A6474X332 VSSV/00 5.40

Operation____________________________________________________ Stabilizer (stab) cylinder raise/lower in radio remote The pump motor must be running in order to raise or lower the stabilizer cylinder.  Press “STAB UP” to raise the stabilizer cylinder. The stabilizer cylinder solenoid remains energized until the key is released.  Press “STAB DOWN” to lower the stabilizer cylinder. The stabilizer cylinder down solenoid remains on until the key is released.

See the operation manual for the radio remote that shipped with your machine for options.

Shear up/down in radio remote

 Press “SHEAR UP” to move the cutter head up. The shear up solenoid remains energized until the key is released (unless height limiting is in force).  Press “SHEAR DOWN” to move the cutter head down. The shear down solenoid remains energized until the key is released.

See the operation manual for the radio remote that shipped with your machine for options.

Gathering head raise/float in radio remote The pump motor must be running in order to raise or lower the gathering head.  Press “PAN UP” to lift the gathering head. The pan up solenoid remains energized until the key is released.  Press “PAN FLOAT” to “float” the head down.

_________________________________________________________________ 5.41 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

The pump motor must be running in order to raise or lower the cutter head.

___________________________________________________Operation Breaker “ON”/”OFF” in radio remote The control system allows the main circuit breaker on the miner to be turned on and off using the radio remote control console. This normally requires that a battery backup version of the power supply be installed on the machine.

To turn the breaker off:  Press and hold the “SHIFT” and “C.B. OFF” keys together for two (2) seconds. After two (2) seconds, the breaker off solenoid will energize, turning off the machine circuit breaker.

© BUCYRUS AMERICA, INC.

To turn the breaker on: It is essential that a battery backup version of the control system power supply be installed for this function to be available. Typically, a hydraulic valve provides the mechanical force for the breaker mechanism. To allow this valve to be operated after loss of power, a hydraulic accumulator is charged by the pump motor during normal “powered” operation of the machine. If the hydraulic accumulator is discharged, then it will not be possible for the breaker to be turned on from the radio remote.  Press and hold the “SHIFT” and “C.B. ON” keys together for two (2) seconds. After two (2) seconds, the breaker on solenoid will energize, turning on the machine circuit breaker.

IMPORTANT! The backup accumulator must maintain a minimum pressure of 500 psi for 12 minutes after the pump has been de-energized.

______________________________________________________________ A6474X332 VSSV/00 5.42

Operation____________________________________________________ Typical cutting sequence CAUTION! Always ensure operator safety while operating the machine.

CAUTION! Always be alert to hazardous conditions and take corrective action as necessary.

IMPORTANT! Care should be taken not to stall cutters on conveyor during cutting operations. Severe damage to motors and gear boxes could occur if cutters or conveyor are repeatedly stalled.  Place gathering head in the float position.

 Start the gathering head and conveyor. Do not start machine in face or with excessive material in the gathering head.  Engage tram and adjust for speed and direction.  Start cutter head prior to contacting area to cut.  Raise cutter head to desired mining height.  Lower the rear stabilizer to the floor to provide stability if necessary.

Do not lower the shoe enough to raise the rear of the machine. If the shoe is lowered too far the machine will not sump into the face properly.  Engage tram in the forward position.

IMPORTANT! Tram is limited in the forward direction while the cutters are running with the cutter head feedback circuit. As the cutter head begins to cut the material from the face, the sump speed will automatically slow the tram down to prevent over sumping the machine.  Continue to sump until the machine stops tramming. The depth of the sump will depend on the type of material being cut, the diameter of the cutter drum, and bit lacing.  Release tram levers.  Shear down (lower cutter head). The shear down rate is controlled by a shear down relief valve to limit the hydraulic pressure being applied to the cylinders. This is an adjustable feature and can be easily changed as mining conditions change.

_________________________________________________________________ 5.43 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

 Position conveyor so it doesn't hit the roof, walls, other equipment or any other obstacle. Never operate the conveyor in its fully limited position, right left, up, or down. If in the fully limited position and contacting any obstacle, damage could occur.

___________________________________________________Operation  To maintain smooth level floor conditions, it may be necessary to tram the machine backward approximately 36 in., thus trimming ridges and smoothing the floor. This may or may not be necessary each cut sequence depending on mine conditions.   Repeat this procedure to desired depth of cut.  Turning crosscuts is accomplished by making a series of partial cuts (sumps) until the machine can be turned to the desired angle.

Relocating the miner  Ensure rear stabilizer is raised from the floor.  Position cutter boom so as to prevent it from hitting roof, ribs, or floor.

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

______________________________________________________________ A6474X332 VSSV/00 5.44

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

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

The following discussion outlines the various steps of an efficient Continuous Miner mining cycle.

Preparation of the face for the next cut The first view in Fig. 34 shows Continuous Miner approaching a freshly cut face. The operator has the cutter head lowered to prepare for making a 2’ to 3’ deep sump cut at the bottom of the face. This is done to make clearance for the gathering head blade when the miner is sumping at the top of the face. In this manner, the miner can make a deeper sump into the top of the face.

Fig. 34: Preparation of the face for the next cut

Approaching a freshly cut face

_________________________________________________________________ 5.45 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

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

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

___________________________________________________Operation The next view in Fig. 35 depicts the miner having made a 30 in. sump cut at the bottom of the face. The operator will now back the miner out of the cut and raise the cutter head to the mine roof.

© BUCYRUS AMERICA, INC.

Fig. 35: Sump cut at the bottom of the face

30” sump cut at the bottom of the face

In the final view in Fig. 36, the operator has backed out of the bottom cut and raised the cutter head to the roof, positioning the miner for making a top sump.

Fig. 36: Positioning for top sump

Positioning for top sump

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Operation____________________________________________________ The next face cut Having cut bottom clearance for the gathering head blade, the operator can now make a deep sump at the top such as a full drum diameter as shown in the first view of Fig. 37. He can commence his down-cut until his gathering head pan is full. Optimally, all this is being done while awaiting the next haulage car so that maximum loading rate can be achieved when the car arrives.

While loading the haulage car, the operator completes the down-cut to the mine bottom as shown in the second view of Fig. 37.

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

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

The stabilizer shoe serves two purposes: ■

To elevate the rear of the miner for maintenance work.

■

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

The advantage of increasing down-cut force at the face while shearing down is important particularly when cutting hard coal seams. Fig. 38 illustrates the advantage of the stabilizer shoe in the down-cut application.

Fig. 37: The next face cut

Miner sumps in at top and begins downcut

Miner completes downcut with small cusp remaining

_________________________________________________________________ 5.47 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

The miner is now in a similar position as shown in the first view of Fig. 37 and the operator can proceed with the next cutting cycle.

___________________________________________________Operation The miner is shown in the middle of its shearing down cycle in Fig. 38.

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

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

The miner is configured with an optional automatic stab function which will lower the stab during the shear down cycle and raise it again automatically.

© BUCYRUS AMERICA, INC.

Fig. 38: Effect of using stabilizer shoe on downcut force

Downcut Force Machine Weight

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

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

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

An alternative particularly useful in softer, easier cutting coal seams is to shear both up and down while advancing, thus maximizing the time spent actually cutting coal in the total cycle. This sequence is illustrated in Fig. 39.

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Operation____________________________________________________ The first view in Fig. 39 shows the miner having sumped in at the top of the coal face. If the operator intends to shear down and up, the depth of sump should be no more than half a drum diameter; otherwise, a cusp will be left at the bottom or top after shearing which will require trimming.

The second view shows the miner in the middle of the downcut.

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

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

© BUCYRUS AMERICA, INC.

Fig. 39: Shearing up and down

Miner shearing down

Miner sumping in at mine bottom

Miner shearing up

_________________________________________________________________ 5.49 Bucyrus – Model 25M0 Continuous Miner

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

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

Cutter head

© BUCYRUS AMERICA, INC.

The Continuous Miner has a rotary, drum type cutter head with bit blocks arranged spirally on a set of cylindrical drums (Fig. 40) that direct the cut material to the center of the gathering head mechanism.

The cutter head has a heavy-duty gear-drive cutting system. The fixeddrum cutter head hinges directly to the machine chassis at its own pivot point at the back of the cutter boom frame. There are no cutting chains on the cutter head assemblies.

With the bits installed, the cutter head has a cutting diameter that varies per specification. The width of the cutter head and cutter motor horse power varies per model specification. The AC electric motors are mounted on each side of the cutter head support frame. A torque shaft through the center of the motor drives an input gear case that is mounted to the support frame. From the input gear case, a shaft is gear driven to the cutter head gear case in the drum. This main gear case on each side of center is driven by the cutter head shaft and removes material from the face to provide clearance for the cutter head gear case on that side of the miner.

Cutting power is transferred through a series of bevel gears. A torque shaft from the clutch (through the center of the motor) drives an input gear case that is mounted to the support frame. This input gear case is removable from the final drive gear case. Different drum rotation speeds are available by changing gear sets in the input gear case.

The operator controls the height of the cutter head by controlling two double-acting cylinders through hydraulic control valves. Cutter head height reach and speed of cutter head rotation varies per model specification (See Technical Data Chapter 6 for specifications).

Fig. 40: Cutter head

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Mechanical assemblies ________________________________________ Carbide bits and bit blocks The carbide-tipped cutter bits are mounted into holders called bit blocks (Fig. 41). While a variety of bit and bit block designs are available to meet light, tough, or average mining conditions, all are designed to absorb vibration to maintain cutter efficiency. The conical bits also rotate as they cut to produce a self-sharpening effect. The bits and blocks may be deployed around the drum in different bit lacing patterns to give the best performance under different conditions.

IMPORTANT! Inspection of the bits and bit blocks before the start of each shift will reduce later problems. Mining with dull, bent or broken bit blocks increases dust and noise levels, as well as putting excessive strain on both cutter and tram drives.

Fig. 41: Cutter bit and bit blocks

© BUCYRUS AMERICA, INC.

Cutter bit Bit block

Conveyor chain The miner is equipped with a conveyor chain assembly that runs through the center of the miner and transports the mined material from the gathering head to the rear of the miner for haulage at a high loading rate compatible with the miner’s cutting output. The conveyor chain (Fig. 42) is made up of one basic chain assembly which repeats sequentially along the entire chain loop (see Maintenance section in this chapter for Conveyor chain maintenance).

Fig. 42: Conveyor chain Conveyor chain

_________________________________________________________________ 5.51 Bucyrus – Model 25M0 Continuous Miner

_______________________________________ Mechanical assemblies Conveyor tail section The conveyor tail section (Fig. 43) pivots and has the ability to be raised and/or lowered. The conveyor pivots on the main frame behind and just below the cutter head pivot. Two single acting hydraulic cylinders permit the operator to raise the conveyor discharge end to a maximum height and clearance varying per machine or to lower the discharge end of the conveyor to a specific ground clearance.

A double-acting hydraulic cylinder on the right side of the conveyor permits the discharge end to swing 45 degrees left or right of the conveyor centerline. The range in height and swing of the conveyor with an overhang permits the conveyor to accommodate any haulage vehicle.

Two AC electric motors drive through the gathering head gear cases to a foot shaft sprocket to propel the conveyor chain.

© BUCYRUS AMERICA, INC.

Fig. 43: Conveyor tail section

Conveyor tail section

Gathering head and Continuous loading arms (CLAs) The gathering head (Fig. 44) loads the material that is mined by the cutter head assembly onto the conveyor for transport to the rear of the machine. The gathering head assembly consists of a gathering pan and two continuous loading arms (CLAs), each driven by a bevel gear case (or pot). Each CLA has 3 to 6 fingers, or blade fan-type rotating assemblies. The CLA’s are driven by rotary drive shafts in their respective gear cases. The CLA’s gather and force the cut material into the conveyor throat and onto the moving flights.

The AC motors that drive both the conveyor and the gathering head are located on each end of the gathering head assembly. Through each motor lies a specially-constructed torque shaft that extends across the rear of the gathering head frame into a heavy duty input gear case on that side driving the bevel gear input shaft to it.

The input gear cases contain bevel and helical gears that drive each main gear case (pot). These in turn drive the CLAs and the foot shaft at the base of the conveyor. The foot shaft extends across the gathering pan from the right gear case to the left gear case and has a sturdy 4 or 5 tooth sprocket at its center to drive the conveyor chain.

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Mechanical assemblies ________________________________________ The left gear case drives the left CLA and the right gear case drives the right CLA. Together, they both drive the foot shaft.

The gathering head pivot is below and in front of the cutter head pivot.

Two hydraulic cylinders raise and lower the gathering head in response to the controls.

Fig. 44: Gathering head and continuous loading arms (CLA’s)

Gathering head pivot (located behind cover)

Footshaft

Gathering head cylinder (2) (located behind cover)

CLA (2) Conveyor

_________________________________________________________________ 5.53 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

Main gearcase pot (located under the CLA)

_______________________________________ Mechanical assemblies Traction system The Continuous Miner is trammed by two individually controlled traction systems (Fig. 45). Each traction assembly has an electric motor connected to a tram drive gear case. The gear case encloses a bevel gear that drives a planetary gear. The gear case reduces the rotation speed, increases torque, and provides a right-angle drive to the drive sprocket.

The drive sprocket is directly connected to a tram drive planetary gear case. This gear case reduces the rotation speed, increases torque, and drives the track belt. (See the Maintenance section in this chapter for track belt adjustment procedures and Traction assembly maintenance procedures.)

There are three (3) tram speeds: 1st, 2nd, and 3rd. The speeds are selected from the radio remote.

© BUCYRUS AMERICA, INC.

Fig. 45: Traction system

Traction case Track belt

tractor frame/chassis tractor (main frame)

The tractor frame (Fig. 46) is a rectangular structure of high-strength steel weldments that supports major operating assemblies such as the cutter head frame, gathering head frame, conveyor and traction units. It houses supporting assemblies, the crawler and take-up mechanisms and planetary gear cases. It anchors the pivots for the conveyor, the gathering head, and the cutter head frame. The clevises for the hydraulic cylinders actuating these assemblies are also on the main/tractor frame. The frame also provides a platform for electrical and hydraulic control modules, all water controls and plumbing and the optional operator’s control compartment. Integral within the frame is the hydraulic reservoir or oil tank.

Fig. 46: Main frame/tractor frame Scrubber components

Rear bumper plate

Cutter head pivot

Stabilizer shoe cylinder clevis

Cutter head cylinder clevis Crawler idler guides

Electrical case Oil tank

Gathering head cylinder clevis

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Mechanical assemblies ________________________________________ stabilizer shoe

A stabilizer shoe (Fig. 47), located beneath and at the rear of the tractor frame, may be lowered to anchor the back end of the machine and provides a greater downward thrust of the cutter head for hard-cutting while preventing backward creep of the miner. The stabilizer shoe is raised and lowered hydraulically by a double acting cylinder that moves the shoe bracket up or down.

Fig. 47: Stabilizer shoe

© BUCYRUS AMERICA, INC.

Stabilizer shoe

_________________________________________________________________ 5.55 Bucyrus – Model 25M0 Continuous Miner

_______________________________________ Mechanical assemblies Conveyor assembly The conveyor assembly (Fig. 48) is attached to the main chassis at right and left hand independent pivot points. The conveyor is articulated vertically around these pivot points to assist in optimum loading into a haulage vehicle. Independent pivots allow removal of the conveyor assembly without disturbing the cutting head or gathering head components.

© BUCYRUS AMERICA, INC.

The conveyor assembly includes the following: ■

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

■

A rear conveyor subassembly that includes: –

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

–

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

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

Fig. 48: Conveyor assembly

Rear conveyor section Conveyor pivot pin

Intermediate conveyor section

Chassis pivot points

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

Fig. 49 gives an overview of hydraulic cylinders located on the 25M0 Continuous Miner. Fig. 51 depicts the location of other hydraulic components.

This section gives a general description of the hydraulic components used on the miner, along with typical schematics for hydraulic functions. The schematics in this section are general; always refer to the hydraulic schematic in your Bucyrus America, Inc. parts manual supplied with your machine.

Operation considerations

© BUCYRUS AMERICA, INC.

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

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

■

maintaining a sufficient oil level in the tank

■

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

■

changing filters and fluids at prescribed intervals

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

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

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Hydraulic ____________________________________________________ Fig. 49: Hydraulic cylinder locations

Gathering head raise cylinder

Gathering head cylinder

Cutter head raise cylinder Cutter head raise cylinder

Cutter head raise cylinder

Stabilizer shoe cylinder

Stabilizer shoe cylinder

Stabilizer shoe cylinder

Conveyor lift cylinder

Conveyor lift cylinder Conveyor lift cylinder

Conveyor swing cylinder

Conveyor chain take-up cylinder (optional)

Conveyor swing cylinder

Conveyor chain take-up cylinder (optional)

Conveyor chain take-up cylinder (optional)

_________________________________________________________________ 5.58 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

Gathering head raise cylinder

___________________________________________________ Hydraulic Fig. 50: Hydraulic component location

Breather

Breaker reset cylinder (Mounted on tram case in crawler)

© BUCYRUS AMERICA, INC.

Breather Gathering head float valve 2-unit valve solenoid Dipstick 1/4” shuttle valve (Qty: 2) 3-unit valve solenoid Oil level float

10 port pressure manifold

Hydraulic pump 2” locking ball valve Breaker reset cylinder

3 micron Nonbypassing pilot filter

0-600 psi pressure gauge 0-1500 psi pressure gauge (Qty: 2) 0-5000 psi pressure gauge SAE-6 control valve Manual breaker reset

100-1000 psi SAE-8 relief valve 10 micron Bypassing pilot filter 10 micron replacement element

Main radio control valve assembly 1/2” NPT flow control

Accumulator Pressure reducing valve

1/2 NPT ball valve 3/4” check valve 3/8” check valve 1” y-strainer 1” jet pump Anti-chatter/maintenance valve

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

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

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

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

Cavitation: Briefly, cavitation means that air bubbles are forming in the liquid that is being pumped. These bubbles are usually formed in the suction line of a pump when an obstruction causes the suction pressure (which is a vacuum) to go significantly below atmospheric pressure.

The actual pressure at which these bubbles form is dependant on the tank fluid level and the integrity of the seal on the suction line components. When these air bubbles are compressed in the pump gears they can cause surface pitting, corrosion and/or erosion. These bubbles can also coalesce to create erratic operation of water hammer problems.

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

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

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

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

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

_________________________________________________________________ 5.60 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

Graphic symbols denote the type of function a component performs but do not necessarily sh ow i ts s hap e or c ons tr ucti on . T hes e schematic symbols are used to trace the system flow from the reservoir to the actual work being performed and then back again to the reservoir. The symbols used are shown individually with a functional description where needed. The study of these symbols helps in understanding the system and thereby aids in troubleshooting the system.

___________________________________________________ Hydraulic

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

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

PSI (psi): Pounds per square inch (unit of pressure).

Open center circuit: A circuit in which flow through the system and back to the oil tank reservoir is open in neutral. Example: the main flow-primary pressure circuit.

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

Reading a hydraulic schematic All valves are shown in the neutral position on the hydraulic schematics.

To follow oil flow through a system, visually imagine the valve spool shifting as shown in Fig. 51.

© BUCYRUS AMERICA, INC.

Fig. 51: Oil flow through a spool

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Hydraulic ____________________________________________________ accumulator

A bladder accumulator (Fig. 52) is essentially a fluid pressure storage chamber in which the potential energy of a fluid under pressure can be stored against a compressible force of a gas to do useful work. This stored fluid is readily available to perform a given task when called upon by the requirements of the system in which it is used.

breather

A breather (Fig. 52) permits air to move in and out of the oil tank reservoir to maintain atmospheric pressure.

cylinders

Cylinders (Fig. 52) are bored and honed steel tubes enclosing a piston connected to a rod that extends out the end of the cylinder.

Working surfaces are ground and finely finished with the seals and gaskets incorporated to prevent leakage. Fig. 50 illustrates the location of the hydraulic cylinders on the miner.

There are four single-acting cylinders on the miner: the conveyor lift cylinders (2) and the gathering head raise cylinders (2). Optionally, there may be conveyor chain take-up cylinders (2), which are also single acting.

There are normally five different double-acting cylinders on a miner: the cutter head raise cylinders (2), the conveyor swing cylinder, and the stabilizer shoe cylinders (2). There is also an optional second conveyor swing cylinder for attaching haulage.

Fig. 52: Accumulator and cylinder hydraulic symbols

Accumulator

Cylinder, single acting

Breather

Cylinder, single acting

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

Cylinder, double acting

Cylinder, single acting with dry pocket

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

_________________________________________________________________ 5.62 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

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

___________________________________________________ Hydraulic filters and strainers

Filters and strainers are designed to protect a hydraulic oil system from harmful levels of particulate contamination. High levels of contaminants accelerate wear of components, cause improper functioning, and add to system sluggishness. Other problems such as seizure of parts, higher temperatures due to increased fluid friction, leakage, and loss of control may occur. Contamination also contributes to oxidation and chemical breakdown of the fluid. Filter and strainer hydraulic symbols are shown in Fig. 53.

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

© BUCYRUS AMERICA, INC.

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

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

There is a y-strainer (Fig. 53) in the supply line of the hydraulic oil fill circuit. The y-strainer contains a replaceable element to filter out contaminants when adding oil to the system. Nevertheless, oil stocked to be added to this system should be kept in closed containers to prevent contamination of the hydraulic system.

y-strainer, main water

There is a y-strainer (Fig. 53) on the water inlet supply circuit with a replaceable stainless steel element that screens out particles from the mine water. The screen should be removed and either cleaned or replaced as required.

Fig. 53: Filter and Y-strainer hydraulic symbols

Filter, bypassing

Filters, non-bypassing

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Hydraulic ____________________________________________________

orifice

A flow meter (Fig. 54) is a visual device which indicates the volume of fluid passing through it per unit time.

An orifice (Fig. 54) is a device that restricts flow.

pressure/return manifold

A pressure manifold (Fig. 54) has one inlet port and many outlet ports to supply flow to many circuits. A return manifold has many inlet ports and only one outlet port for flow to return to tank. Note: You can have the same part number for a pressure or return manifold.

pressure gauge

A pressure gauge (Fig. 54) is a visual device used to indicate the pressure in a hydraulic or water circuit.

pump

The purpose of a pump (Fig. 54) is to produce flow; it does not produce pressure. Pressure is caused by a resistance to flow. All system components have some resistance to flow. Hydraulic cylinders, which power machine functions, are the major components causing this resistance. Each circuit is protected by a relief valve so that the pressure in the system will not exceed the rating of its components. To ensure that everything works correctly and in proper sequence, relief valve pressure settings closely match the load requirements.

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

pump, jet (venturi)

quick disconnect female/male coupling

The miner may be equipped with optional venturi jet pumps (Fig. 55).

These pumps have no moving parts and are made from a metal tube that narrows over its full length. When liquid passes through the narrowing tube, a vacuum is formed according to the “Venturi” principle.

This vacuum is used to draw liquid into or out of reservoirs. For more information, reference the detailed circuit descriptions.

A quick disconnect (Fig. 54) is a coupling which can quickly join or separate lines.

Fig. 54: Hydraulic symbols

Flow meter

Pressure/return manifold

Orifice

Pressure gauge

Pump, jet Pump, hydraulic two section

Quick disconnect male half coupling

Quick disconnect female half coupling

_________________________________________________________________ 5.64 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

flow meter

___________________________________________________ Hydraulic valves ball valve

check valve

© BUCYRUS AMERICA, INC.

directional control valve

The hydraulic symbols for the different types of valves are given in Fig. 55.

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

A valve that allows fluid flow in one direction only.

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

flow control valve

A valve with a primary function of controlling flow rate.

flow control valve with internal check

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

load holding valve

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

A load holding valve locks a load in any position without allowing drift.

It may provide static overload relief and thermal expansion relief with open-center control valves, as are on the cutter head raise circuit, or be combined with an atmospheric relief, as on the conveyor raise circuit of the miner. Cartridge style valves allow installation directly into the cylinder.

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

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

MSHA directives of 1980 demand that load holding valves be required on all miners with elevating cutter heads and conveyors, and that they be integrally-mounted to the cylinder. The miner has four (4) of these valves.

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

______________________________________________________________ A6474X332 VSSV/00 5.65

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

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

There are no adjustments required on the load holding valves.

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

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

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

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

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

relief valve

Some relief valves are atmospheric. These valves are used for overpressure protection only. Should the preset pressure be reached, they discharge oil into the air. An example of this is on the conveyor raise circuit where the pressure is set to relieve at 3,000 psi, which is well above expected operating pressures. There are a number of relief valves in the hydraulic system that are set for individual sub-circuit protection (conveyor elevation, gathering head, etc.) Each pump section also has a main relief valve for protection against over-pressurization.

The main hydraulic pump section is typically set at 3000 psi. The pilot section is typically set at 600 psi. If your system has 3 pump sections, consult your system schematic in your Bucyrus parts manual for the auxiliary pump section relief valve setting. For relief valve adjustment procedures, see the Adjustment section of this chapter.

_________________________________________________________________ 5.66 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

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

___________________________________________________ Hydraulic shuttle valve

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

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

Each section of the main control valve is piloted by a solenoid valve that is mounted on top of that particular section. Reduced pilot pressure is supplied to these 2-way normally closed valves to control the main spool inside the larger working section of the directional control valve.

Energizing the solenoid opens the pilot valve to allow the pilot pressure to move the spool in the proper direction to achieve the desired function of the directional control valve.

© BUCYRUS AMERICA, INC.

When the coil in the front is energized, the spool shifts and allows oil flow to “A” port (front = closest working port to handle). If the coil in the back is energized, the spool shifts and allows oil flow to “B” port (back = furthest working port from handle). Unless a detent spool is being used, the spool will spring return to the neutral position when the coil is de-energized. solenoid pilot valve, hydraulic control (with radio option)

These 2-way normally closed valves are used to supply reduced pilot pressure that controls a number of functions on the machine. These functions include the control of hydraulically piloted water valves for the Dust/Cooling, Fire and Scrubber Spray System circuits. They also are used to control the Breaker ON/Breaker OFF function.

water valve, hydraulic piloted

A valve that is piloted open with hydraulic pressure to allow water to pass through it.

water valve, detented hydraulic piloted

A valve that is piloted open with hydraulic pressure to allow water to pass through it and stays open until manually closed.

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Hydraulic ____________________________________________________ Fig. 55: Valve hydraulic symbols

Check valve

Ball valve Manual Control valve

Flow control valve

Flow control valve with internal check Gathering head float valve

Directional control valve

Load holding valve Pressure reducing/ relieving valve

Relief valve

Shuttle valve

Solenoid valve 2-unit

Water valve, hydraulically piloted, detented

Water valve, hydraulically piloted

_________________________________________________________________ 5.68 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

Anti-chatter/maintenance valve

___________________________________________________ Hydraulic Hydraulic pump assembly circuit Hydraulic power for all of the hydraulically actuated functions originates with the pump assembly (Fig. 56). This pump assembly is made up of single-stage pump with a piggy-back hydraulic pump (2-section tandem pump). The pump outlets are designated A1 (main flow) and A2 (pilot flow). The pump assembly is typically mounted on the left side of the machine frame. Oil is supplied from the oil tank reservoir to the suction side of pump through a 2” suction line.

© BUCYRUS AMERICA, INC.

Fig. 56: Hydraulic pump circuit

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Hydraulic ____________________________________________________ Major hydraulic circuit components main control valve (MCV)

The main control valve consists of a series of directional control valves assembled in a row. This row of valves is commonly referred to as a valve bank. The main control valve directs fluid flow to perform a specific function of work that transforms hydraulic energy into mechanical energy. Control may be initiated manually or electrically (through the solenoid pilot valve).

The main control valve (Fig. 57) is typically located on the right side of the machine.

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

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

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

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

■

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

_________________________________________________________________ 5.70 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

Each working section on a control valve has a uniquely designed internal spool. Typically, there are (5) five working sections. Spools may be spring-loaded to return the spool to a preset position (usually neutral) when not held in the required position. When more than one function is activated, those functions will slow down in comparison to operating a single function.

___________________________________________________ Hydraulic ■

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

© BUCYRUS AMERICA, INC.

Fig. 57: Main control valve schematic symbols (typical)

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Hydraulic ____________________________________________________ Main flow - primary pressure circuit The main flow-primary pressure circuit (Fig. 59) is powered by hydraulic pump gear section A1. The A1 gear section is rated at 17gpm at a pressure of 3,000 psi. The system is an open-center circuit and it supplies oil flow to the main control valve. The main control valve operates the cutter head, conveyor raise and swing, gathering head, and stabilizer shoe cylinders along with oil tank fill. After passing through the pump gear section A1, oil enters the main control valve whose relief is set at 3,000 psi. On the return side of the system, oil exits the main control valve. There is a tee to allow external filling of the reservoir (see conveyor raise/lower circuit). Oil enters a 10 micron by-passing return filter before entering the oil reservoir. Once in the reservoir, the oil is forced to flow through and around baffle plates for cooling and deaerating before re-entering the suction line. Also, located in the reservoir are floor magnets which will trap ferrous metal particles.

Fig. 58: Main flow-primary pressure

_________________________________________________________________ 5.72 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

The schematic shown in Fig. 58 is a typical primary pressure circuit.

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

___________________________________________________ Hydraulic Pilot pressure circuit The pilot pressure circuit is a closed-center system powered by hydraulic pump gear section A2. It supplies oil flow to the pressure manifold.

The pilot gear section is rated at 4 gpm at 600 psi. After passing through the pump gear section A2, oil enters a 10-micron bypassing pressure filter (tri-filter) and circuit relief valve set at 1000 psi. Oil then flows to a 3-micron non by-passing pressure filter. The oil continues to the pilot pressure manifold where the oil separates to the accumulator, all solenoid valves, and the gathering head float circuit.

The schematic shown is Fig. 59 is typical for a pilot pump circuit. Always refer to the schematic in the Bucyrus America, Inc. parts book for your machine.

© BUCYRUS AMERICA, INC.

Fig. 59: Pilot pressure circuit

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Hydraulic ____________________________________________________ Tank Ports Bucyrus filters the oil system on all new Continuous Miners according to a minimum ISO code 19/17/14 for cleanliness. There is a quick disconnect (with plug) to hook up a filtering cart and can also be used underground for contamination clean-up of the hydraulic system. Return oil from hydraulic components connects to a return manifold. Oil flows from the return manifold to the oil tank reservoir. The oil tank reservoir includes two oil tank manifolds and two tank breathers.

The schematic shown in Fig. 60 is typical for tank port connections.

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

© BUCYRUS AMERICA, INC.

Fig. 60: Tank port connections

_________________________________________________________________ 5.74 Bucyrus – Model 25M0 Continuous Miner

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

There are two port reliefs in the working section on the main control valve. The port relief to lower the stabilizer shoe is set at 2,500 psi. The port relief to raise the stabilizer shoe is sat at 1,200 psi. Pushing the handle extends the cylinders and lowers the stabilizer shoe. Pulling the handle retracts the cylinders and raise the stabilizer shoe. Solenoid designations are SSU (stabilizer shoe up) and SSD (stabilizer shoe down).

© BUCYRUS AMERICA, INC.

The schematic shown is Fig. 61 is a typical stabilizer shoe cylinder circuit. Always refer to the schematic in the Bucyrus America, Inc. parts book for your machine.

Fig. 61: Stabilizer shoe circuit

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Hydraulic ____________________________________________________

conveyor raise/lower

Oil is supplied by hydraulic pump section A1 to the conveyor raise/lower working section on the main valve control. By manual or remote solenoid control, the spool allows oil to enter the conveyor raise/lower cylinder circuit. The conveyor raise/lower cylinder is a single-acting cylinder with a load holding cartridge. There are two (2) conveyor raise/lower cylinders. There are two (2) port reliefs in the working section on the main control valve. The front port relief for raising the conveyor is set at 1,800 psi and the rear port relief for lowering the conveyor is set at 1,400 psi. Pull the handle to extend the cylinders and raise the conveyor. Oil free flows through the flow control check valve to the extend port of the cylinders free flowing through the check valve of the load holding cartridge to extend the cylinders. Push the handle to retract the cylinders and lower the conveyor. Oil goes to the retract port of the cylinders and pilots open the load holding cartridge, allowing oil to exit the cylinders. Oil then passes through a flow control valve to adjust the speed of the conveyor lowering and continues to the main control valve.

Oil then travels thru a 10-micron bypassing return filter to tank.

oil tank fill

The oil tank fill operates from the conveyor lower circuit. Oil goes to lower the conveyor and tees off to a ball valve that is normally closed.

With the conveyor in the down position, the ball valve is manually opened. By manual or remote solenoid control, the spool allows oil to enter the conveyor lower cylinder circuit and runs the oil tank fill. Oil passes through the ball valve to a jet pump, which creates a venturi (vacuum) effect pulling oil from the clean oil reservoir through a y-strainer and a check valve joining the return oil going thru 10-micron bypassing return filter to tank.

IMPORTANT! When not in use, ensure that the suction hose is tightly plugged to prevent dirt and contaminants from entering the hydraulic system when not in used.

IMPORTANT! The power fill is activated by opening the ball valve then engaging the conveyor down function.

When referring to Fig. 62, note that solenoid designations are CD (conveyor down) and CU (conveyor up).

The schematic is typical conveyor raise/lower circuit. Always refer to the schematic in the Bucyrus America, Inc. parts book for your machine.

_________________________________________________________________ 5.76 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

Conveyor raise/lower circuit - oil tank fill

___________________________________________________ Hydraulic

© BUCYRUS AMERICA, INC.

Fig. 62: Conveyor raise/lower - oil tank fill circuit

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Hydraulic ____________________________________________________ Conveyor swing circuit Oil is supplied by hydraulic pump section A1 to the conveyor swing working section on the main control valve. By manual or remote solenoid control, the spool allows oil to enter the swing circuit. The swing cylinder is a double-acting cylinder. The range on the cylinder will allow the conveyor tail to move 45 degrees off the centerline of machine in both directions. There are two (2) port reliefs in the working section on the main control valve both of which are set at 1,800 psi. The purpose of the port reliefs is to protect the swing cylinder from damage in either right or left direction in the event of an excessive external load due to the impact of the conveyor tail with the rib, haulage vehicle, or some other object.

An optional right hand cylinder may be required for attached haulage.

The flow output to the two cylinders powers each in the opposite direction. The right hand cylinder retracts as the left hand cylinder extends and vice-versa.

The schematic shown is Fig. 63 is a typical conveyor swing cylinder circuit. Always refer to the schematic in the Bucyrus America, Inc. parts book for your machine.

Note: Solenoid designations are CSL (conveyor swing left) and CSR (conveyor swing right).

Fig. 63: Conveyor swing cylinder circuit

_________________________________________________________________ 5.78 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

Push the handle and the left hand cylinder will retract, moving the conveyor tail to left. Pull the handle out and the cylinder will extend, moving the discharge conveyor to the right. The left and right movement is based off standing at the rear of machine looking forward to the cutter head.

___________________________________________________ Hydraulic Gathering head raise/hold/float-lower circuit

© BUCYRUS AMERICA, INC.

Oil is supplied by hydraulic pump A1 to the gathering head working section on the main control valve. By manual or remote solenoid control, the spool allows oil to enter the gathering head raise circuit. When raising the gathering head pan, oil free flows through the gathering head float valve (check valve) and splits to both cylinders. At any time during raising the gathering head, the operator can stop the gathering head pan and the pan will hold in position.

The Gathering Head Lower function is controlled through the working section of the main control valve and through the Gathering Head Float valve block. The spool in the main control valve is open to tank which allows control of the gathering head lower to be controlled by the Gathering Head Float valve block. The counterbalance valve stamped “VR” is set to relieve at 1,200 psi to allow the gathering head to drift down at a controlled rate of speed. This valve is adjustable and the rate of retract speed for the cylinders can be increased by decreasing the pressure setting of the valve. Conversely, the retract speed for the cylinders can be decreased by increasing the pressure setting of the valve.

The oil from the gathering head cylinders returns to the gathering head working section of the main control valve then through a 10 micron bypassing return filter to tank.

The counterbalance valve that is stamped “CR” is set to relieve at 1,800 psi. This fixed setting will relieve pressure directly to the tank in the event of a forced movement of the gathering head to grade level.

This can occur if the cutter head is lowered onto a raised gathering pan, or by some other external force.

The gathering head raise cylinders are single acting. Each has a dry pocket providing additional stoke beyond its pressure-extend limit in the event that the gathering head is trammed into an obstruction forcing it to raise beyond its normal travel limit. When in the float condition, the cylinders carry some of the gathering head pan weight to prevent the gathering head leading edge from digging into the soft bottom of the mine, thus moving the machine’s center of gravity forward when mining.

The pilot pressure oil supply for the gathering head float comes from hydraulic pump at A2 through a 10 micron by-passing pressure filter to the relief valve set 600 psi and splits going to conveyor chain take-up circuit (optional) and through a 3 micron non by-passing filter, then through the pilot pressure manifold to the gathering head float valve. The pilot pressure oil is make-up oil for the gathering head cylinders.

When the pan goes over a roll it may raise quickly, extend the gathering head cylinders and create a vacuum in the pilot oil supply. In extreme cases, the pilot pressure may decrease to the point where the solenoid controlled main control valve may not have sufficient pilot pressure to shift. It is therefore possible to experience a momentary loss of radio control of the machine.

To minimize the chance of this occurrence, a restrictor orifice is installed in the pilot supply for the valve block. This orifice is protected from contamination by an upstream filter.

______________________________________________________________ A6474X332 VSSV/00 5.79

Hydraulic ____________________________________________________ A downstream check valve keeps system pressure from entering the pilot pressure lines. An adjustable needle valve allows for the bleeding off of pressure for maintenance. A gauge is incorporated into the valve block for maintenance and troubleshooting. The schematic shown in Fig. 64 is a typical gathering head circuit. Always refer to the schematic in the Bucyrus America, Inc. parts book for your machine.

Note: Solenoid designations are GHD (gathering head down) and GHU (gathering head up).

_________________________________________________________________ 5.80 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

Fig. 64: Gathering head circuit

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

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

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

© BUCYRUS AMERICA, INC.

There are two (2) port reliefs in the working section of the main control valve. Both port reliefs are set at 2,800 psi. To raise the cutter head (extend cylinders), pull the handle. Oil goes to port “P2” of the antichatter/maintenance valve free flowing thru the check valve out of port “P1” and continues to the retract port of the cylinders free flowing thru the check valve of the load holding cartridge to retract the cylinders.

To lower the cutter head (retract cylinders), push the handle. Oil goes to the extension port of the cylinders and also pilots open the load holding cartridge allowing oil to exit the retract ports on the cylinders. The oil continues to the anti-chatter/maintenance valve block where it passes through a counterbalance valve which is set to relieve at 1,200 psi, then through the main control valve and a 10-micron bypassing return filter into the oil tank. shear down/maintenance valve (anti-chatter)

The shear down/anti chatter manifold has three primary functions: 1. It provides back pressure against the shear cylinder pistons when shearing down to prevent the machine form climbing the face (raising the machine off of the ground).

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

3. It allows for bypassing of the counterbalance valve to eliminate the back pressure against the shear cylinder pistons. This provides the maximum pressure differential between the two sides of the shear cylinders which allows the machine to be raised off the ground (jack-knifed). To jack-knife the miner, the stabilizer shoe is first lowered and then the cutter head is lowered with the bypass opened. At this point, the machine can be inspected, adjustments can be made to the crawler tracks, and the tram voltage can be adjusted.

______________________________________________________________ A6474X332 VSSV/00 5.81

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

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

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

This schematic shown is Fig. 65 is a typical cutter head cylinder raise circuit. Always refer to the schematic in the Bucyrus America, Inc. parts book for your machine.

© BUCYRUS AMERICA, INC.

Fig. 65: Cutter head raise circuit

Note:

Solenoid designations are CHD (cutter head down) and CHU (cutter head up).

_________________________________________________________________ 5.82 Bucyrus – Model 25M0 Continuous Miner

Hydraulic ____________________________________________________ Reduced (MCV) pilot pressure circuit - radio function main control valve The pilot pressure circuit is powered by hydraulic pump gear section A2 which is rated at 4 gpm at 600 psi. From the pump, oil passes through a 10 micron by-passing pressure filter and provides hydraulic power to the three pilot pressure circuits.

The oil continues to a manifold where the oil separates and goes thru a pressure reducing valve. The pressure reducing valve is set at 350 psi.

Oil continues to the pilot port of the main control valve. The reduced pressure is required to prevent damage to the main control valve. This circuit supplies pilot pressure which allows the small solenoid pilot valves to shift the spools in the working sections of the main control valves.

The five (5) working sections are as follows: cutter raise, conveyor raise, conveyor swing, gathering head, and stabilizer. The pilot circuit allows the miner operator to operate the main control valve by the radio system.

When the solenoid coil is energized it shifts the spool in the main control valve, allowing oil flow to the selected function. When the solenoid coil is de-energized, the spool in the main control valve goes to the neutral position.

The schematic shown is Fig. 6 is a typical reduced pilot pressure circuit. Always refer to the schematic in your Bucyrus America, Inc. Parts Book for your machine.

_________________________________________________________________ 5.83 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

The pilot pressure oil passes through a 3 micron non-bypassing filter and is controlled by a pressure regulator that is normally set to 600 psi.

When the non by-passing 3 micron filter element starts clogging with trapped particles the radio system/solenoid functions will slow down, indicating it is time to change the 3 micron element. For filter element maintenance and changing schedules, see the Maintenance section in this chapter.

___________________________________________________ Hydraulic

© BUCYRUS AMERICA, INC.

Fig. 66: Reduced (MCV) pilot pressure circuit - radio function main control valve circuit

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Hydraulic ____________________________________________________ Accumulator circuit The accumulator is pre-charged with nitrogen to 400 psi. The difference between the pilot pressure of 600 psi and the pre-charge pressure of 400 psi provides a volume of oil to allow for remote operation of the fire suppression and breaker on/off control valves when the pump is not operational. The accumulator pressure should closely track the pilot circuit pressure. If the accumulator pressure drops below 500 psi, shutdown the machine and call maintenance.

The accumulator circuit is supplied from the pilot pressure manifold which is supplied by hydraulic pump section A2 . This circuit is used for manual and automatic reset for the breaker on and off (main and tram) using hydraulic cylinders and also for the deluge fire suppression system. From the pilot pressure manifold, oil free flows thru a check valve and charges the one gallon accumulator. The check valve traps oil pressure in the circuit since the three unit solenoid manifold has normally closed cartridges. The manual control valve is blocked allowing pressure to be available when the machine pump is not running to reset the breakers and to set off the fire suppression system.

The breaker reset function can be operated by the manual breaker control valve or by radio via solenoids. The shuttle valve has two oil supply ports with one outlet port. One oil supply is from the manual breaker control valve and the other is from the solenoid valve. The outlet port goes to the cylinder to operate the breaker. There are two shuttle valves, one to turn on the breaker and one to turn the breaker off.

Breaker On (BON), the coil is energized and shifts the spool allowing oil to travel to the extend side of the main breaker cylinder and to the retract side of the tram breaker cylinders. In both cases, the BON turns on. Breaker Off (BOF), the coil is energized and shifts the spool allowing oil to travel to the retract side of the main breaker cylinder and to the extend side of the tram breaker cylinders. In both cases, the BOF turns off. If there is no radio function, the manual breaker control valve will use the accumulator pressure to supply oil for breaker reset on and off.

The remaining solenoid in the 3-unit manifold is for the deluge fire suppression system. When the solenoid coil is energized it shifts the spool, allowing oil to travel to the 2-way/2-position water valve, shifting its spool to allow water pressure to pass through it to the deluge fire spray manifolds. The water valve has a detent spool which keeps the water valve open if the battery back-up uses up its energy.

IMPORTANT! You must manually reset the 2-way, 2-position water valve to reset the deluge fire spray circuit.

_________________________________________________________________ 5.85 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

WARNING! Shutdown the machine and call maintenance if the accumulator pressure drops below 450 psi.

___________________________________________________ Hydraulic IMPORTANT! The backup accumulator must maintain a minimum pressure of 500 psi for 12 minutes after the pump has been de-energized. For maintenance on the circuit, loosen the fitting SLOWLY until the pressure is released.

The schematic shown in Fig. 67 is a typical accumulator circuit. Always refer to the schematic in the Bucyrus America, Inc. parts book for your machine.

© BUCYRUS AMERICA, INC.

Fig. 67: Accumulator circuit

Note: See the water section for further scrubber and dust/cooling systems information and for the water circuit.

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Hydraulic ____________________________________________________ Dust-scrubber sprays hydraulic circuit The pilot hydraulic pressure circuit is powered by hydraulic pump gear section A2 which is rated at 5 gpm at 600 psi. From the pump, oil passes through a 10 micron by-passing pressure filter and provides hydraulic power to the hydraulic tension conveyor chain take-up (optional) and to the three pilot pressure circuits. The pilot pressure oil passes through a 3 micron non-bypassing filter and is controlled by a pressure regulator that is normally set to 600 psi.

When the dust sprays (DS) coil is energized it shifts the spool allowing oil to travel to the pilot operated normally closed water valve, shifting its spool to allow water pressure to pass through it to the dust/cooling water circuit. When the scrubber sprays (SS) coil is energized it shifts the spool, allowing oil to travel to the pilot operated normally closed water valve, shifting its spool to allow water pressure to pass through it to the scrubber spray circuit.

In both cases, when the solenoid coil is de-energized, the spool in the hydraulic pilot valve shifts back to its neutral position which vents the hydraulic pilot pressure on the water control valve. This venting allows the water control valves to return to their normally closed positions.

The dust sprays automatically turn on when the cutter head starts. The dust sprays can be turned on or off manually from the radio.

The scrubber sprays automatically turn on when the scrubber motor starts. The scrubber sprays cannot be turned on or off from the radio.

The schematic shown in Fig. 68 is a typical dust-scrubber sprays circuit.

Always refer to the schematic in your Bucyrus America, Inc. Parts Book for your machine.

_________________________________________________________________ 5.87 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

The oil continues to the pilot pressure manifold where the oil separates for the dust and scrubber sprays hydraulic circuit. From the pilot pressure manifold oil flows to a 2-unit solenoid manifold which has normally closed cartridges. One cartridge is for the scrubber spray system and the other is for the dust/cooling water system.

___________________________________________________ Hydraulic Fig. 68: Dust and scrubber sprays hydraulic circuit

© BUCYRUS AMERICA, INC.

Note: See water circuit in Water section of this chapter.

______________________________________________________________ A6474X332 VSSV/00 5.88

______________________________________________________ Water Continuous Miner water system overview Water is supplied to the continuous miner for the following purposes: ■

deluge water fire protection

■

cooling water for motors, transformers, etc.

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cooling water for dust suppression

■

air cleaning via the scrubber system

■

washdown hoses

© BUCYRUS AMERICA, INC.

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

flow rate of 10 gpm minimum for cooling

■

total flow rate: based on customer dust plan

■

pressure of 250 psi (dynamic) minimum, 500 psi maximum

Bucyrus America, Inc. offers straight, left hand, right hand, or bidirectional cutter head spray manifolds. This section describes bidirection sprays.

The schematics in this section are for reference only. Always refer to the schematic in the Bucyrus America, Inc. parts book for your machine.

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Water _______________________________________________________ Water supply circuit The water pressure manifold supplies water to all the water circuits (Fig. 69). Mine water is connected to a ball valve typically mounted on the right rear corner of the machine. From the ball valve the water passes through a y-strainer, the cleaning side of which is connected to a ball valve with the right hand washdown hose attached. The water continues on to the water pressure manifold. For component location see Fig. 70.

© BUCYRUS AMERICA, INC.

Fig. 69: Water supply circuit

_________________________________________________________________ 5.90 Bucyrus – Model 25M0 Continuous Miner

______________________________________________________ Water Fig. 70: Scrubber and dust-cooling component locations RH CH spray manifold 3/8” spray nozzle BD-3 spray pattern (Qty: 16)

LH CH spray manifold 3/8” spray nozzle BD-3 spray pattern (Qty: 18)

1/2” 3-way ball valve

1/2” 3-way ball valve

1/2” relief valve 1/2” relief valve 2-unit throat spray manifold (LH & RH) 3/8” spray nozzle BD-3 spray pattern (Qty: 9) Venturi spray 1912 #3 nozzle (Qty: 2)

3-unit GH spray manifold 3/8” spray nozzle BD-3 spray pattern (Qty: 3)

© BUCYRUS AMERICA, INC.

2-unit throat spray manifold 3/8” spray nozzle BD-3 spray pattern (Qty: 2)

Side spray manifold 1/2” 3-way ball valve 3/8” spray nozzle BD-3 spray pattern (Qty: 2)

Scrubber sprays 1/4” spray nozzle GG-10W spray pattern (Qty: 10) 1/2” ball valve

Spray block manifold (Qty: 2) 3/8” spray nozzle BD-3 spray pattern (Qty: 2)

Mounted in sump box:1” NPT suction strainer-water only 1/4” flow control valve Spray nozzle HI/4 VV-110 08 (flat) spray pattern 1” jet pump 1/2” ball valve 1 NPT pressure regulator gauge Scrubber sprays 1 NPT 1/2” flow control valve Hyd piloted water valve Crawler spray nozzle HT/4 VV-110 08

1/2” NPT ball valve (Qty: 2)

Hyd piloted water valve 1/4” flow control valve (Qty: 2) 1/2” ball valve scrubber water bypass 3/4” ball valve dust/water bypass Crawler spray nozzle HT/4 VV-110 08

0-1000 psi pressure gauge 1/2” ball valve 1” y-strainer 1/2” female quick disconnect 1/2” female quick disconnect

______________________________________________________________ A6474X332 VSSV/00 5.91

Water _______________________________________________________ Deluge water fire circuit The deluge fire suppression circuit (Fig. 71) can be operated by manual or remote solenoid control (see Electrical section in this chapter).

When the solenoid coil is energized, it shifts a spool, allowing hydraulic oil to travel to a 2-way, 2-position water valve. The hydraulic fluid shifts the spool, allowing the water to pass through it to the deluge fire spray manifolds. The water valve has a detent spool, which keeps the valve open. The 2-way, 2-position valve can be operated manually and is typically mounted on the left hand side of the machine. The valve must be manually reset to reset the fire suppression circuit.

In addition, there is a ball valve used to manually operate the fire suppression circuit typically located on the right rear corner of the machine.

The valve must be manually turned off to reset the fire suppression system.

The fire suppression circuit must be tested once per shift, minimum (see Maintenance section in this chapter).

For deluge water fire circuit component locations, see Fig. 72.

Fig. 71: Deluge water fire circuit

_________________________________________________________________ 5.92 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

The optional left hand washdown hose water is supplied by the deluge fire suppression system.

______________________________________________________ Water

© BUCYRUS AMERICA, INC.

Fig. 72: Deluge fire component location

3/8” spray nozzle BD-10 spray pattern (Qty: 3) 3-unit fire spray manifold

3/8” spray nozzle BD-10 spray pattern (Qty: 3) 3-unit fire spray manifold

3/8” spray nozzle BD-10 spray pattern (Qty: 3) 3-unit fire spray manifold

3/8” spray nozzle BD-10 spray pattern (Qty: 3) 3-unit fire spray manifold

3/8” spray nozzle BD-10 spray pattern (Qty: 3) 3-unit fire spray manifold

3/8” spray nozzle BD-10 spray pattern (Qty: 3) 3-unit fire spray manifold

Fire activation/ reset valve

1/2” ball valve fire activation

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Water _______________________________________________________ Scrubber sprays and sump dump circuit The scrubber spray circuit (Fig. 73) can be operated by manual or remote solenoid control (see Electrical section in this chapter). When the scrubber spray solenoid coil is energized, it shifts a spool, allowing hydraulic oil to flow to the hydraulic pilot operated normally closed water valve. The hydraulic oil shifts a spool, allowing water to pass though it to the scrubber spray circuit.

There is a manual ball valve that is used to bypass the pilot operated water valve so that the miner can be operated until maintenance can be performed.

The scrubber sprays automatically turn on when the scrubber motor starts. They cannot be turned on or off from the radio.

The final portion of this circuit is used to empty the excess water from the scrubber sump box (slurry water). Located in the bottom of the scrubber sump box are a stir spray nozzle, a flow control valve, a jet pump, and a water strainer. The flow control valve is used to control the amount of water stirring, which keeps the water strainer from becoming clogged and keeps the jet pump clean to discharge the slurry water. The pressure regulator valve and gauge are used to operate this circuit, which is normally set at 75 psi.

Fig. 73: Scrubber sprays and sump dump circuit

_________________________________________________________________ 5.94 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

There is a flow control valve that controls the cleaning sprays located in the scrubber duct work. The scrubber screen cleaning sprays are controlled by a pressure regulated valve with a gauge and an adjustable flow control valve. The pressure regulator is normally set at 50 psi.

______________________________________________________ Water Dust-cooling water supply circuit The dust-cooling water circuit (Fig. 74) can be operated by manual or remote solenoid control (see Electrical section in this chapter). When the dust-cooling water solenoid coil is energized, it shifts a spool, allowing hydraulic oil to travel to the hydraulic pilot operated normally closed water valve.

There is a manual ball valve that is used to bypass the pilot operated water valve so that the miner can be operated until maintenance can be performed.

The dust sprays typically turn on when the cutter head starts. The sprays can be turned on or off from the radio.

© BUCYRUS AMERICA, INC.

The dust-cooling circuit described below is for a typical Bucyrus miner containing optional bi-directional spray manifolds and side sprays. The circuit for your machine may vary depending on your dust plan and unique requirements. Always refer to the schematic in the Bucyrus America parts book for your machine.

Fig. 74: Dust-cooling water supply circuit

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Water _______________________________________________________ Dust-cooling left hand machine circuit The dust-cooling left hand chassis circuit (Fig. 75) is supplied from the water pressure manifold. This circuit cools the left hand pump, tram, continuous loading arm (CLA) and left hand cutter head motors. A portion of the CLA motor cooling water is used for the gathering head pan sprays and the (optional) gathering head side sprays. A portion of the cutter head motor cooling water is used to supply the left hand throat spray manifold. The throat spray manifold helps keep dust from flowing up the conveyor as the coal is being transported.

A 3-way ball valve is used to turn off or on the chassis side sprays for the left to right cutter head spray direction. With the ball valve open, water supplies two manifolds: one mounted near the cutter head (spraying towards the front of the machine) and one mounted to the right (spraying toward and away from the left hand side of the cutter head). The side sprays assist airflow direction and dust control.

The dust-cooling circuit described below is for a typical Bucyrus miner containing optional bi-directional spray manifolds and side sprays. The circuit for your machine may vary depending on your dust plan and unique requirements. Always refer to the schematic in the Bucyrus America parts book for your machine.

Fig. 75: Dust-cooling left hand machine circuit

_________________________________________________________________ 5.96 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

The cooling water continues from the cutter head motor to a water input manifold. This portion of the circuit is equipped with an atmospheric relief valve in case pressure builds up from clogged spray nozzles.

______________________________________________________ Water Dust-cooling right hand machine circuit The dust-cooling right hand chassis circuit (Fig. 76) is supplied from the water pressure manifold. This circuit cools the tram motor tram case, continuous loading arm (CLA) motor and right hand cutter head motors.

A portion of the CLA motor cooling water is used for the gathering head pan sprays and the (optional) gathering head side sprays. A portion of the cutter head motor cooling water is used to supply the right hand throat spray manifold. The throat spray manifold helps keep dust from flowing up the conveyor as the coal is being transported.

© BUCYRUS AMERICA, INC.

The cooling water continues from the cutter head motor to a water input manifold. This portion of the circuit is equipped with an atmospheric relief valve in case pressure builds up from clogged spray nozzles.

A 3-way ball valve is used to turn off or on the chassis side sprays for the left to right cutter head spray direction. With the ball valve open, water supplies two manifolds: one mounted near the cutter head (spraying towards the front of the machine) and one mounted to the left (spraying toward and away from the left hand side of the cutter head).

The side sprays assist airflow direction and dust control.

The dust-cooling circuit described below is for a typical Bucyrus miner containing optional bi-directional spray manifolds and side sprays. The circuit for your machine may vary depending on your dust plan and unique requirements. Always refer to the schematic in your Bucyrus America parts book for your machine.

Fig. 76: Dust-cooling right hand

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Water _______________________________________________________ Tram trickle circuit The tram trickle circuit (Fig. 77) can be operated by manual or remote solenoid control (see Electrical section in this chapter). When the dustcooling water solenoid coil is energized, it shifts a spool, allowing hydraulic oil to travel to the hydraulic pilot operated normally closed water valve. For the hydraulic portion of this circuit, see Fig. 67 in the Hydraulic section of this chapter.

Water then flows through a flow control valve to left- and right-mounted crawler sprays. The sprays can be turned on or off from the radio.

The tram trickle circuit described below is for a typical Bucyrus miner containing optional bi-directional spray manifolds and side sprays. The circuit for your machine may vary depending on your dust plan and unique requirements. Always refer to the schematic in your Bucyrus America parts book for the machine.

© BUCYRUS AMERICA, INC.

Fig. 77: Tram trickle circuit

_________________________________________________________________ 5.98 Bucyrus – Model 25M0 Continuous Miner

___________________________________________________ Electrical Continuous Miner electrical system overview Electrical energy is used to power the Continuous Miner. The electrical system is assembled for 950 3-phase AC voltages, at 60 Hertz (Hz) to match local mine power supplied via a trailing cable. Mine electrical power, stepped down by transformers, fed through circuit breakers and set up through electrical control circuitry, provides energy for the watercooled drive motors.

Basic principles

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An electrical circuit provides a means of changing electrical energy into some other form of energy. An electrical circuit may cause electrical energy to change into mechanical energy, as in the case of an electrical motor, or into heat or light, as in the case of a light bulb. Just as the components in a hydraulic circuit control the flow of hydraulic fluid, many electrical components are used in an electrical circuit to direct or limit the flow of electrical energy so it can be utilized to do a particular job on the miner. Other components in an electrical circuit are protective devices to avoid damage to equipment and injuries to personnel.

Permissibility The 25M0 Continuous Miner for use in the United States is designed and built to be MSHA (Mine Safety and Health Administration) permissible: that is, the electrical system uses MSHA certified explosion proof enclosures and MSHA approved intrinsically safe circuits. All of the electrical circuit components are located within explosion proof enclosures except - the radio remote, the radio receiving antenna, the manual tram control switches, the low oil level float switch, and the methane monitor.

A permissible explosion proof enclosure will prevent an explosion inside the enclosure from causing ignition of a methane-air atmosphere or a coal dust layer outside the enclosure. The electrical circuit components not located within an explosion proof enclosure are intrinsically safe circuits.

An intrinsically safe circuit (ISC) is incapable of producing a spark or thermal effect, under the approval criteria, which would cause an ignition of a methane-air atmosphere or a coal dust layer.

Insuring the miner is permissible and safe is the most important maintenance job. Operating equipment must be maintained by a “Qualified Person” as defined in Part 75, Title 30, of the Federal Code of Regulations.

Schematics A schematic diagram is an illustration which shows the electrical relationship of the components and the circuits typically with standard electrical symbols (Fig. 78). A schematic diagram does not show the physical location of the components. In an electrical schematic, components are shown in their deenergized position. A set of normally open contacts (N.O.) close when the coil is energized and a set of normally closed (N.C.) open when the coil is energized.

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Electrical ____________________________________________________ Related components share the same designation and when tracing a particular circuit, it may be helpful to think of the flow of electricity as being similar to the flow of water through a hose. When a set of contacts are open, the current cannot flow across them, and when contacts are closed, the current can flow. When three (3) lines are connected in a tee, the current will flow in whatever direction that it can. Like water or hydraulic fluid, an electrical current will also tend to follow the path of least resistance through a circuit. Finally, for a circuit to work, the electrical current must make a complete loop, similar to hydraulic fluid going through a circuit and returning to a tank.

© BUCYRUS AMERICA, INC.

Fig. 78: Standard electrical symbols

_________________________________________________________________ 5.100 Bucyrus – Model 25M0 Continuous Miner

___________________________________________________ Electrical Fig. 79: Electrical component locator

Left cutter motor

Left conveyor motor

Right cutter motor

Right conveyor motor

Tram transformer

Hydraulic tank float switch

© BUCYRUS AMERICA, INC.

Conveyor junction box

Left tram motor Right tram motor Pump motor

Main circuit breaker enclosure Scrubber (fan) motor

Antenna

Main control case Case machine stop

Text display Left machine stop

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___________________________________________________ Electrical

© BUCYRUS AMERICA, INC.

Fig. 80: Electrical component layout

1. Left cutter motor 2. Right cutter motor 3. Left CLA motor 4. Right CLA motor 5. Pump motor 6. Left tram motor 7. Right tram motor 8. Emergency stop 9. Methane monitor display 10. Methane warning light 11. Circuit breaker reset 12. Main controller 13. I.S. tram switch

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Electrical ____________________________________________________

© BUCYRUS AMERICA, INC.

Fig. 81: Electrical component layout (cont.)

A. B. C. D. E. F. G. H.

Headlights Area light Graphics display Scrubber motor Antenna Text display Fire spray Dust spray

_________________________________________________________________ 5.103 Bucyrus – Model 25M0 Continuous Miner

___________________________________________________ Electrical Trailing cable A trailing cable (Fig. 78) with three power conductors, labeled L1, L2, L3, two (2) ground conductors (G), and a ground check conductor (GC) supplies power to the machine. A three-conductor 2/0 to 4/0 cable is used with the 950V machines.

Cables are designed with a fire-proof, tough outer jacket to withstand the constant abuse of flexing, reeling, and the exposure to sharp objects on the mine floor. They are not designed to withstand being run over by mobile equipment, especially Continuous Miners. Trailing cables exposed to moving equipment are required to be hung on the trailing cable hanger (Fig. 82) to prevent damage to insulation.

IMPORTANT! Hang trailing cables to prevent damage from moving equipment!

© BUCYRUS AMERICA, INC.

Fig. 82: Trailing cable

Trailing cable hanger

Trailing cable

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

The trailing cable may have breaks in its insulation. These defects in the insulation could cause exposure to high electrical currents. Never handle an energized trailing cable without the properly rated personal protective equipment (electrically insulated gloves and shoes or boots).

Never let the energized trailing cable come in contact with unprotected (uninsulated) parts of your body.

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

Trailing cables on reels can present a hazard. The reels keep the trailing cable under tension at all times. Starting and stopping of the equipment causes a tension change on the trailing cable causing the cable to move or flex constantly. The closer to the machine, the more noticeable the movement. Anyone standing near or crossing over the trailing cable could be tripped or struck by the trailing cable as it flexes.

WARNING! Always use caution when standing near or crossing trailing cables. The trailing cable may move as the machine moves. ______________________________________________________________ A6474X332

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5.104

Electrical ____________________________________________________ Trailing cable temporary splices Trailing cables may only be repaired under certain conditions and following specific guidelines which are outlined in MSHA 30 CFR Part 75, Subpart G (Trailing Cables).

General

The machine breakers must be in the ON position before operating in remote control mode. The power center breaker can be tripped from the remote control to provide an emergency shutdown of the machine. The power center must be reset.

Controller case The controller case (Fig. 83) is located on the right rear side of the machine and houses the major electrical components of the miner. The control circuit breakers and the tram/fan circuit breaker can be reset from the front of the controller case. There is a machine stop button located on the front of the controller case.

The electrical components are mounted inside the controller on the top, bottom, front, rear, right, and left walls and on the front and rear side of the swing panel.

Fig. 83: Controller case

Controller case assembly

_________________________________________________________________ 5.105 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

The incoming 950V power supply is connected to the machine via the cable handler and the incoming main circuit breaker. AC power is then transferred to the main case where it is distributed via contactors to the pump, fan, cutter, and CLA motors. Power to the DC tram motors comes from the drives. A tram transformer reduces the incoming power to 270V for the drives. The control system operates at 110V AC and consists of the control transformer, the radio control unit, the graphic display, 110V control solenoids, and various power supplies and barriers. In addition to the control system, a methane and water monitoring system is installed as an additional safety system. The machine is controlled by the radio remote of the emergency tram pendant.

Electrical ____________________________________________________ Other electrical circuit components Located in the controller assembly, fuses and control breakers protect the miner’s control circuits from over loads and short circuits. Two fuses are normally used in each circuit (primary control, secondary control, headlight, and methane monitor circuit).

ammeters

The ammeters display the current being drawn by each cutter motor and conveyor motors.

volt meters

The voltmeter, located in the controller assembly is wired across two legs of the 120 VAC line.

hour meter (s)

The hour meters, located in the controller assembly, are wired in parallel with the cutter motors circuit and the conveyor motors circuit to record the total amount of time that the motors are energized.

circuit breaker

Mounted inside the operator’s case, the circuit breaker provides maximum protection for the electrical components on the miner in the event of short circuits and extreme overload conditions. The magnetic type breaker has 400 or 600 amperes continuous rating.

A circuit breaker is a device for interrupting current flow in a circuit under normal or abnormal conditions. Under normal continuous current rating, a circuit breaker is a single switching device. When the current is above the normal rating, either on overload or short circuit current, the circuit breaker is an automatic overcurrent protective device. The function of the circuit breaker corresponds basically to that of a switch in combination with a fuse. A circuit breaker will automatically interrupt current flow when the conditions are abnormal without damage to itself.

The circuit breaker mechanism is set to interrupt the current at a particular overload value and it can interrupt a short circuit current.

vacuum contactors

The vacuum contactor will close when the 120 VAC energizes the coil.

The contactor opens when the coil or 120 VAC is de-energized.

IMPORTANT! If the low oil warning light comes on when the circuit breaker is closed. Be sure to fill the reservoir before starting the motors.

low oil warning

This circuit is controlled by a float switch assembly located in the hydraulic tank. The level one switch is normally open and when the oil level gets low, the switch closes and completes a circuit across the low oil warning light.

_________________________________________________________________ 5.106 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

fuses

___________________________________________________ Electrical Relays

© BUCYRUS AMERICA, INC.

ANSI defines a relay as “...an electrically controlled device that opens and closes electrical contacts to affect the operation of other devices in the same or another electrical circuit”. Relays are one of the most common auxiliary devices used in electrical circuits. They are used for switching control circuits and for controlling light loads. instantaneous overload relay

The adjustable instantaneous overload relays, designated “OL1”, “OL3”, “OL5”, and “OL7”, protect the miner from sudden surges of current.

While called “instantaneous” overloads the current sensing relays have an adjustable start-up delay after which they operate as soon as the motor current exceeds the preset level. The instantaneous overloads have normally open contacts in the motors’ control circuit which close when controlled voltage is applied. The instantaneous overloads protect the motors from stall currents.

time-delay relays

Time-delay relays (TD’s) are used to cause a time lapse between the time a circuit is energized and the time the contactors close in a circuit.

thermally operated overload relay

The thermally operated overload relays are located in the controller assembly. They are used to protect the motors against long, steady current overloads which are not strong enough to trip the instantaneous overloads.

The heart of the thermally-operated overload relay is two thin sheets of different kinds of metal bonded together. Heater strips, connected to a line voltage through “CT’s” ratio current reducing transformers provide a heat source for the thermally operated overloads. When a continuous overload causes these strips to heat up, the bimetallic strips are heated.

As they are heated, the metal strips try to expand but, being different types of metal they want to expand at different rates. Since the strips are bonded together, they bend when heated and trip the overload relay causing a break in the protected circuit and shutting down the motor.

After the heater strips cool, the bimetallic strips return to their normal position. When a thermal overload has been tripped, it is indicated by a visual trip indicator built into the relay unit. A selector switch permits a tripped thermal overload relay to be reset automatically or manually.

The relays are normally adjusted for automatic reset operation.

machine stop

The machine stop switch is located on the left side of the miner, opposite the operator’s area. The contacts in the machine stop switch are normally closed. Depressing the large mushroom push button causes the moving contact to be pushed away from the stationary contact, breaking the control circuit and de-energizing all the coils wired in the main control circuit. The de-energized coils open all their contacts, shutting down the miner except for the headlights. Once the button is released, power is again available up to the control circuit.

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Electrical ____________________________________________________ electric motor

Squirrel-cage type induction motors are used on miners. The operation of the motors depends on a rotating magnetic field created by current flow in the stator windings. As the field rotates around the stator, voltages are induced in the rotor conductors, causing currents to flow.

These currents create magnetic fields that cause a repelling force between the rotor and the stator causing the rotor to turn.

electrical tram case

The tram case is located on the right side of the machine inside of the crawler frame. It is an explosion proof enclosure, which houses the electrical traction components: the tram transformer, two DC drives, the tram breaker , junction block for the right side conveyor motor and cutter motor and the tram interface for radio and manual. To adjust the tram interface, see cutter motor feedback adjustment.

main controller case

The main controller case is located on the left side of the machine, midway the tractor frame inside the crawler frame. It is an explosion proof enclosure, which houses many of the electrical components.

Inside the enclosure is a hinged swing out panel. Mounted on the front side of the panel are the PLC unit, battery back-up power supply, fuses, and terminal strips.

Mounted on the back side of the swing out panel are the conveyor forward and reverse contactors, instantaneous overloads, conveyor motor thermal overloads, scrubber contactor, scrubber motor thermal overload, timer which is in the conveyor forward circuit, and the e-stop relay.

Mounted on the rear wall of the enclosure are the cutter motor contactors (A and B) , pump motor contactor, the delay between cutter contactors A & B, pump motor thermal overload, cutter motor instantaneous overloads, cutter motor thermal overloads and terminal boards.

Located on the floor, left side is a connection point for the left traction motor. The connection block is provided so if there is a need to change the left traction motor leads, it can be done without passing a cable through the frame of the machine. Also, on the floor on the left side is a low oil level relay assembly.

_________________________________________________________________ 5.108 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

To describe the rotating field action of a typical motor, as the current changes in value and direction, the field rotates clockwise around the stator. Lines of magnetic force cut across the conductors in the rotor.

The magnetic lines pass through the air gap between the rotor and the stator at right angles to the face of the rotor inducing voltages in the rotor conductors which causes large alternating currents to flow. Since a current carrying conductor in a magnetic field has force exerted on it that tends to move at right angles to the magnetic field, torque is exerted on the rotor periphery. Stator currents are identical in magnitude and lag their respective voltages by the same angle. They are spaced electrically 120 degrees apart.

___________________________________________________ Electrical operator’s controller case

The operator’s case is located on the right side of the machine near the rear bumper or in the operator’s compartment. It is an explosion proof case.

Mounted inside the case is the main circuit breaker/auxiliary circuit breaker, control transformer, methane monitor relay, methane bridge varistor, electrical metering package, control fuses and breakers, headlight switch, lighting relay and O.E. relay, and radio/manual switches.

Also located inside the auxiliary controller are the manual start/stop switches as well as bridge rectifiers and scrubber water solenoid.

The trailing cable enters into this enclosure at the bottom left corner, facing the case. The panic bar for the right side of the machine is mounted to the enclosure and operates the pump stop switch to shut the machine down. On the front bottom of the case are breaker levers.

The lever to the left operates the main circuit breaker, the lever in the center operates the auxiliary breaker.

© BUCYRUS AMERICA, INC.

methane monitor

Explosive methane gas is one of the greatest hazards in the mines.

Because methane is colorless and odorless, a person cannot easily detect its presence. For this reason, the miners offer a methane monitor to “sniff out” methane in the air. When energized, the methane monitor maintains a continuous check on methane gas concentration.

A typical readout has LED indicators that display the percentage of methane gas in larger numerals.

Consult the manufacturer’s manual and literature in the Bucyrus parts book for your machine for the setup, operation, and maintenance of the methane monitoring system.

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Electrical ____________________________________________________ Traction case The traction case (Fig. 84) is accessed by opening the controller cover and then opening the swing panel. Typically mounted on the rear wall are motor mates and a terminal block.

IMPORTANT! This component location information is typical. Always verify component layout with the information in the Bucyrus parts book for your machine.

motor mate “MMG”

Motor mate “MMG” is the current transducer for the left drive motor.

motor mate “MMH”

Motor mate “MMH” is the current transducer for the right drive motor.

Fig. 84: Traction case

Motor Mate “MMH”

Terminal block

Motor Mate “MMG”

_________________________________________________________________ 5.110 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

Each motor mate is triple output inductive current transducer. It takes the current from each leg of the motor and reduces it to a 4 to 20mA output that is sent to the control system.

___________________________________________________ Electrical Controller case—control breakers

© BUCYRUS AMERICA, INC.

Mounted on the front wall of the controller case (Fig. 85) are control breakers.

control breaker “CB4”

“CB4” is a 15A breaker for the 120VAC- supply voltage.

control breaker “CB5”

“CB5” is a 15A breaker for the 120VAC+ supply voltage.

Control breaker “CB6”

“CB6” is a 10A breaker for the 120VAC- side of the area light circuit.

control breaker “CB7”

“CB7” is a 10A breaker for the 12V0AC+ side of the area light circuit.

control breaker “CB8”

“CB8” is a 20A breaker for the 12VAC- side of the head light circuit.

control breaker “CB9”

“CB9” is a 20A breaker for the 120VAC+ side of the head light circuit.

control breaker “CB10”

“CB10” is a 5A spare breaker.

control breaker “CB11”

“CB11” is a 5A breaker on the 120VAC side of the machine controller power supply circuit.

control breaker “CB12”

“CB12” is a 5A breaker on the 120VAC- side of the solenoid circuit.

control breaker “CB13”

“CB13” is a 5A breaker on the 120VAC+ side of the solenoid circuit.

Fig. 85: Controller case

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Electrical ____________________________________________________ System overview: radio remote control radio/manual mode

The miner is radio remote controlled. Manual operation is not allowed for production operation unless the miner has an operator’s pit and canopy. Manual operation is for troubleshooting and maintenance, and must be operated under roof support.

The operating controls are available either in radio remote control or in manual control. The control mode is selected by using three switches: SW1, SW2, and the Light Switch.

Switch SW1 sections 1-2 and 5-6 selects 120v power to be connected to either the manual push buttons or to the machine controller. Section 7-8 of SW1 connects +24v power from the machine controller power supply when in “radio”. SW1 removes manual control from the tram interface when radio control is selected.

The Light Switch has three positions: manual, off, and radio. In the radio position, the miner operator can turn the head lights on and off from the radio remote by controlling the HR relay. radio remote control

The radio remote control system consists of a battery powered portable remote, which, sends UHF radio signals to the miner. The encoded control signals, from the remote, are decoded by the machine controller unit located in the main controller case. The remote has a built-in antenna while the machine controller, located in the explosion proof main controller, has a external antenna.

machine controller, power supply, and module tram case

The machine controller responds to the control signals from the remote and activates the machine functions. The machine controller power supply provides 110 VDC for the solenoids to control the hydraulic valves and 24 VDC for the radio display, and traction module. The traction module provides tram direction and speed radio signals to the tram interface. Machine controller outputs also control the 120 VAC machine circuits.

radio system battery

An optional battery back-up to the power supply will provide power to operate the fire suppression solenoid and the breaker on and off.

The radio remote has a rechargeable battery, which has a recharge socket for connection to the out-by battery charger. The complete remote unit is changed out each shift. The remote panel has switches or “keys” for all of the miner functions.

The complete system includes a battery charger which is used to recharge the remote battery. This unit is usually located above ground.

Four remote units can be recharged at the same time. A built-in radio receiver and screen will allow the remote to be tested before use underground and to change channels on the remote.

_________________________________________________________________ 5.112 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

SW2 connects motor control to the manual push buttons and isolates control from the machine controller. In the radio position, SW2 isolates the push buttons and connects motor control to the machine controller.

© BUCYRUS AMERICA, INC.

___________________________________________________ Electrical battery back-up

The machine controller power supply has an optional battery back-up which provides control power to operate the machine controller and solenoids for fire suppression, breaker on and off and to reset the power supply and tram breaker. The battery back-up, in conjunction with a hydraulic accumulator, will allow control of those functions from the remote in the event of a power outage.

radio system diagnostics

The radio system has a diagnostic display on the miner in an explosion proof enclosure, which, can be seen at the right rear of the miner. Refer to the separate radio manual that came with your machine for complete use of the diagnostic display.

machine stop/e-stop bypass

The machine stop/e-stop bypass circuit allows the operator, when using radio remote control, to bypass the machine stop/emergency stop palm switch located on the left side of the miner for about 30 seconds.

This is useful in cases where the miner has become jammed against a rib causing the normally closed machine stop/e-stop switch to be stuck open. The ESB relay contacts bypass the emergency stop push button.

scrubber fan

The manual start push button for the scrubber fan motor contactor, E, does not have a holding circuit. Therefore, when in manual control the fan motor and the scrubber spray will only operate as long as the push button is held. There is no manual stop push button.

For miners with an operator’s pit and canopy, there is a holding circuit for the scrubber fan motor contactor. The fan motor stops, after a short time delay, when the cutter motors are stopped.

tram dead man (optional)

The tram “deadman” switch, also called the foot switch, is a handoperated push button located at the operator’s control panel for miners without an operator’s pit. If there is an operator’s pit, the tram “deadman” is a foot operated control switch which must be held closed.

motor control

The two DC tram motors each have an SCR drive with solid state reversing. The schematic shows a circuit breaker, CB-T, for over current protection. Some miners may have fuses instead of a circuit breaker.

All of the Continuous Miners have a power transformer to reduce the three phase voltage to the SCR drives. All of the motor contactors are vacuum type. The pump motor contactor, F, also connects power to the tram transformer primary. The gathering head / conveyor motors have forward and reverse contactors, CF and CR.

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cutter motor feedback

The miner operator has control over the tram speed when the cutter motors are not running. The Continuous Miners have a feedback circuit from the cutter motors to the tram motors so that when the cutter motors are running the maximum forward tram speed is determined by the load on the cutter motors. This is accomplished by monitoring the phase current for one of the cutter motors and feeding this current level to the tram control circuit. The amount of phase current on a cutter motor is a measure of the load on the motor.

motor overloads

All of the motors have thermal overloads relays. They are designated OL-2, OL-4, OL6, OL-8, OL-10, OL-11, OL-12, and OL-13. They are bimetallic type, ambient compensated, monitoring motor currents in all three phases. The cutter motors units, OL-2 and OL-4 are driven by current transformers, CTs. Using CTs allow smaller current size overload relays to be used. The thermal overload relays have normally closed contacts wired in the control circuit, which open on a overload and stop the motor(s). The contacts will automatically reset after the thermal overload cools down. If another overload occurs right away then the overload relay will trip faster and the time to reset will be longer.

_________________________________________________________________ 5.114 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

Electrical ____________________________________________________

___________________________________________________ Electrical Power circuit with control Electric power is supplied to the control transformer and is available to the methane monitor and to all contactors after the trailing cable is connected, the circuit breakers CB1 and CB2 are turned on, and when CB2 contacts close in the control circuit.

The schematic shown in Fig. 86 is typical of a power schematic. Always refer to the schematic in the Bucyrus America, Inc. parts book for your machine.

© BUCYRUS AMERICA, INC.

Fig. 86: Power circuit with control

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Electrical ____________________________________________________ Methane monitor circuit The methane monitor detects methane gas when the continuous miner is powered up. Before any motor or function occurs, the methane monitor checks for methane gas. If the methane monitor shows zero methane, the methane monitor relay will close. When the methane monitor relay closes, it supplies power to the area lights including the head light if the light switch is on. The methane monitor is powered from the control transformer. The low oil system will also have control power.

The schematic shown in Fig. 87 is a typical methane monitor circuit.

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

© BUCYRUS AMERICA, INC.

Fig. 87: Methane monitor circuit

_________________________________________________________________ 5.116 Bucyrus – Model 25M0 Continuous Miner

___________________________________________________ Electrical Control headlights and area lights circuit The light switch has three positions: manual, off and radio. When the power is turned on to the continuous miner, the methane monitor relay is closed and the light switch is off. When the light switch is turned to the manual position, the headlights and the area lights will come on.

When the light switch is turned to the radio position, the headlights only (not the area lights) can be turned on and off with the radio. The schematic shown is typical of a headlight switch schematic. Always refer to the schematic in the parts manual for this machine.

The headlights can be turned off and on from the remote console at any time that the system is remote position and the remote console is on by: The schematic shown in Fig. 88 is a typical lighting circuit. Always refer to the schematic in the Bucyrus America, Inc. parts book for your machine.

© BUCYRUS AMERICA, INC.

Fig. 88: Control headlights and area lights circuit

______________________________________________________________ A6474X332 VSSV/00 5.117

Electrical ____________________________________________________ Low oil circuit The low oil circuit indicates when the oil is low in the hydraulic oil tank.

The float switch energizes the LOR (low oil relay) and turns on the LOL (low oil light) in the case that the oil level becomes too low. The low oil switch is not located within an explosion proof enclosure. It is part of an intrinsically safe circuit. A permissible ISC (intrinsically safe circuit) is incapable of producing a spark or a thermal effect.

The schematic shown in Fig. 89 is a typical low oil circuit. Always refer to the schematic in the Bucyrus America, Inc. parts book for your machine.

Fig. 89: Low oil circuit

© BUCYRUS AMERICA, INC.

TO 120 VAC CONTROL SYSTEM

_________________________________________________________________ 5.118 Bucyrus – Model 25M0 Continuous Miner

___________________________________________________ Electrical Pump motor power circuit with control The pump motor can be started in manual by depressing the momentary switch. This completes the circuit across coil “F” and starts the pump motor. There are three thermal overloads in the pump circuit: OL11 is the thermal overload for the pump and OL12 and OL13 are the thermal overloads for the tram. This will supply three (3) phase power to the tram transformer and to the electrical tram drives. For the control circuit, when the pump contactor energizes, the “F” interlock closes. When the three (3) phase power is on the tram drives, the control contacts in the tram drives close and will complete the holding circuit for the pump motor. To stop the pump motor, depress the momentary pump stop switch. The pump motor has to be running before any other motor can be started.

© BUCYRUS AMERICA, INC.

The schematic shown in Fig. 90 is a typical pump motor power circuit.

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

______________________________________________________________ A6474X332 VSSV/00 5.119

Electrical ____________________________________________________

© BUCYRUS AMERICA, INC.

Fig. 90: Pump motor circuit with control

_________________________________________________________________ 5.120 Bucyrus – Model 25M0 Continuous Miner

___________________________________________________ Electrical Cutter motor power circuit with control The pump motor must be running before the cutter motors will start.

The cutter motor is a two-hand start. To start: push the pump start and the cutter motor start momentary switch at the same time. The cutter motor can be started in manual by depressing the pump and the cutter momentary switch. This completes the circuit across coil “A” and starts the left cutter motor, as well as starting the TD2 timer for the “B” contactor right cutter motor. Both cutter motors do not start at the same time. When the Time Delay (TD2) timer times out, this completes the circuit across coil “B” and starts the right cutter motor. The holding circuit interlock “A” and “B” must be closed. There are two (2) thermal overloads and two (2) instantaneous overloads; one (1) for each motor Overload (OL)1, 2, 3 and 4. To stop the cutter motor, depress the momentary cutter stop switch.

© BUCYRUS AMERICA, INC.

The schematic shown in Fig. 91 is a typical cutter motor power circuit.

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

______________________________________________________________ A6474X332 VSSV/00 5.121

Electrical ____________________________________________________

© BUCYRUS AMERICA, INC.

Fig. 91: Cutter motor power circuit

_________________________________________________________________ 5.122 Bucyrus – Model 25M0 Continuous Miner

___________________________________________________ Electrical Conveyor motor circuit with control The pump motor must be running before the conveyor motors will start.

The conveyor motors can be started in manual by depressing the momentary switch. This completes the circuit across coil conveyor forward (CF) and will start both conveyor motors. There are four (4) overloads in the conveyor circuit. There are two (2) thermal overloads and two (2) instantaneous overloads; one (1) for each motor OL5, 6, 7 and 8 for the control circuit when the conveyor contactor comes in the “CF” interlock closes. This completes the holding circuit. To stop the conveyor motor, depress the momentary conveyor stop switch.

The schematic shown in Fig. 92 is a typical conveyor motor circuit. Always refer to the schematic in the Bucyrus America, Inc. parts book for your machine.

TO POWER TRANSFORMER

© BUCYRUS AMERICA, INC.

Fig. 92: Conveyor forward and reverse motor circuits with control

______________________________________________________________ A6474X332 VSSV/00 5.123

___________________________________________________ Electrical Scrubber motor circuit with control The pump motor must be running before the scrubber motor will start.

The scrubber motor can be started in manual by depressing the momentary switch. This completes the circuit across coil “E” and starts the scrubber motor. This energizes the screen sprays for the scrubber.

There is one (1) overload in the scrubber circuit called the OL10 thermal overload. The scrubber does not have a holding circuit.

The schematic shown in Fig. 93 is a typical scrubber motor circuit. Always refer to the schematic in the Bucyrus America, Inc. parts book for your machine.

© BUCYRUS AMERICA, INC.

Fig. 93: Scrubber motor circuit with control

______________________________________________________________ A6474X332 VSSV/00 5.124

___________________________________________________ Electrical Fire suppression in radio remote The control system uses a solenoid output to drive the fire suppression system on the continuous miner. The fire suppression can be activated at any time from the remote control console. If the machine is fitted with the battery backup version of the power supply, the fire suppression can also be activated in battery standby mode. The system will remain in battery standby mode for at least ten minutes after loss of main power to the machine.

The schematic shown in Fig. 94 is a fire suppression circuit in radio remote. Always refer to the schematic in the Bucyrus America, Inc. parts book for your machine.

© BUCYRUS AMERICA, INC.

Fig. 94: Fire suppression in radio remote schematic

______________________________________________________________ A6474X332 VSSV/00 5.125

Electrical ____________________________________________________ Shear up/down in radio remote The shear up solenoid is energized and moves the cutter boom up.

When the shear down solenoid is energized, the cutter boom is lowered. Pressing and holding the radio remote key keeps the shear up and shear down solenoid energized. The pump motor must be running in order to raise or lower the cutter boom.

The schematic shown in Fig. 95 is a typical shear up/down in radio remote circuit. Always refer to the schematic in your Bucyrus America, Inc. parts book for your machine.

© BUCYRUS AMERICA, INC.

Fig. 95: Shear up/down schematic

_________________________________________________________________ 5.126 Bucyrus – Model 25M0 Continuous Miner

___________________________________________________ Electrical Stabilizer cylinder raise/lower in radio remote The stabilizer lower solenoid is energized and moves the stabilizer down. When the stabilizer raise solenoid is energized, the stabilizer is raised. Pressing and holding the radio remote key keeps the stabilizer lower solenoid energized. The pump motor must be running in order to raise or lower the stabilizer cylinder.

The schematic shown in Fig. 96 is a typical stabilizer cylinder raise/ lower in radio remote circuit. Always refer to the schematic in the Bucyrus America, Inc. parts book for your machine.

© BUCYRUS AMERICA, INC.

Fig. 96: Stabilizer cylinder raise/lower schematic

______________________________________________________________ A6474X332 VSSV/00 5.127

Electrical ____________________________________________________ Gathering pan raise/float in radio remote The gathering pan raise solenoid is energized and moves the gathering pan up. When the gathering pan float solenoid is energized, the gathering pan is floated down. Pressing and holding the radio remote key keeps the gathering pan raise solenoid energized. The pump motor must be running in order to raise or lower the gathering pan.

The schematic shown in Fig. 97 is a typical gathering pan raise/float in radio remote circuit. Always refer to the schematic in the Bucyrus America, Inc. parts book for your machine.

© BUCYRUS AMERICA, INC.

Fig. 97: Gathering pan raise/float schematic

_________________________________________________________________ 5.128 Bucyrus – Model 25M0 Continuous Miner

___________________________________________________ Electrical Conveyor left/right in radio remote The conveyor left solenoid is energized and moves the conveyor left.

When the conveyor right solenoid is energized, the conveyor is moved right. When the conveyor raise solenoid is energized, the conveyor is raised. When the conveyor lower solenoid is energized, the conveyor is lowered. Pressing and holding the radio remote key keeps the conveyor solenoid energized. The pump motor must be running in order to control the conveyor raise, lower, and swing left/right.

The schematic shown in Fig. 98 is a typical conveyor left/right in radio remote circuit. Always refer to the schematic in the Bucyrus America, Inc. parts book for your machine.

© BUCYRUS AMERICA, INC.

Fig. 98: Conveyor left/right raise lower in radio remote schematic

______________________________________________________________ A6474X332 VSSV/00 5.129

___________________________________________________ Electrical Cutter dust sprays in radio remote The cutter dust sprays are typically turned on automatically when the cutter motors are started. The control system has the possibility to turn the cutter water sprays on and off from a key on the remote console. However, this function is normally not available due to the wiring configuration of most miner electrical systems. If remote control of the water sprays is required, contact your local Bucyrus America, Inc. representative or mine personnel.

The schematic shown in Fig. 99 is a typical cutter dust sprays in radio remote circuit. Always refer to the schematic in the Bucyrus America, Inc. parts book for your machine.

© BUCYRUS AMERICA, INC.

Fig. 99: Cutter dust sprays in radio remote schematic

______________________________________________________________ A6474X332 VSSV/00 5.130

Electrical ____________________________________________________ Breaker on and off in radio remote The control system allows the main circuit breaker CB1, CB2, or auxiliary and tram breaker to be turned on, off, and to reset a tripped breaker using the radio remote control console. This normally requires that a battery backup version of the power supply to be installed on the machine.

The schematic shown in Fig. 100 is a typical breaker on/off in radio remote circuit. Always refer to the schematic in the Bucyrus America, Inc. parts book for your machine.

© BUCYRUS AMERICA, INC.

Fig. 100: Breaker on/off in radio remote schematic

_________________________________________________________________ 5.131 Bucyrus – Model 25M0 Continuous Miner

___________________________________________________ Electrical Tramming The miner can be trammed manually or via the remote console. Before the tram motors will start, the pump motor must be running. While the cutters are running, reverse speed can be incremented even while the forward tram keys are being pressed.

© BUCYRUS AMERICA, INC.

The schematic shown in Fig. 101 is a typical tram circuit. Always refer to the schematic in the Bucyrus America, Inc. parts book for your machine.

______________________________________________________________ A6474X332 VSSV/00 5.132

Electrical ____________________________________________________

© BUCYRUS AMERICA, INC.

Fig. 101: Power tram circuit

_________________________________________________________________ 5.133 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

___________________________________________________ Electrical

______________________________________________________________ A6474X332 VSSV/00 5.134

________________________________________________ Maintenance Instructions on the maintenance Maintenance at regular intervals increases the operational safety and prolongs the service life of the machine. Observe the safety instructions in chapter 2 “Your safety”.

Important notes

© BUCYRUS AMERICA, INC.

Please observe the following: ■

In order to avoid individual components not being serviced or being only inadequately serviced during maintenance work on the machine as a whole, we recommend that a general maintenance plan be drawn up. You can, for example, draw up a checklist using this operation manual and the manuals of the other components.

■

Inadequate maintenance can result in machine damage which leads to considerable costs.

■

Use only suitable and approved tools for maintenance work.

■

Use only original Bucyrus spare parts when replacing components.

■

All electrical work must be supervised and inspected by a certified electrician.

■

Anyone performing maintenance on this equipment must be trained to operate it and be familiar with this Bucyrus America, Inc. guide.

Before maintenance Please observe the following: ■

Shutdown the machine on level ground.

■

Disconnect the electrical power. The circuit breaker must be in the "OFF" position. If work is to be done inside the electrical controller, the power should be disconnected.

WARNING! Before performing maintenance on the machine the circuit breaker must be in the “OFF” position and the power should be disconnected at the main power source. Follow all Federal and Mine safety regulations for lockout/tagout procedures. Accidental machine movement or electrical shock can result in serious injury or death to you or other personnel.

■

Only work on the miner in an area where the roof is properly supported.

■

Block any and all elevated assemblies before working under them.

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

■

Relieve all hydraulic pressures and position the levers and controls in Neutral or Off.

______________________________________________________________ A6474X332 VSSV/00 5.135

Maintenance _________________________________________________ ■

Test the controls to ensure that the unit will not move.

■

Test the air for methane before and during any maintenance or repair work.

■

Do not perform maintenance on a circuit while there is a load resting on the hydraulic cylinder. Booms must be securely blocked if maintenance is to be performed with the boom in the raised position.

WARNING! Never disconnect a hydraulic hose if the circuit is pressurized or if there is a load on the circuit. If a hose is disconnected while the circuit is pressurized or a load is on the circuit, the load will fall causing damage to the machine or serious injury or death to you or other workers.

WARNING! You could be seriously injured or even killed by falling loads.

Observe the safe working load limits of lifting or blocking devices and keep a safe distance from suspended loads.

■

Do not perform maintenance in a congested area. This could endanger the maintenance person or others in the vicinity.

■

Whenever a potential problem is uncovered during a periodic maintenance check, it is imperative that it be corrected immediately by a qualified maintenance technician.

Cleanliness cannot be overemphasized as the essential ingredient of a good maintenance program. Machines should be kept as free as possible of dirt and debris which could impede performance or infiltrate systems and cause premature wear or failure.

■

Torque values When installing bolts, refer to the torque values on the drawings in the Bucyrus America, Inc. part book for your machine. If a torque value is not listed, refer to Chapter 6 of this manual.

_________________________________________________________________ 5.136 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

WARNING! Do not move any hydraulic control lever unless you are certain that everyone is completely clear of any machine movement.

Accidental machine movement can cause serious injuries or even death to you or the maintenance person.

________________________________________________ Maintenance Lubricants and fluid capacities Table 1: Lubricants and fluid capacities Location

Specification

Approximate capacity

Hydraulic oil tank Crawler Idler roller GH Assembly CLA Primary GH Assembly CLA POT Tram Drive Assembly Drum Drive Assembly, high speed (back) Drum Drive Assembly, low speed (front) Motor Lube Hoses

Spec. 100-1 Spec. 100-3 Spec. 100-15 Spec. 100-15 Spec. 100-15 Spec. 100-15

75 gals. (284 L) 1 gal (3.79 L) 1 gal (3.79 L) 2.5 gal (9.46 L) 3 gal (11.36 L) 0.5 gallon (1.89 L)

Spec. 100-15

5 gal (18.93 L)

Spec. 100-14

variable

Notes

1

© BUCYRUS AMERICA, INC.

Notes: 1. All motor lube hoses are to be filled with high temperature synthetic lithium complex grease (Spec. 100-14) before assembling them to the electric motor to ensure that there are no air gaps between the grease nipple and the point where the grease enters the motor.

IMPORTANT! As lubrication technology evolves, manufacturers continue to reformulate their products to obtain improved characteristics regarding wear, water dispersion, water absorption, environmental impact and a variety of other performance criteria. When an approved lubricant on this list has been superseded by a new formulation, it is recommended that the new formulation be tested to ensure compliance with the appropriate Bucyrus specification. At a minimum, a statement of conformance from the lubricant supplier should be obtained.

Reference Permissible Media in Chapter 6 for approved lubricants and specifications.

______________________________________________________________ A6474X332 VSSV/00 5.137

Maintenance _________________________________________________

Item

Description

Places

Lubricant

Specification

1

Every Shift Cutter head lift cylinder pins

2

Lithium based grease

Spec. 100-3

2

Conveyor swing cylinder pin, front

1

Lithium based grease

Spec. 100-3

3

Conveyor swing cylinder pin, rear

1

Lithium based grease

Spec. 100-3

4

Cutter head frame pivot pin, right

1

Lithium based grease

Spec. 100-3

5

Cutter head frame pivot pin, left

1

Lithium based grease

Spec. 100-3

6

Cutter head bits (Inspect)

1

7

Conveyor roller

2

Lithium based grease

Spec. 100-3

8

Daily Gathering head hinge pin, left

1

Lithium based grease

Spec. 100-3

9

Gathering head hinge pin, right

1

Lithium based grease

Spec. 100-3

10

Crawler idler roller

2

Lithium based grease

Spec. 100-3

11

Conveyor to tractor frame pin, left

1

Lithium based grease

Spec. 100-3

12

Conveyor to tractor frame pin, right

1

Lithium based grease

Spec. 100-3

13

Stabilizer shoe pin

2

Lithium based grease

Spec. 100-3

14

Conveyor swivel pin, top

1

Lithium based grease

Spec. 100-3

15

Conveyor swivel pin, bottom

1

Lithium based grease

Spec. 100-3

16

Hood hinge pin (Inside/Outside)

2

Lithium based grease

Spec. 100-3

17

Gathering pan raise pin

4

Lithium based grease

Spec. 100-3

18

Conveyor chain take-up pin

2

Lithium based grease

Spec. 100-3

19 20

CLA head pot assembly (Check) CLA head transfer case (Check)

2 2

High demulsibility EP gear oil High demulsibility EP gear oil

Spec. 100-15 Spec. 100-15

21

Tram gear case (Check)

2

High demulsibility EP gear oil

Spec. 100-15

22

Input cutter head gear case (Check)

2

High demulsibility EP gear oil

Spec. 100-15

23

Main cutter head gear case (Check)

2

High demulsibility EP gear oil

Spec. 100-15

24

Hydraulic oil level (Check)

1

AW hydraulic oil

Spec. 100-1

25

Weekly Crawler chain (Inspect)

2

Spec. 100-8

28

Conveyor chain (Inspect)

1

Spec. 100-8

29

Footshaft

30

Fasteners (nuts, bolts, screws)

Inspect

31

Electrical cables, conduits, and glands

Inspect

32

Hydraulic/water hoses and connections

Inspect

33

Lighting

Inspect

34

Reflectors and warning tags

Inspect

35

Machine stop/E-stop switch

Inspect

36

Chain take-up locknut

2

37

Jet pump, hydraulic (Inspect)

1

See Parts Book

38

Jet pump, water (Inspect)

1

See Parts Book

39

Water filter (Change)

1

See Parts Book

2

Lithium based grease

Spec. 100-3

Lithium based grease

Spec. 100-3

_________________________________________________________________ 5.138 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

Table 2: Lubrication and maintenance schedule

________________________________________________ Maintenance Table 2 (continued): Lubrication and maintenance schedule

© BUCYRUS AMERICA, INC.

Item

Description

40 41 42 43 44 45 46 47 48 49 50

Monthly CLA head pot assembly (Change) CLA head transfer case (Change) Input cutter head gear case (Change) Main cutter head gear case (Change) CLAs Input cutter head gear case Main cutter head gear case CLA head pot assembly CLA head transfer case Tram gear case Main hydraulic tank

51 52 53

Non-bypassing pilot filter element (Change) Bypassing pilot filter element (Change) Return filter element (Change)

Places

Lubricant

Specification

2 2 2 2 Inspect 2 2 2 2 2 1

High demulsibility EP gear oil High demulsibility EP gear oil High demulsibility EP gear oil High demulsibility EP gear oil

Spec. 100-15 Spec. 100-15 Spec. 100-15 Spec. 100-15

Sample Sample Sample Sample Sample Sample

See Note 1 See Note 1 See Note 1 See Note 1 See Note 1 See Note 1

1 2 1

See Parts Book See Parts Book See Parts Book

Every three months 54

RH cutter motor rear bearings (Front & Rear)

2

High temperature lithium complex grease

Spec. 100-14

55

LH cutter motor front bearings (Front & Rear)

2

High temperature lithium complex grease

Spec. 100-14

56

Pump motor bearings (Front & Rear)

2

High temperature lithium complex grease

Spec. 100-14

57

Scrubber motor bearings (Front & Rear)

2

High temperature lithium complex grease

Spec. 100-14

High demulsibility EP gear oil AW hydraulic oil

Spec. 100-15 Spec. 100-1

Every six months 58 59

Tram gear case (Change) Hydraulic oil (Change)

2 1

60 61 62

Strainers (Change) Hydraulic oil filter (Change) Breather, hydraulic tank (Change)

1 1 3

See Parts Book See Parts Book See Parts Book

Note 1: When the oil sample and oil change interval are identical, a sample of the old oil is to be taken and sent for analysis prior to changing the oil (see the Oil sampling procedure in this chapter). Always inspect breathers when taking hydraulic oil samples.

______________________________________________________________ A6474X332 VSSV/00 5.139

Maintenance _________________________________________________ Fig. 102: Lubrication chart 24, 45, 48 (check)

24, 42, 45 (check)

6

23,41,44 24,45,48 (fill)

40

20,36,49 (check)

28

50,54

21,40,47(check)

44

20,36,46 (fill) 43

21,40,47(fill) 18

10, 58 11,12

17 8,9 52 4,5 52 25,49, 58,60 22,48,57 (check) 22,48,56 (drain)

22,48,56 (fill)

28

13 60

59,37 55

53

38

51

39

39 14,15

2

35

3

19

7 _________________________________________________________________ 5.140 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

26

________________________________________________ Maintenance Specific lubrication and maintenance procedures Every shift cutter head lift cylinder pins

Lubricate the right and left cylinder pins (upper and lower) through the grease fittings and remote lube block located on each cylinder (Fig. 103). Pump approximately 3 cu. in. (50 cu. cm.) into each fitting.

Fig. 103: Cutter head cylinder pin location

© BUCYRUS AMERICA, INC.

Cutter head cylinder pin (upper) (2)

Cutter head cylinder pin (lower) (2) (remote lube block)

conveyor swing cylinder pin (front and rear)

Lubricate the front and rear conveyor swing cylinder pins through the grease fittings located on each end of the cylinder (Fig. 104). Pump approximately 3 cu. in. (50 cu. cm.) into each fitting.

Fig. 104: Conveyor swing cylinder pin lubrication Conveyor swing cylinder pin grease fitting

Conveyor swing cylinder pin grease fitting

______________________________________________________________ A6474X332 VSSV/00 5.141

Maintenance _________________________________________________ cutter head frame pivot pin (left and right)

Lubricate left and right cutter head frame pivot points through the grease fittings located on the left and right front lubrication blocks (Fig. 105). Pump approximately 3 cu. in. (50 cu. cm) of grease into each fitting.

Fig. 105: Cutter head frame pivot pins

Cutter head cylinder boom pin

cutter head bits

Inspect the cutter head bits to ensure that they will rotate in their holders and for damaged or missing bits (Fig. 106). Replace bits immediately if any are missing or damaged.

Fig. 106: Cutter head bit

Bit block

conveyor roller

Cutter bit

Lubricate the conveyor roller through the two (2) grease fittings located on the shaft (Fig. 107). Pump approximately 3 cu. in. (50 cu. cm.) into each fitting.

Fig. 107: Conveyor take-up shaft lubrication

Grease fitting

Grease fitting

_________________________________________________________________ 5.142 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

Cutter head frame pivot pin lube block (2)

________________________________________________ Maintenance Daily gathering head hinge pin (right and hand)

Lubricate the left and right gathering head hinge pins through the grease fittings located on the left and right front lubrication blocks (Fig.108). Pump approximately 3 cu. in. (50 cu. cm.) of grease into each fitting.

Fig. 108: Gathering head hinge pin

© BUCYRUS AMERICA, INC.

Gathering head

crawler idler roller (right and left)

Lubricate the left and right crawler idler rollers (Fig. 109) through the grease fittings located on the outside face of the crawler idler roller.

Pump approximately 3 cu. in. (50 cu. cm.) of grease into each fitting.

conveyor to tractor frame pin (left and right)

Lubricate the left and right conveyor to tractor frame pin through the grease fittings located on the right and left front lubrication blocks (Fig. 109). Pump approximately 3 cu. in (50 cu. cm) of grease into each fitting.

Fig. 109: Crawler idler roller and conveyor to tractor frame pin lubrication

Conveyor to tractor frame pin

Crawler idler roller

______________________________________________________________ A6474X332 VSSV/00 5.143

Maintenance _________________________________________________ stabilizer shoe pin (right and left)

Lubricate the stabilizer shoe pins (right and left) through the grease fittings located on the lubrication block on the right side of the machine (Fig. 110). Pump approximately 3 cu. in (50 cu. cm) of grease into each fitting.

Fig. 110: Lubrication block - stabilizer shoe

conveyor swivel pins (top and bottom)

Lubricate the top and bottom conveyor swivel pin located on the pins (Fig. 111). Pump approximately 3 cu. in (50 cu. cm) of grease into each fitting.

Fig. 111: Conveyor swivel pins

Conveyor swivel pin (top)

Conveyor swivel pin (typical)

_________________________________________________________________ 5.144 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

Lubrication block

________________________________________________ Maintenance conveyor boom pivot pins (left and right)

Lubricate the conveyor boom pivot pins (Fig. 112) through the lubrication blocks on the right hand and left hand sides of the machine. Pump approximately 3 cu. in (50 cu. cm) of grease into each fitting.

Fig. 112: Conveyor boom pivot pin

© BUCYRUS AMERICA, INC.

Conveyor boom pivot pins (2)

gathering head raise cylinder pins (left and right)

Lubricate the gathering head raise cylinder pins (Fig. 113) through the grease fittings located on each end of the cylinder. Pump approximately 3 cu. in (50 cu. cm) of grease into each fitting.

Fig. 113: Gathering pan raise cylinder pins

Gathering head raise cylinder pin (upper)

conveyor chain take-up pin (left and right)

Gathering head raise cylinder pin (lower)

Lubricate the conveyor chain take-up pin (Fig. 114) through the grease fitting located on the pin. Pump approximately 3 cu. in (50 cu. cm) of grease into each fitting.

Fig. 114: Conveyor chain take-up pin and nut

Conveyor chain take-up pin

______________________________________________________________ A6474X332 VSSV/00 5.145

Maintenance _________________________________________________

CLA head pot assembly (right and left)

Level the miner and place the gathering head on grade before checking or adding lubricant. Check the oil level in the pot assembly (Fig. 115).

If oil is needed, add oil through the fill hole until oil comes out of the breather.

CLA head transfer case (right and left)

Level the miner and place the gathering head on grade before checking or adding lubricant. Check the oil level in the hydraulic transfer case (Fig. 115). If oil is needed, add oil through the fill hole until oil comes out of the breather.

Oil fill, transfer case

Oil fill, pot assembly

Oil check (breather), pot assembly

Oil check (breather), transfer case

tram gear case (right and left)

With the miner in a level position, check the oil level in both tram gear cases by looking at the sight glass located on the side of each gear case (Fig. 116). Oil should be visible in each sight glass. If oil level is low, add oil through the fill plug hole.

Fig. 116: Tram gear case oil level

Oil fill

Oil check

_________________________________________________________________ 5.146 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

Fig. 115: CLA head pot assembly and transfer case lubrication

________________________________________________ Maintenance input cutter gear case

With the gathering head lowered to ground level and the cutter head boom level with ground, check the oil level in both of the input cutter gear cases by removing the check plug located on each side of the cutter head assembly (Fig. 117). Oil should flow from check plug hole when plug (s) is removed. If oil level is low, add oil through the fill plugs located on each side of the gathering head.

Fig. 117: Input cutter head gear case (s) oil level

© BUCYRUS AMERICA, INC.

Oil fill plug and check (one per side)

main cutter gear case

With the cutter head boom level with the ground, and the check plug positioned at 3 or 9 o’clock, check the oil level in both of the main cutter head gear cases by removing the check plug located on the front of each gear case (Fig. 118). Oil should flow from check plug hole when plug(s) is removed. If oil level is low, add oil through the fill plug hole located on top of each gear case.

Fig. 118: Main cutter head gear case(s) oil level

Oil check plug (one per side)

Oil fill plug (one per side)

______________________________________________________________ A6474X332 VSSV/00 5.147

Maintenance _________________________________________________ hydraulic oil level

With all of the machine cylinders in the fully collapsed position, check the hydraulic oil level (Fig. 119). Remove dipstick from tank and wipe clean. Insert dipstick back into tank and remove. The oil should be level with the full line indicated on dipstick. If oil level is low, add oil until full level is met.

Fig. 119: Hydraulic oil tank level

Dipstick location

Weekly footshaft

Lubricate the footshaft (Fig. 120) through the grease fittings located on the footshaft couplings. Pump approximately 3 cu. in (50 cu. cm) of grease into each fitting.

Fig. 120: Footshaft

Footshaft

_________________________________________________________________ 5.148 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

Hydraulic oil tank

________________________________________________ Maintenance crawler track tension

Check the crawler tracks for proper tension (Fig. 212). If adjustment is necessary, see the Crawler track adjustment procedure in this chapter.

To check the track for proper tension:  Raise the complete crawler assembly off of the ground and securely block under the machine. The machine must be securely supported off the ground.  Chain sag should be 2-1/2 inches (64 mm) to 3-1/2 inches (89 mm) at the center of the crawler (Fig. 114).

Fig. 121: Crawler track tension measurement

© BUCYRUS AMERICA, INC.

Bottom of tractor wear shoe

conveyor chain tension

2 1/2” - 3 1/2” gap (64 - 89 mm)

Top of tram track

Check the conveyor chain tension with the machine running. The conveyor chain should rise about 51 mm (2 inches) or less above the gathering head foot shaft sprocket as the chain emerges from under the conveyor pan (Fig. 122). If adjustment is necessary, see the Conveyor chain tension adjustment procedure in this chapter.

Fig. 122: Conveyor chain tension measurement

Chain measurement area

______________________________________________________________ A6474X332 VSSV/00 5.149

________________________________________________ Maintenance

© BUCYRUS AMERICA, INC.

fasteners

electrical cables, conduits, and glands hoses and fittings

Due to the machine being subjected to continual shock loading and vibration, close attention to all mounting bolts and screws is required.

Loose fasteners will cause premature wear and failure to bearings, couplings, etc. Inspect and tighten as required the following fasteners: ■

cutter head gear case: bolts

■

cutter head motor bolts

■

center drums: bolts

■

end drums: bolts

■

tram cases: bolts

■

tram motors: bolts

■

gathering head CLAs: bolts

■

gathering head pots: bolts

■

gathering head motors: bolts

Visually inspect all electrical cables and glands for signs of wear or damage.

Visually inspect and hydraulic and water hoses and fittings for signs of wear, damage, or leakage. This inspection should be performed with the machine running.

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

WARNING! Escaping fluids under pressure can penetrate skin and cause serious personal injury. Do not attempt to locate hydraulic leaks by feeling around hoses and fittings with bare hands. "Pin-hole" leaks can penetrate the skin.Observe the following precautions to avoid hydraulic hazards: ■ Always relieve pressure before disconnecting hoses.

■ Check for leaks with a piece of cardboard. Do not use hands to check for leaks!

■ Do not exceed working pressure of hydraulic hoses.

■ Visually inspect hoses regularly and replace if damaged.

______________________________________________________________ A6474X332 VSSV/00 5.150

Maintenance _________________________________________________ lighting

Turn on the lights and visually inspect for bulbs that need to be replaced.

reflectors and warning tags

Visually inspect the condition and readability of all warning tags, labels, and reflectors for signs of wear or damage. Replace any reflector or tag that is missing or damaged.

“machine stop/e-stop” switches

Check the “machine stop/e-stop” switches located on each side of the machine for proper operation. Start the machine and strike the “e-stop” switch. The machine pump motor will shutdown, in turn shutting down all other motors. Repeat for the other switch.

chain take-up pin (right and left)

Lubricate the chain take-up pin (Fig. 123) through the grease fitting located on the nut. Pump approximately 3 cu. in (50 cu. cm) of grease into each fitting.

© BUCYRUS AMERICA, INC.

Fig. 123: Chain take-up pin

Chain take-up pin lubrication

hydraulic jet pump

The jet pump and water filter are located on the back left hand side of the machine (Fig. 124).

water jet pump

Inspect the hydraulic jet pump. A change may be required depending on necessity.

water filter

Inspect the water jet pump. A change may be required depending on necessity.

Change the water filter. A more frequent change interval may be required depending on necessity.

Fig. 124: Jet pump and water filter

Water filter

Hydraulic jet pump

Water jet pump

_________________________________________________________________ 5.151 Bucyrus – Model 25M0 Continuous Miner

________________________________________________ Maintenance Monthly CLA head pot assembly

Change the oil in both CLA head pot assemblies (Fig. 125).  Level the miner, raise the gathering head pan, and secure in place.  Clean dirt and debris from around the drain plug located under the gear case.  Remove the drain plug and allow oil to completely drain from the gear case.  Clean and reinstall drain plug.  Clean dirt and debris from around the check plug and remove the plug.

© BUCYRUS AMERICA, INC.

 Clean dirt and debris from around the fill plug and remove the plug.  Slowly add oil through the fill plug until oil begins to flow from the check plug hole. Allow sufficient time for the oil to ravel through the gear case when filling.  Clean and reinstall the check and fill plugs.

CLA head transfer case

Change the oil in both CLA head transfer cases (Fig. 125).  Level the miner, raise the gathering head pan, and secure in place.  Clean dirt and debris from around the drain plug located under the gear case.  Remove the drain plug and allow oil to completely drain from the gear case.  Clean and reinstall drain plug.  Clean dirt and debris from around the check plug and remove the plug.  Clean dirt and debris from around the fill plug and remove the plug.  Slowly add oil through the fill plug until oil begins to flow from the check plug hole. Allow sufficient time for the oil to ravel through the gear case when filling.  Clean and reinstall the check and fill plugs.

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

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

______________________________________________________________ A6474X332 VSSV/00 5.152

Maintenance _________________________________________________ Fig. 125: CLA pot assembly and transfer case CLA head pot drain plug

© BUCYRUS AMERICA, INC.

CLA head transfer case drain plug

Oil fill, transfer case

Oil fill, pot assembly

Oil check (breather), transfer case

Oil check (breather), pot assembly

_________________________________________________________________ 5.153 Bucyrus – Model 25M0 Continuous Miner

________________________________________________ Maintenance input cutter head gear case

Change the oil in both input cutter head gear cases (Fig.126).  Position the cutter head horizontally (flat back in a vertical position).

Clean dirt and debris from around the drain plug located under the gear case.  Remove the drain plug and allow oil to completely drain from the gear case.  Clean and reinstall the drain plug.  Clean dirt and debris from around the check plug and remove the plug.  Clean dirt and debris from around the fill plug and remove the plug.  Slowly add oil through the fill plug until oil begins to flow from the check plug hole. Allow sufficient time for the oil to travel throughout the gear case when filling.

© BUCYRUS AMERICA, INC.

 Clean and reinstall the check and fill plugs.

Fig. 126: Input cutter head gear case Oil fill plug (one per side)

Oil check plug (one per side)

Drain plug (one per side)

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

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

______________________________________________________________ A6474X332 VSSV/00 5.154

Maintenance _________________________________________________ main cutter head gear case

Change the oil in both main cutter head gear cases (Fig. 127).  Lower the cutter head completely to the ground. Clean dirt and debris from around the drain plug, located under the gear case.  Remove the drain plug and allow oil to completely drain from the gear case.  Clean and reinstall the drain plug.  Clean dirt and debris from around the check plug and remove the plug.  Clean dirt and debris from around the fill plug and remove the plug.  Slowly add oil through the fill plug until oil begins to flow from the check plug hole. Allow sufficient time fro the oil to travel throughout the gear case when filling.

© BUCYRUS AMERICA, INC.

 Clean and reinstall the check and fill plugs.

Fig. 127: Main cutter head gear case

Oil check plug (one per side)

Oil fill plug (one per side)

CLAs

Inspect the CLAs (Fig. 128) for damage and CLA bolts for torque by moving with a slate bar. If a CLA needs replaced, see CLA removal and installation procedure in this chapter.

Fig. 128: CLAs

CLA

CLA

_________________________________________________________________ 5.155 Bucyrus – Model 25M0 Continuous Miner

________________________________________________ Maintenance Oil sampling plan This plan contains specific instructions to be followed in order to correctly collect gear case lubricant samples, and preparation of the samples for laboratory analysis. Adherence to these instructions will insure that all oil sample analysis reports give an accurate picture of the oils condition as well as wear trends of gears, bearings, etc. Accurate reporting and analysis of oil samples will prove extremely beneficial providing a tool to allow planning of scheduled down-time and prevention of costly equipment breakdown.

Preparation prior to sample collection For each machine to be sampled, you will need a supply of sample collection bottles and identification labels (Fig.129) sufficient to sample each identified gear case (every sixty shifts).

© BUCYRUS AMERICA, INC.

One sample bottle and collection hose is required for each gear case to be sampled. Label each container with the identifying name of the gear case (crawler gear case, left or cutter head gear case, right front, etc.).

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

Each oil sample should be taken while the oil is at normal operating temperature. If the machine has not been operating just prior to sampling, run the machine until oil temperature reaches approximate normal operating temperature. Shutdown the machine and allow 2 - 3 minutes for the oil to drain back and stabilize it’s level.

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

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

After taking sample, check and refill gear case back to proper fill level.

Following collection of all oil samples, record the specific brand and product name of the lubricant that has been installed in each gear case.

Recommended gear cases to be sampled: ■

Input cutter head gear case (left and right)

■

Main cutter head gear case (left and right)

______________________________________________________________ A6474X332 VSSV/00 5.156

Maintenance _________________________________________________ ■

Input gathering head gear case (left and right)

■

Main gathering head gear case (left and right)

■

Tram gear case (left and right)

■

Main hydraulic oil tank

Fig. 129: Oil sampling procedure Oil fill plug

Place end of siphon tube approximately half way into sump

filters and strainers

Note: Hold sample pump and bottle below oil level

The following filter elements must be changed as required by the conditions at the mine. Refer to the Hydraulic component location drawing (Fig. 51) in the Hydraulic section of this chapter and the Scrubber and dust-cooling component location drawing (Fig. 71) in the Water section of this chapter for component locations.

■

pilot filter, by-passing

■

pilot filter, non by-passing

■

return filter

_________________________________________________________________ 5.157 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

Typical siphon pump and bottle

Oil level

________________________________________________ Maintenance Every three months IMPORTANT! For motor bearings that require high temperature lithium complex grease, Bucyrus provides a special “button” style lubrication fitting (Fig. 129) to prevent the accidental use of multi-purpose lithium complex grease at these locations. cutter motor bearings

Lubricate the left and right cutter head motor bearings (Fig. 129) with high temperature lithium complex grease through the grease fittings located on each side of the cutter head assembly. To lubricate the motors:  Remove the cover to access the motor.  Inspect the grease fittings on the exit side of the front and rear motor bearing.

© BUCYRUS AMERICA, INC.

 If the exit side motor bearing ports are equipped with a spring loaded relief fitting (as shown in Fig. 130):   Lubricate both motor bearings using the “button” fittings (Fig. 120) until new grease appears out of the relief port on the exit side of the bearing.   Operate the motor for five minutes.   Inspect for any grease leakage in the area around the bearing.

If the grease fitting on the exit side of the motor bearing is fitted with a plug:   Remove the plug.   Lubricate both motor bearings using the “button” fitting (Fig. 129) until new grease appears out of the exit side of the bearing.   Operate the motor for five minutes.   Inspect for any grease leakage in the area around the bearing.   Replace the plug.

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

IMPORTANT! For motor bearings that require high temperature lithium complex grease, Bucyrus provides a special “button” style lubrication fitting (Fig. 129) to prevent the accidental use of multi-purpose lithium complex grease at these locations.

______________________________________________________________ A6474X332 VSSV/00 5.158

Maintenance _________________________________________________ Fig. 130: Cutter motor bearing lubrication Relief fitting

Spring loaded grease relief fitting

Relief port

Lubricate the pump motor (Fig. 131) with high temperature lithium complex grease through the two (2)grease fittings located the right side of the machine. To lubricate the motors: 

Remove the cover to access the motor.



Inspect the grease fittings on the exit side of the front and rear motor bearing.



If the exit side motor bearing ports are equipped with a spring loaded relief fitting (as shown in Fig. 130):





Lubricate both motor bearings using the “button” fittings (Fig. 130) until new grease appears out of the relief port on the exit side of the bearing.





Operate the motor for five minutes.





Inspect for any grease leakage in the area around the bearing.

If the grease fitting on the exit side of the motor bearing is fitted with a plug: 

Remove the plug.



Lubricate both motor bearings using the “button” fitting (Fig. 130) until new grease appears out of the exit side of the bearing.



Operate the motor for five minutes.



Inspect for any grease leakage in the area around the bearing.



Replace the plug.

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

_________________________________________________________________ 5.159 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

pump motor bearings

________________________________________________ Maintenance Fig. 131: Pump motor bearings

Pump motor (located behind cover)

© BUCYRUS AMERICA, INC.

IMPORTANT! For motor bearings that require high temperature lithium complex grease, Bucyrus provides a special “button” style lubrication fitting (Fig. 130) to prevent the accidental use o f multi-purpose lithium complex grease at these locations. scrubber motor bearings

Lubricate the scrubber motor bearings (Fig. 132) with high temperature lithium complex grease through the grease fittings located on the scrubber side of the machine. To lubricate the motors:   Remove the cover to access the motor.  Remove grease plug (s) on exit side of bearing (s).  Lubricate bearing using “button” fitting until new grease appears out of open port on exit side of bearing (s).  Operate motor (s) for five (5) minutes.  Replace grease plug (s) in all port (s).

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

Fig. 132: Scrubber motor bearings

Scrubber motor (located under cover)

______________________________________________________________ A6474X332 VSSV/00 5.160

Maintenance _________________________________________________ Every six months tram gear cases

Change the oil in both tram gear cases (Fig. 133).  Remove the two drain plugs and allow oil to completely drain from the gear case. One drain plug is located under the check and fill plugs, and one drain plug is underneath the reach gears.  Clean and reinstall the drain plugs.  Remove the fill plug located on top of the gear case.  Add oil through the fill plug hole until oil is visible in the sight glass.

When filling, allow sufficient time for the oil to travel throughout the gear case.

Oil drain

Oil fill

Secondary oil drain

Oil check (breather)

_________________________________________________________________ 5.161 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

Fig. 133: Tram gear case

________________________________________________ Maintenance hydraulic oil

Change the oil in the hydraulic oil tank (Fig. 134).  Clean all dirt and debris from around the fill cap and the drain plug.  Remove the drain plug and allow the oil tank to completely drain.  Clean and remove the drain plug.  Manually add oil until the fill pump picks it up.

WARNING! The hydraulic oil fill pump will be damaged if it is run dry.  Fill the tank with oil using the power fill pump until the oil level reaches the full level as indicated on the dipstick. To activate the power fill:  Engage the conveyor down function.

© BUCYRUS AMERICA, INC.

 Open the ball valve.  After filling, start the machine and engage all cylinders for the full length of travel (full extend and retract) in order to purge the hydraulic system of air.  Recheck the oil level on the dipstick. Add more oil as needed.

Fig. 134: Hydraulic oil tank Dipstick location

Hydraulic oil tank

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Maintenance _________________________________________________ The following filter elements must be changed as required by the conditions at the mine. Refer to the Hydraulic component location drawing in the Hydraulic section of this chapter and the Scrubber and dustcooling component location drawing in the Water section of this chapter for component locations.

■

pilot filter, by-passing

■

pilot filter, non by-passing

■

main pressure filter

■

return filter

■

water filter

■

oil filter

■

breathers

■

y-strainers

■

Jet pump strainers

_________________________________________________________________ 5.163 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

filters and strainers

_______________________________________ Adjustment procedures Setting hydraulic pressures ■

Always refer to the hydraulic schematic in the Bucyrus America, Inc. parts book supplied with your miner.

■

Most relief valves are set to factory specifications and should require no further adjustment. If a problem occurs which requires the reliefs to be adjusted, make certain the correct procedures are followed and all work is performed by a qualified person.

■

Remember when adjusting relief valves that turning the adjusting screw in (clockwise) will increase the pressure setting.

© BUCYRUS AMERICA, INC.

WARNING! Use extreme caution when performing test procedures and making adjustments. Unless noted in the procedures, all controls are to be in the neutral position.

The miner is equipped with seven pressure gauges, typically mounted in a gauge panel, to aid in setting relief pressures (typical). The gauges are for: ■

main flow - primary pressure circuit (all functions of the main control valve can be read from this gauge),

■

pilot pressure circuit,

■

accumulator,

■

anti-chatter/maintenance (shear down) valve for cutter head,

■

gathering head float valve, and

■

the reduced pilot pressure circuit.

There will be occasions when relief valves, or other pressure control valves, must be set or adjusted. Setting relief valve pressure is necessary when a relief valve is replaced with a new unit or when an existing relief valve needs to be adjusted, for example, during the course of troubleshooting a hydraulic system fault. This section describes the proper procedure for setting the relief valves.

______________________________________________________________ A6474X332 VSSV/00 5.164

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

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

Load holding valve adjustment The load holding valve is factory preset and should never be field adjusted.

Always refer to your parts manual when ordering load holding valves for the cutter or conveyor cylinders.

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

Adjustment procedures should start with the pilot pressure circuit because this system is a “closed center circuit” and will build pressure as soon as the pump is started. The main flow-primary pressure circuit is an “open-center circuit” and no pressure is present in this circuit until a function is activated.

Reference Pilot and Main flow-primary pressure circuits and Abbreviation and terms in the Hydraulic section of this chapter.

_________________________________________________________________ 5.165 Bucyrus – Model 25M0 Continuous Miner

© Bucyrus America, Inc.

Never rely on the load holding valve as a means of supporting the cutter boom or conveyor boom while making repairs. Always support the cutter boom and conveyor boom with adequate material before working around or underneath the cutter or conveyor.

_______________________________________ Adjustment procedures Pilot pump circuit relief valve adjustments The following procedure is for start up of new and rebuilt machines.

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

© BUCYRUS AMERICA, INC.

WARNING! Two people are required to adjust pressure settings. One person will make the adjustments while the second person must remain at the “machine stop” at all times during the adjustment procedure. Failure to do so may result in serious injury or death.  1. Reduced pilot pressure circuit: loosen the nut on the relief valve cartridge and turn the screw out (counter-clockwise) using an Allen wrench to prevent over pressuring the gauge on this circuit.  2. Conveyor chain take-up circuit (optional): open the needle valve by turning the knob counter-clockwise, opening flow to tank.  3. Start the pump motor (see Startup procedure in this chapter) and adjust the pilot pressure relief valve.  Loosen the nut on the valve cartridge and, using an Allen wrench, turn the screw in (clockwise) to increase pressure or out (counter-clockwise) to decrease pressure. The pressure should be set at 600 psi.

IMPORTANT! Before making any further adjustments, verify that the hydraulic oil is at operating temperature.  4. Adjust the conveyor chain take-up pressure reducing valve (optional).  Close the needle valve by turning the knob clockwise, opening flow to the take-up cylinders. The pressure reading should be 175 psi.  Remove the hex socket head plug to adjust the inner spool.

Using an Allen wrench, turn the screw in (clockwise) to increase pressure or out (counter-clockwise) to decrease pressure.  Replace the hex socket head plug.

______________________________________________________________ A6474X332 VSSV/00 5.166

Adjustment procedures ________________________________________  5. Adjust the reduced pilot pressure valve.  Turn the cartridge in (clockwise) until the pressure reading is 350 psi.  While holding the cartridge in place, tighten the nut to lock the spool in place. Double check the pressure reading to ensure that the cartridge was not turned while tightening the nut.  6. Readjust the pilot pressure relief valve, is necessary, to 600 psi.

Relief valve replacement  Pilot relief valve replacement: Set the pilot relief to 600 psi, per Step 3, making sure that the conveyor chain take-up knob is closed (turn clockwise to close).  Conveyor chain take-up pressure reducing valve replacement: Set the pilot relief to 175 psi, per Step 4, making sure the conveyor chain take-up knob is closed (turn clockwise to close).

Main control valve working port relief adjustment Each valve bank section, with the exception of the gathering head, has two (2) working port reliefs. When the handle is pulled (spool in), oil is directed to the work port and relief closest to the handle; this is “A” port. When the handle is pushed in (spool out), oil is directed to the work port and relief farthest from the handle; this is ‘B” port.

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

_________________________________________________________________ 5.167 Bucyrus – Model 25M0 Continuous Miner

© Bucyrus America, Inc.

 Reduced pilot pressure valve replacement: See Steps 1 and 5.

_______________________________________ Adjustment procedures Main control valve adjustment IMPORTANT! The main relief is set higher than the port reliefs and will only relieve if a spike occurs in the system or if the port relief does not function properly. This provides protection of the main pump section, A1.

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

CAUTION! Always be alert for any unintended machine movement.

© BUCYRUS AMERICA, INC.

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

WARNING! Two people are required to adjust pressure settings. One person will make the adjustments while the second person must remain at the “machine stop” at all times during the adjustment procedure. Failure to do so may result in serious injury or death.

Main relief adjustment  Remove the protective cap on the front port relief of the cutter head working section and loosen the nut on the adjusting screw. Turn the adjusting screw in all the way.  Loosen the nut on the main relief cartridge. Turn the main relief adjusting screw two turns clockwise.  Start the pump (see Start up procedure in this chapter) and activate the stabilizer shoe down function. This will raise the back portion of the machine off the ground.

WARNING! Keep body parts clear of machine while in raised position or serious injury could result.  With the stabilizer shoe down function bottomed out, turn the main relief cartridge adjusting screw in (clockwise) until a pressure of 3,000 psi is obtained.  With the stabilizer shoe function in the neutral position, hold the main relief cartridge screw in place and tighten the nut to lock the screw in place. Check the pressure setting to verify that the screw was not moved while tightening the nut.  Adjust the stabilizer shoe down port relief (see port relief adjustment procedure in this chapter).  Replace the protective cap. ______________________________________________________________ A6474X332 VSSV/00 5.168

Adjustment procedures ________________________________________ Port relief valve adjustment Port relief valves are functional when operating the circuit in which they are installed. As the particular function is activated and the pressure reaches the adjusted setting, the port relief will relieve excessive pressure to the tank cavity within the valve bank, preventing damage to the circuit.

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

If the correct pressure reading is not obtained as noted in Items 1 through 5 below, the port relief for that function must be adjusted.

The adjustment procedure for each port relief is the same and is:  Remove the protective cap on the port relief and loosen the nut on the adjusting screw.

 Once the correct pressure reading is obtained, return the function to the neutral position, hold the screw in place, and tighten the lock nut. Check the pressure reading to ensure that the screw did not turn while the lock nut was being tightened.

Pressure readings: 1. Stabilizer shoe port relief  Activate the stabilizer shoe raise circuit to fully raise the stabilizer shoe. The main control valve pressure gauge should read 1,200 psi.  Activate the stabilizer shoe lower circuit to fully lower the stabilizer shoe. The main control valve pressure gauge should read 2,500 psi.

2. Cutter head port relief  Activate the cutter head raise circuit to fully raise the cutter head. The main control pressure gauge should read 2,800 psi.  Activate the cutter head lower circuit to fully lower the cutter head and raise the front of the machine off the ground. The main control pressure gauge should read 2,800 psi. Note that you must push in on the selector valve of the anti-chatter/ maintenance valve to get full reading.

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

_________________________________________________________________ 5.169 Bucyrus – Model 25M0 Continuous Miner

© Bucyrus America, Inc.

 Turn the port relief screw in (clockwise) to increase pressure and out (counter-clockwise) to decrease pressure.

_______________________________________ Adjustment procedures 3. Conveyor raise/lower port relief  Activate the conveyor raise circuit to fully raise the conveyor.

The main control valve pressure gauge should read 1,800 psi.  Activate the conveyor lower circuit to fully lower the conveyor.

The main control valve pressure gauge should read 1,400 psi.

Note: Be sure that the ball valve is closed on the tank oil fill part of this circuit.

4. Conveyor swing port relief  Activate the conveyor swing left circuit to fully swing the conveyor to the left. The main control valve pressure gauge should read 1,800 psi.

© BUCYRUS AMERICA, INC.

 Activate the conveyor swing right circuit to fully swing the conveyor to the right. The main control valve pressure gauge should read 1,800 psi.

5. Gathering head port relief  Activate the gathering head raise circuit to fully raise the gathering head. The main control valve pressure gauge should read 1,700 psi.  If 1,700 psi is not obtainable, check that the relief in the gathering head float valve that is stamped “CR” is set to 1,800 psi (see Gathering head raise/hold/float-lower circuit in the Hydraulic section of this chapter).

______________________________________________________________ A6474X332 VSSV/00 5.170

Adjustment procedures ________________________________________ Tram track adjustment  1. Lower the conveyor tail section until it is level with the floor.  2. Raise the gathering head and cutter head and block both assemblies following standard blocking procedures.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all blocking devices.  3. Lower the gathering head and cutter head onto the blocking so that the front end of the miner lifts off the floor.  4. Extend the stabilizer completely so that the rear end of the miner lifts off the floor.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load of all blocking devices.  6. Raise the stabilizer, gathering head, and cutter head assemblies so that the weight of the miner rests on the blocking.  7. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine lockout/tagout regulations.

WARNING! Follow all Federal and mine lockout/tagout regulations and procedures. Failure to do so could result in machine damage or serious injury or death to personnel.  8. Double check the tractor frame support blocking now that the weight of the tractor frame is completely upon it.  9. Evaluate the tram track for proper tension (Fig. 135). The tram track is at the proper tension when it hangs approximately 2 1/2” to 3 1/2” from the bottom wear shoes when the tractor frame is blocked off the floor. Using this evaluation, determine whether step 13, 14, or 15 provides the appropriate subprocedure to correct improper track tension.

Fig. 135: Tram track adjustment

Bottom of tractor wear shoe

64 - 89 mm gap (2-1/2 to 3-1/2 inches) Top of tram track

_________________________________________________________________ 5.171 Bucyrus – Model 25M0 Continuous Miner

© Bucyrus America, Inc.

 5. Securely block under the machine. The machine must be securely supported off the ground with the tram track free to turn.

_______________________________________ Adjustment procedures

  10. Remove the hex head capscrews and lock washers that secure the front rub rail to the tractor frame (Fig. 136) and open the front rub rail cover.

Fig. 136: Rub rail removal Capscrew and lock washer

Capscrew and lock washer

© BUCYRUS AMERICA, INC.

Tram rub rail

 11. Remove the cover plate to allow access to the idler assembly.   12. Locate the front idler take-up jack grease fitting and attach the grease gun to the fitting.  13. If the tram track tension is too tight, readjust the idler position using the following steps: ■

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

■

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

■

Open the pressure release valve for the front idler take-up jack and allow the jack to contract. The pusher plate will slide backwards until it is stopped by the remaining idler shims.

■

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

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Adjustment procedures ________________________________________

 ■

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

■

Insert shims (Fig. 137) into the idler slide channel until the space between the tractor frame and the pusher plate is filled.

■

Open the pressure release valve for the front idler take-up jack and allow the cylinder to contract. The idler adjustment shims will keep the idler stationary and the track tensioned.

■

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

CAUTION! Shims must be inserted completely into the idler slide channel. A shim that is not correctly seated on the idler slide channel’s inside surface provides uneven support that can cause idler slant. A slanted idler can cause uneven wear and stress on the tram track and can cause improper operation of or damage to the tram system.

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

Fig. 137: Tram track adjustment

Pressure relief valve

Take-up cylinder

Spacer Plate (can be turned 180°)

Pusher plate

Shims Idler assembly

_________________________________________________________________ 5.173 Bucyrus – Model 25M0 Continuous Miner

© Bucyrus America, Inc.

 14. If the tram track is too loose, readjust the idler position using the following steps:

_______________________________________ Adjustment procedures

  15. If the tram track tension is still too loose when the entire 5” shim set is inserted into the idler slide channel, re-adjust the idler position after removing a tram track link using the following steps:  The spacer plate can be turned 180° (Fig. 138). This will allow for approximately 3 more inches of adjustment.  Pump grease into the take-up jack to extend the cylinder and remove the pusher plate pressure on the idler shims.  Remove all of the idler adjustment shims from the idler slide channel.  Open the pressure release valve for the front idler take-up jack and allow the cylinder to contract.  The tram track tension should now be reduced and separation of the tram track will be easier.

© BUCYRUS AMERICA, INC.

 Locate a tram track link near the tram idler.  Using the hammer and punch, remove the four roll pins of the two tram track pins (Fig. 143) that secure the tram track link to the track.  Using the hammer and punch, remove the tram track pins to disconnect the link from the track. Remove the disconnected link.  Store the tram track link, one of the tram track pins and two of the roll pins in a safe place.  Connect the two ends of the tram track and using the hammer and punch, secure the two end links together with the remaining tram track pin.  Using the hammer and punch, secure the tram track pin between the two links with the remaining two roll pins.  Pump grease into the idler take-up jack to extend the cylinder, move the idler assembly forward and tighten the tram track until it is at the correct tension. The tram track is at the proper tension when it hangs approximately 2 1/1” to 3 1/2” from the bottom wear shoes when the tractor frame is blocked off the floor.  Insert shims into the idler slide channel until the space between the tractor frame and the pusher plate is filled.  Open the pressure release valve for the front idler take-up jack and allow the cylinder to contract. The idler adjustment shims will keep the idler stationary and the track tensioned.  The idler adjustment shims will keep the idler stationary and the track tensioned.  Evaluate the resulting track tension and repeat until the track reaches proper tension. ______________________________________________________________ A6474X332 VSSV/00 5.174

Adjustment procedures ________________________________________ Fig. 138: Tram track adjustment

Track retention pin Pad

Lock pin

 17. Open the pressure release in order to take pressure off of the take-up cylinder.  18. Close the front rub rail cover and secure the front rub rail to the tractor frame with hex head capscrews and lock washers.  19. Connect the trailing cable to energize the miner.  20. Raise the tractor frame off the blocking by lowering the stabilizer and gathering head and cutter head assemblies.  21. Carefully remove the support blocking from under the tractor frame.  22. Lower the tractor frame onto the floor by raising the stabilizer and gathering head and cutter head assemblies.  23. Carefully remove the blocking from underneath the raised stabilizer, gathering head, and cutter head assemblies.

_________________________________________________________________ 5.175 Bucyrus – Model 25M0 Continuous Miner

© Bucyrus America, Inc.

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

_______________________________________ Adjustment procedures Tail shim adjustment As the conveyor wears the tail section may sag relative to the conveyor front section. The conveyor has been designed to allow correction of the sag by adding shims.  1. Lower the cutter head and gathering head assemblies until they touch the floor.  2. Position the conveyor tail section directly behind the miner and raise it to its highest position.  3. Insert blocking under the tail section and lower the tail onto the blocking. The conveyor should be at an angle with the rear end of the tail section slightly higher than the front.

© BUCYRUS AMERICA, INC.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all blocking devices.  4. Insert blocking between the top of the tractor frame and the bottom of the conveyor, leaving about 2” of space between the blocking and the conveyor bottom.  5. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine lockout/tagout regulations.

WARNING! Follow all Federal and mine lockout/tagout regulations and procedures. Failure to do so could result in machine damage or serious injury or death to personnel. 

6. Loosen the hex head capscrews that secure the shims between the shim retainer and the conveyor lower pivot plate (Fig. 139).

Fig. 139: Shim removal Hex head capscrews

Lower pivot plate

Shim retainer

Shims

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Adjustment procedures ________________________________________

  7. Connect the trailing cable to energize the miner.

WARNING! The following steps releases the shims, which will fall free. Watch out for falling shims when loosening the capscrews.  8.

Slowly lower the conveyor slightly so that the front section rests on the frame support blocking. The slotted shims will now fall free.

 9.

Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine lockout/tagout regulations.

WARNING! Follow all Federal and mine lockout/tagout regulations and procedures. Failure to do so could result in machine damage or serious injury or death to personnel.  10. Replace the removed shims (Fig. 140) and add the number of shims required to level the conveyor front and tail sections.

© Bucyrus America, Inc.

 11. Tighten the hex head capscrews.

Fig. 140: Tail shim adjustment Hex head capscrews

Shim retainer

Lower pivot plate

Shims

 12. Connect the trailing cable to energize the miner.  13. Raise the conveyor tail from the blocking.  14. Remove both sets of blocking and lower the conveyor tail until it is level with the floor.  15. Check the gap and alignment (Fig. 141) at the juncture of the conveyor front and tail sections for alignment. If the sections are not horizontally aligned, then add or subtract shims as required.

_________________________________________________________________ 5.177 Bucyrus – Model 25M0 Continuous Miner

_______________________________________ Adjustment procedures Fig. 141: Tail shim adjustment Correct gap and alignment Conveyor tail section

Conveyor front section

Add shims Conveyor tail section

Conveyor front section

Remove shims

© BUCYRUS AMERICA, INC.

Conveyor tail section

Conveyor front section

 16. Re-insert the blocking between the top of the tractor frame and the bottom of the conveyor following mine standard blocking procedures.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all blocking devices.  17. Securely retighten the hex head capscrews.

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Adjustment procedures ________________________________________ Chain tension adjustment - mechanical take-up  1. Lower the gathering head and cutter head until they touch the floor. 2. Position the conveyor tail section straight behind the miner and lower onto blocking until the tail is level with the floor. Follow all mine procedures for blocking.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all blocking devices.  3. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine lockout/tagout regulations.

4. On the right side of the conveyor loosen (but do not remove) the two hex bolts that secure the rod guide to the take up rod (Fig. 142). The rod should be able to rotate freely.  5. Repeat this step on the conveyor’s left take up rod.

Fig. 142: Chain tension adjustment - mechanical take-up Take-up rod

Hex bolt (2)

Rod guide

 6. To tighten the conveyor chain: Using a 3/4” hex head socket wrench inserted in the take-up rod’s crank socket (Fig. 143), alternately rotate the right and left take-up rods clockwise one rotation at a time until the proper chain tension is reached.  7. To loosen the conveyor chain: Using a 3/4” hex head socket wrench inserted in the take-up rod’s crank socket (Fig. 143), alternately rotate the right and left take-up rods counter clockwise one rotation at a time until the proper chain tension is reached.

IMPORTANT! Left and right take-up rods should be rotated equally. This maintains steady, equal pressure on the tail roller assembly and keeps the conveyor chain from drifting off center.

_________________________________________________________________ 5.179 Bucyrus – Model 25M0 Continuous Miner

© Bucyrus America, Inc.

WARNING! Follow all Federal and mine lockout/tagout regulations and procedures. Failure to do so could result in machine damage or serious injury or death to personnel.

_______________________________________ Adjustment procedures Fig. 143: Chain tension adjustment Tighten

Crank socket

Crank socket

Crank socket

Tighten

Loosen

© BUCYRUS AMERICA, INC.

Loosen

Crank socket

 8. When the proper chain tension has been reached, tighten the two hex bolts that secure the rod guide to the conveyor’s right take-up rod. The take-up rod should be securely clamped between the split block.  9. Repeat step 6 or 7 if loosening or tightening the conveyor chain.  10. Connect the trailing cable to energize the miner.  11. Slowly raise the conveyor tail section and carefully remove the blocking from underneath.  12. Start the conveyor and CLAs running and observe the chain for proper tension.  13. When the chain tension is properly adjusted with the conveyor tail straight behind the miner, slowly swing the tail section from left to right behind the miner and check the chain’s tension when the tail section is farthest from center (Fig. 144).

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Adjustment procedures ________________________________________

 IMPORTANT! Chain tension decreases as the tail section moves away from center. Check the chain tension when the tail is at an angle to confirm that it is properly adjusted.

Fig. 144: Tail section position

Farthest from center

Chain tension adjustment - grease take-up  1. Lower the gathering head and cutter head until they touch the floor. 2. Position the conveyor tail section straight behind the miner and lower onto blocking until the tail is level with the floor. Follow all mine procedures for blocking.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all blocking devices.  3. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine lockout/tagout regulations.

WARNING! Follow all Federal and mine lockout/tagout regulations and procedures. Failure to do so could result in machine damage or serious injury or death to personnel.   4. Pump grease into the take-up jack (Fig. 145) to extend the cylinder rod and remove pressure on the adjustment shims. Repeat this step on the other side.  5. Alternately, left and right, add shims to increase chain tension or remove shims to decrease chain tension. An equal number of shims must be used on each side of the conveyor.

_________________________________________________________________ 5.181 Bucyrus – Model 25M0 Continuous Miner

© Bucyrus America, Inc.

Farthest from center

_______________________________________ Adjustment procedures Fig. 145: Chain tension adjustment - grease take-up Take-up rod

Shims

© BUCYRUS AMERICA, INC.

Grease fitting

Grease take-up valve

6. Once proper chain tension is achieved open the grease takeup valve and allow pressure to bleed from the cylinder. Repeat for the other side.   7. Check for proper adjustment   Connect electrical power to the miner.   Slowly raise the conveyor tail section and remove the blocking.   Start the conveyor / gathering head and observe the chain for proper tension. The conveyor chain should rise about 2” or less above the gathering head’s foot shaft sprocket as the chain emerges from under the conveyor pan. Check that there is no contact between the CLAs and the chain flights.  Slowly swing the conveyor tail section from left to right behind the miner and check the chain tension. The chain tension de creases when the tail section moves away from center.

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Adjustment procedures ________________________________________ Cutter motor feedback adjustment The tram motor speed voltages are limited in the forward direction when the cutter motors are running. How much the tram speed is limited is controlled by the load on the cutter motors. When the load is light, as in a clean-up operation, the tram speed is less limited that when there is high cutter motor loading, as in a sumping operation. The cutter motor loading is monitored by using a current transformer, CT3, in a phase lead.

This cutter motor feedback is connected to the tram interface to control the tram motor speed voltages. The “clean-up” and “sump” tram voltages are factory set. It may be necessary to adjust these voltages to suit the actual mining conditions.

Reference Fig. 146: Tram interface and Fig. 147: SCR tram drive.

 Current Generator: Bucyrus America, Inc. has a current generator which can be used to simulate the secondary current in the feedback current transformer, CT3. The current generator needs to be connected to 120 vac. This can be tapped at terminal numbers 14 and 79 on the tram interface terminal strip (Fig. 146).

Remove the feedback wires number 196 and 197 from the tram interface terminal strip and connect the output of the current generator (flat cable) to the tram interface terminals 196 and 197. Be sure the power switch is off and the adjustable dial is set at zero.  Volt-Ohm Meter:  To check the left tram reference voltage connect VOM to tram interface terminal 41 pos. and D42 neg.  To check the right tram reference voltage connect VOM to tram interface terminal 51 pos. and D52 neg.  To check left armature voltage connect VOM to left SCR drive terminals A1 pos. and A2 neg.  To check right armature voltage connect VOM to right SCR drive terminals A1 pos. and A2 neg.

       

_________________________________________________________________ 5.183 Bucyrus – Model 25M0 Continuous Miner

© Bucyrus America, Inc.

 Open the tram case and access the traction case.

_______________________________________ Adjustment procedures  Before setting the clean-up and sump tram reference voltages, made sure the maximum high tram reference voltage is at 2.5 VDC to 3.0 VDC. This voltage is a fixed internal design and is not field adjustable.

Notes: ■

The left and right tram voltages must be adjusted separately.

■

The pump motor must be running for all tests/adjustments.

■

Always adjust clean-up voltage first.

■

If the miner does not track properly after the voltages are correctly adjusted do not readjust the voltages. Look for excessive looseness of a crawler track, binding in the traction drive train, or even missing cutter bits or bit holders.

© BUCYRUS AMERICA, INC.

 To set the tram clean-up speed:   Apply 1.0 amp from the current generator to terminals #196 and #197 on the tram interface.   Move the tram control lever to full on forward.   A VOM armature voltage reading of 200 to 225 VDC should be on the SCR drive terminals A1 - A2. Note: The reference voltage will be approximately 1.25VDC.   Adjust the clean-up voltage using the adjustment screws marked “C” on the tram interface. Set the left and right tram voltages the same.  To set the sump speed:   Apply 4 amp from the current generator to terminals #196 and #197 on the tram interface.   Move the tram control lever to full on forward.   A VOM armature voltage reading of 85 VDC should be on the SCR drive terminals A1 - A2.

NOTICE! The reference voltage will be approximately 0.55 VDC. Adjust the sump voltage using the adjustment screws marked “S” on the tram interface. Set the left and right tram voltages the same.  Reconnect the cutter motor feedback wires to the tram interface terminals #196 and #197 and reconnect tram control wires to the tram interface terminals and #51.

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Adjustment procedures ________________________________________ Fig. 146: Tram interface Sump and clean-up voltage adjustments

Reference voltage, left tram (41& D42)

Reference voltage, right tram (D52 & 51)

Cutter motor feedback terminals (196 & 197)

© Bucyrus America, Inc.

120 VAC connection (14 & 79)

Fig. 147: SCR tram drive

DC motor connections (S1, S2, A1, A2)

DC motor connections (S1, S2, A1, A2)

_________________________________________________________________ 5.185 Bucyrus – Model 25M0 Continuous Miner

____________________________________ Replacement of wear parts Instructions on the replacement of wear parts It is essential that wear parts are replaced before they reach the lowest wear limit. Inspect the wear parts at regular intervals.

CAUTION! Because these maintenance techniques are specialized, they should be performed only be qualified personnel.

Cutter head (boom) assembly The cutter head assembly (Fig. 148) can be removed as an assembly or in individual components.

Fig. 148: Cutter head assembly

© BUCYRUS AMERICA, INC.

Shear cylinder

Cutter boom pivot

cutter head assembly removal

Shear cylinder clevis pin

Cutter boom

Drum drive torque limiting clutch

Drum drive gear case

Drum drive motor

End drum

To remove the cutter head assembly (Fig. 149):  1. Attach an appropriate lifting device to the boom assembly.

Take up the slack in the lift assembly so that the weight is supported as the assembly is unpinned from the miner.

WARNING! You could be seriously injured or even killed by falling loads. Observe the safe working load limits of lifting and blocking devices and keep a safe distance from suspended loads.   2. Lower the gathering head and the cutter head to the floor and position the conveyor tail section level with floor.  3. Disconnect and lock out the electrical power to the miner. Follow all applicable Federal and mine regulations regarding lockout/tagout procedures.

______________________________________________________________ A6474X332 VSSV/00 5.186

Replacement of wear parts _____________________________________ WARNING! Follow all Federal and mine regulations for lockout/tagout. Failure to do so may result in serious injury or death.   4. Disconnect the power cables and water hoses from the cutter motors (see Cutter motor removal procedure in this chapter).

Be sure to tape up the power cables since electrical power will be connected to the miner.  5. Disconnect the water hoses to the dust suppression sprays.  6. Remove the 2 boom pivot pins (see Boom pivot pin removal procedure in this chapter).  7. Connect electrical power to the miner.  8. Extend the shear cylinders to push the boom pivots out of their tractor frame clevises.

WARNING! You could be seriously injured or even killed by falling loads. Observe the safe working load limits of lifting or blocking devices and keep a safe distance from suspended loads.  10. Disconnect power to the miner. Follow all applicable Federal and mine regulations regarding lockout/tagout procedures.

WARNING! Follow all Federal and mine regulations for lockout/tagout. Failure to do so may result in serious injury or death.  11. Remove the shear cylinder boom clevis pins (see Shear cylinder removal procedure in this chapter).  12. Connect electrical power to the miner. 

 13. Retract the shear cylinders to pull their bearings free from the boom clevises.  14. Disconnect power to the miner. Follow all applicable Federal and mine regulations regarding lockout/tagout procedures.  15. Raise the rear of the boom assembly until it is above the top edge of the gathering head backboard.  16. Slowly tram the mine backwards until the cutter boom pivot points clear the front of the gathering head.

_________________________________________________________________ 5.187 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

 9. Block the boom and shear cylinders to keep them stationary during their pin removal.

____________________________________ Replacement of wear parts Fig. 149: Cutter head assembly removal

Shear cylinder

Shear cylinder clevis pin

Cutter boom

Cutter boom pivot

© BUCYRUS AMERICA, INC.

cutter head assembly installation

To install the cutter head assembly (Fig. 150)   1. Slowly tram the miner forward toward the raised end of the boom until the pivot pins clear the gathering head backboard.   2. Lower the boom pivot points until the shear cylinders can reach their boom clevises. Block the boom to keep it in a secure position.  3. Extend the shear cylinders until their rod end bearings can be inserted into the cutter boom clevises.  4. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations regarding lockout/tagout procedures.

WARNING! Follow all Federal and mine regulations regarding lockout/tagout procedures. Failure to do so may result in serious injury or death.

WARNING! Do not test the alignment of the shear cylinder rod end bearings and the cutter boom clevis using your fingers. Shifting of the aligned pieces could cause serious injury.    5. Position the right cylinder’s rod end bearing in the boom clevis.

IMPORTANT! The pin should be inserted so that its retaining channel remains outside the bushing.  6. Insert the rod end pin through the aligned clevis bushings and rod end bearing.

______________________________________________________________ A6474X332 VSSV/00 5.188

Replacement of wear parts _____________________________________  7.

Insert the pin retaining plate and secure to the boom clevis with hex head capscrews and lock washers.

 8.

Repeat steps 4 through 7 on the left shear cylinder.

 9.

Connect the trailing cable to energize the miner.

 10. Once the shear cylinders are secured to the cutter boom, remove the boom blocking to allow the cylinders to move the boom.  11. Contract the shear cylinders to pull the cutter boom pivot points into position in the tractor frame boom pivot clevises.

 12. Install both cutter boom pivot pins (see Boom pivot pin procedure).  13. Replace the motor cooling water and scrubber spray water hoses onto the cutter head boom.  14. Replace the electrical power cables onto the cutter head boom.

_________________________________________________________________ 5.189 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

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

____________________________________ Replacement of wear parts Boom pivot pin removal and installation boom pivot pin removal

To remove the boom pivot pin:  1. Lower the conveyor tail section until it is level with the floor and gathering head and cutter head until they rest on the floor.  2. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations regarding lockout/tagout procedures.

WARNING! Follow all Federal and mine regulations regarding lockout/tagout procedures. Failure to do so may result in serious injury or death.  3. Locate the miner’s front rub rail and remove the hex head capscrew and lock washer that secures the rub rail to the tractor frame.

© BUCYRUS AMERICA, INC.

 4. Open the front rub rail (Fig. 151).

Fig. 151: Front rub rail

Capscrew and lock washer

Capscrew and lock washer

Tram rub rail

 5. Locate the front idler take-up jack bracket assembly (Fig. 152), which is mounted directly to the rear of the idler shim channel.  6. Pull the flip pin from the half link to release the take-up jack bracket from the tractor frame.  7. Lower the end of the bracket until it clears the half link and pull the bracket straight out to remove it from the tractor frame.

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

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

______________________________________________________________ A6474X332 VSSV/00 5.190

Replacement of wear parts _____________________________________

 Fig. 152: Half link

Tale-up jack bracket Half link

 8. Locate the end of the boom pivot pin in the area from which the take-up jack bracket was removed.

To remove the pin:  9.

Remove the hex head capscrews and lockwashers that secure the boom pivot pin retaining plate to the tractor frame.

 10. Remove the pin retaining plate and its support block.  11. Insert a slide hammer adapter into the threaded hole in the end of the boom pivot pin.

IMPORTANT! Pressure from the cutter boom onto the boom pivot pin can make its removal very difficult. The shear cylinders can be used to find the boom position that puts the least pressure onto the pin. This position can be determined by striking the pin, slightly contracting or extending the shear cylinder, then striking the pin again and comparing the “ring”; as boom pressure on the pin decreases, the “ring” of the pin when it is struck becomes lower. When the “ring” of the pin becomes short and low, pin removal is much easier.

CAUTION! Use extreme caution when adjusting the boom with the shear cylinder to find the pivot pin’s pull point.  12. When the pivot pin’s pull point is found, block the cutter boom to keep it from dropping or moving when the pin is pulled.  13. Attach the slide hammer to its adapter and pull the boom pivot pin.

_________________________________________________________________ 5.191 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

Flip pin

____________________________________ Replacement of wear parts

boom pivot pin installation

To install the boom pivot pin:  1. Position the boom pivot pin so that the end with the two flats (the end without the adapter) is inserted first. The single flat of the pin’s opposite end must face the four retaining plate holes.

IMPORTANT! On the back of the tractor frame clevis there is a welded strap that keeps the boom pivot pin from rotating. One of the flats of the boom pivot pin must parallel this strap or the pin cannot be completely inserted.

© BUCYRUS AMERICA, INC.

 2. Use the hammer to insert the boom pivot pin through the aligned tractor frame clevis and boom pivot bushings.

IMPORTANT! If it is extremely difficult to insert the boom pivot pin through the aligned tractor frame clevis and boom pivot bushings, extend or contract the shear cylinders to improve the alignment between the clevis and boom.

CAUTION! Use extreme caution when adjusting the clevis and boom alignment with the shear cylinders.  3. Replace the support block over the four threaded holes in the tractor frame.  4. Place the retaining plate onto the support block. The end of the retaining plate L-extension should be positioned against the flat of the boom pivot pin.  5. Insert and tighten the hex head capscrews lockwashers to secure the boom pivot pin retaining plate to the tractor frame.

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Replacement of wear parts _____________________________________ Shear cylinder removal and installation shear cylinder removal

To remove the shear cylinder:

  1.

Lower the gathering head until it touches the floor and lower the conveyor tail section until it is level with the floor. Advance the conveyor chain so that its flights do not block the shear cylinder piston end pin access plates on the conveyor bed.

 2.

Raise the cutter head assembly until it reaches its highest point. Place blocking underneath the cutter head. Lower the assembly onto the blocking at a level where the shear cylinder is partially but not fully contracted.

 3.

Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine lockout/tagout regulations.

WARNING! Follow all Federal and mine lockout/tagout regulations and procedures. Failure to do so could result in machine damage or serious injury or death to personnel.

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

WARNING! Replacement of the shear cylinder involves working around a raised cutter head assembly. Never work under any raised assembly without proper blocking. Always block between the raised assembly and the tractor frame in addition to between the raised assembly and the floor.

WARNING! This procedure involves disconnecting the hydraulic hoses. Always use caution when working with or around hydraulic systems because they can be under extremely high pressures.  4. Locate the shear cylinder guard, if equipped.  5. If there is a guard, then using pliers, remove the two cotter pins from the hinge pin at the front of the guard. Remove the hinge pin to detach the guard from the boom plate collar.

_________________________________________________________________ 5.193 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all blocking devices. Do not stand near the blocked cutter head.

____________________________________ Replacement of wear parts  6.

On the boom clevis of the shear cylinder’s rod end, locate the rod end pin and its retaining bracket.

 7. Remove the hex head capscrews and lock washers that secure the pin retaining plate to the cutter boom.  8. Remove the retaining plate.  9. Insert the slide hammer’s adapter into the threaded hole in the end of the pin.  10. Attach the adapter to the slide hammer and pull the pin from the clevis bushings.  11. Connect the trailing cable to energize the miner.

© BUCYRUS AMERICA, INC.

WARNING! Stand clear of the blocked cutter head assembly during shear cylinder contraction.  12. Slowly contract the shear cylinder until the rod end comes free from its clevis.  13. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine lockout/tagout regulations.

WARNING! Follow all Federal and mine lockout/tagout regulations and procedures. Failure to do so could result in machine damage or serious injury or death to personnel.  14. Raise and lower the shear cylinder control lever to release any pressure from the shear cylinder.

WARNING! The next steps disconnect the shear cylinder from the tractor frame. The shear cylinder is extremely heavy. Be prepared to support its weight before performing the following steps.   15. Locate the shear cylinder’s piston end pin and pin retaining plate.  16. Remove the two hex head capscrews and lockwashers that secure the pin retaining plate to the frame.  17. Remove the pin retaining plate.  18. Locate the shear cylinder piston end pin access plate on the conveyor bed.  19. Remove the hex head capscrew and lock washer that secures the access plate to the conveyor bed.

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Replacement of wear parts _____________________________________  20. Remove the access plate (Fig. 153).

Fig. 153: Shear cylinder access plate and pin

Access plate

 21. Locate the pin.  22. Insert the slide hammer adapter into the threaded hole in the end of the pin.  23. Attach the adapter to the slide hammer and pull the pin.  24. Disconnect, tag, and cap the hydraulic hoses going to the cylinder.

WARNING! Never disconnect a hydraulic hose if the circuit is pressurized or if there is a load on the circuit. If a hose is disconnected while the circuit is pressurized or a load is on it, the load will fall, causing damage to the machine or serious injury or death to personnel.  25. Remove the hydraulic fittings from the shear cylinder and store in a clean place.  26. Disconnect the grease hose from the grease fitting on the piston end of the shear cylinder. Plug the hose end to keep it clean.  27. Remove the grease fitting from the piston end of the shear cylinder.  28. The shear cylinder is now free and can be removed.

_________________________________________________________________ 5.195 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

Pin

____________________________________ Replacement of wear parts shear cylinder installation

To install the shear cylinder:  1. Position the shear cylinder piston end close to its frame clevis.

IMPORTANT! The following steps may require opening unsecured top covers.  2. Insert the grease fitting into the piston end of shear cylinder.  3. Attach the grease hose to the grease fitting.  4. Insert the hydraulic fittings into the piston end of the cylinder.  5. Reconnect hydraulic hoses to the cylinder.

© BUCYRUS AMERICA, INC.

 6. Place the shear cylinder’s piston end into its frame clevis.  7. Insert the shear cylinder piston end pin from the access opening on the conveyor bed into the aligned tractor frame clevis and shear cylinder piston end. The end of the pin with the retaining channel should be inserted first.  8. Tap on the pin with a hammer until its retaining channel emerges from the bushing on the other side of the clevis.  9. Insert the pin retaining plate in the pin’s channel to secure the pin in the clevis.  10. Insert and tighten the hex head capscrews and lock washers that secure the pin retaining plate to the frame clevis.  11. Replace the shear cylinder piston end pin access plate.  12. Insert and tighten the hex head capscrew and lock washer to secure the access plate to the conveyor bed.  13. Connect the trailing cable to energize the miner.

WARNING! Stand clear of the shear cylinder and the blocked cutter head assembly during extension of the shear cylinder.  14. Slowly extend the shear cylinder’s rod end so that it can be inserted into the boom clevis.  15. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine lockout/tagout regulations.

WARNING! Follow all Federal and mine lockout/tagout regulations and procedures. Failure to do so could result in machine damage or serious injury or death to personnel.

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Replacement of wear parts _____________________________________  16. Position the shear cylinder’s rod end bearing in the boom clevis.

IMPORTANT! The pin should be inserted so that its retaining channel remains outside the bushings.  17. Gently tapping on the pin with a hammer, insert the rod end pin through the aligned clevis bushings and rod end bearing.  18. Insert the pin retaining plate in the pin’s channel to secure the pin in the clevis.  19. Insert and tighten the hex head capscrews and lock washers to secure the pin retaining plate to the boom clevis.

 23. Insert the hinge pin through the jack guard and boom plate collar.  24. Using the pliers, insert and flare the two cotter pins through the cylinder guard hinge pin to secure the jack guard.

_________________________________________________________________ 5.197 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

 22. Replace the shear cylinder guard assembly (optional) into the boom plate collar.

____________________________________ Replacement of wear parts Center cutter drum center cutter drum removal

To remove the center cutter drum (Fig 154): WARNING! Replacement of the cutter head center drum involves working around a raised cutter head assembly. Never work under any raised assembly without proper blocking. Always block between the raised assembly and the tractor frame in addition to between the raised assembly and the floor.

WARNING! This procedure involves disconnecting and reconnecting the miner’s trailing cable. Always be aware of whether or not the miner is energized. Never perform maintenance on an energized miner.

Fig. 154: Center cutter drum removal/installation (typical shown)

© BUCYRUS AMERICA, INC.

Center drum

Drum seam

Strap

Capscrews Alignment key (square ends)

Retainer (strut bolts) Capscrews Strap

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Replacement of wear parts _____________________________________  1. Lower the gathering head completely until its touches the floor.

Lower the conveyor tail assembly until it is level with the floor.  2. Rotate the cutter head slowly until one of the center drum seams (Fig. 154) appears directly in front and one appears directly in rear of the cutter head.   3. Lower the cutter head assembly until it touches the floor.  4.

Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine lockout/tagout regulations.

WARNING! Follow all Federal and mine lockout/tagout regulations and procedures. Failure to do so could result in machine damage or serious injury or death to personnel.

DANGER! Never work under any raised assembly without proper blocking.  5. Remove the socket head capscrews securing the front seam of the center drum.  6. Remove the socket head capscrews securing the rear seam of the center drum.  7. Collect the retaining plates for the center drum’s capscrews.

Store the retaining plates in a safe place for a center drum reassembly.  8. Attach chains to the upper half of the center drum. The chains should be capable of supporting the entire weight of the upper half of the center drum.  9. Using the pry bar and other necessary force, break the seal between the center drum so that the bottom half is free from the top half.  10. Using an appropriate lifting device, connect the chains on the upper half of the center drum.

_________________________________________________________________ 5.199 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

CAUTION! Make sure the lifting device is capable of lifting the drum weight.

Use care when handling the cutter drum.

____________________________________ Replacement of wear parts

  12. Using an appropriate lifting device, lift the upper half of the center drum off the cutter head assembly. The cutter head and the lower half of the center drum should remain on the floor.

WARNING! Serious injury or death can result from falling loads. Observe the safe working load limits of lifting devices and keep a safe distance from suspended loads.  13. Connect trailing cable energize the miner.  14. Slowly raise the cutter head assembly until it is completely clear of the lower half of the center drum.  15. Slowly tram the miner backwards away from the suspended upper half and the resting lower half of the center until the cutter head assembly is completely clear of both of these pieces.

© BUCYRUS AMERICA, INC.

To install the center cutter drum (Fig. 154):

center cutter drum installation

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of lifting devices and keep a safe distance from suspended loads.  1. Slowly lower the cutter head assembly into the bottom half of the center drum. The bottom drum drive keys should fit into the interior of the lower half of the center drum.

WARNING! Stand clear of the cutter head assembly and the unsecured upper half of the center drum while lowering it.  2. Using an appropriate lifting device, slowly lower the upper half of the center drum onto the cutter head assembly. The top drum drive keys should fit into the underside interior of the upper half of the center drum.  3. Disconnect the chains that supported the upper half of the center drum.  4. Remove the chains from the upper half of the center drum.

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Replacement of wear parts _____________________________________  5. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine lockout/tagout regulations.

WARNING! Follow all Federal and mine lockout/tagout regulations and procedures. Failure to do so could result in machine damage or serious injury or death to personnel.  6. Insert the socket head capscrews into the holes in the top half of the drum through the alignment keys and through the bottom half of the drum. Use the following steps to equally distribute the torque over the center drum (Fig. 155):



 Alternating from front to back and moving from right to left, repeat this threading process on the other nine pairs of capscrews and nine retaining plates.



 When all capscrews have been inserted into their retaining plates, start with the paired capscrews on the right of the front seam of the center drum and torque.



 Proceed to the paired capscrews on the back right seam of the center drum and torque.



 Alternating from front to back and moving from right to left, torque the eight remaining pairs of capscrews into their retaining plates.

 7.

Double check that all bolts have been properly torqued.

Fig. 155: Bolt torqueing order

_________________________________________________________________ 5.201 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

 Starting with the pair of capscrews at the right front of the center drum, place a retaining plate under the bottom half of the drum where the capscrews emerge and thread the capscrews into the retaining plate.

____________________________________ Replacement of wear parts End cutter drum end cutter drum removal

To remove the end cutter drum:  1. Lower the gathering head completely until it touches the floor.

Lower the conveyor tail assembly until it is level with the floor.  2. Raise the cutter head assembly to its highest position. Place blocking underneath the cutter head assembly and lower the cutter head assembly onto the blocking.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of lifting devices and keep a safe distance from suspended loads.

© BUCYRUS AMERICA, INC.

 3. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine lockout/tagout regulations.

WARNING! Follow all Federal and mine lockout/tagout regulations and procedures. Failure to do so could result in machine damage or serious injury or death to personnel. 

4. Drain the gear case oil before removing the drums.

 5. Remove the lock tabs tack welded to the capscrews using a cutting torch.

Fig. 156: Lock tabs tack welded to capscrews

Lock tab welded in place

Oil drain plug

Access to center drum input shaft

 6. Remove the long capscrews and nuts on the two alignment dowels which secure the end drum to the cutter drum drive assembly.  7. Remove plug and center drum input shaft.  8. Remove the drum by sliding it off the hub.  9. Remove the drum alignment key (Fig. 157) and store for reinstallation. ______________________________________________________________ A6474X332 VSSV/00 5.202

Replacement of wear parts _____________________________________ Fig. 157: Drum alignment key

Drum alignment key

WARNING! You could be seriously injured by falling loads. Use extreme caution when working near suspended loads.

To install the end cutter drum:  1.

Locate the timing arrows (Fig 158) on the intermediate drum and the end drum about to be installed. The end drum must be installed so that its timing arrow is directly adjacent to the intermediate drum timing arrow.

Fig. 158: Intermediate drum timing arrows

Timing arrow on intermediate drum

Timing arrow on intermediate drum

 2.

Insert drum alignment key.

 3.

Slide the end drum onto the cutter drum drive gear case.

 4.

Install the plug and center drum input shaft. Add oil as necessary.

 5.

Tighten the long capscrews and nuts onto the two alignment dowels which secure the end drum to the cutter drum drive assembly.

 6.

Torque the capscrews to 350 lb.-ft. Tack weld the lock tabs.

_________________________________________________________________ 5.203 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

end cutter drum installation

____________________________________ Replacement of wear parts Drum drive motor drum drive motor removal

To remove the drum drive motor:  1. Lower the gathering head completely until it touches the floor.

Lower the conveyor tail assembly until it is level with the floor.  2. Raise the cutter head assembly to its highest position. Place blocking underneath the cutter head assembly. Lower the cutter head assembly WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all blocking devices. Do not stand near the blocked cutter head.

© BUCYRUS AMERICA, INC.

 3.

Disconnect the two cooling water hoses from the top manifold.

Plug the hose ends to keep them clean.

WARNING! Follow all Federal and mine lockout/tagout regulations and procedures. Failure to do so could result in machine damage or serious injury or death to personnel.

Fig. 159: Drum drive motor

Drum drive motor

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Replacement of wear parts _____________________________________  4. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine lockout/tagout regulations. Disconnect the two cooling water hoses from the top manifold. Plug the hose ends to keep them clean.  5. Remove the hex head bolts and lock washers that secure the manifold.  6. Remove the two manifolds to expose the top of the motor. Two o-rings on the top and bottom will be visible. Secure o-rings for use in re-installation.  7. Remove the flat bar connecting the hex head capscrews and lockwashers that secure the side motor cover.  8. Remove the cover (Fig. 160) to expose the side of the motor and the motor’s junction box.

Fig. 160: Cover removal Hex head bolts (4)

Flat bar

Manifold

Capscrews (8)

_________________________________________________________________ 5.205 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

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

____________________________________ Replacement of wear parts

  9. Remove the cutter motor shaft.  10. Place blocking under the motor to keep it supported when it becomes free from the cutter boom.  11. Remove the hex head caps crews and lockwashers that secure the junction box cover (Fig. 160).  12. Remove the cover and O-ring.  13. Locate the three taped power connections.  14. Strip off the three layers of tape covering these lug connections.

© BUCYRUS AMERICA, INC.

IMPORTANT! Before detaching these lugs, mark the wires to facilitate reconnection during motor installation.  15. Tag the lugs for correct reconnection then remove the hex head capscrew, flat washer, lock washer and hex head nut that secure the three power cable lugs to the three motor lugs.  16. Remove the socket head capscrews and lockwashers that secure the stuffing box’s half-moon clamp to the junction box. 17. Remove the clamp and slide the stuffing box out of the junction box. The power cable should be completely disconnected from the motor.

WARNING! While this power cable is detached from the motor, the trailing cable should not be reconnected to energize the miner. Damage to the miner, personal injury or death could result.  18. To prevent damage to the power cable lugs and gland assembly, cover the power cable and secure it to the miner in a safe location.  19. To protect the motor’s electrical connections, replace the motor junction box cover and secure it using hex head capscrews and lock washers.

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Replacement of wear parts _____________________________________ WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all lifting devices.  20. Remove the four socket head capscrews that secure the cutter drive motor to the cutter gear case (Fig. 161).  21. Remove motor and remove bottom manifold. Secure o-rings ( 2 ea.). Manifolds (top and bottom) do not come on exchange motors.  22. Remove plates on exchange motor (installed to cooling ports) and re-install on motor removed.

Fig. 161: Drum drive motor Manifold

© BUCYRUS AMERICA, INC.

Hex head bolts (4)

Capscrews (8)

_________________________________________________________________ 5.207 Bucyrus – Model 25M0 Continuous Miner

____________________________________ Replacement of wear parts drum drive motor installation

To install the drum drive motor: WARNING! Federal law requires that mining equipment electrical connections must be inspected by a certified electrician before the equipment can be operated.

WARNING! This procedure involves attaching an electrical power cable to the cutter head drum drive motor. The trailing cable must be disconnected to safely perform this operation or serious injury or death will result.  1.

Block up cutter head drum drive motor into position against the rear of the boom so that the motor’s mounting holes align with the boom’s threaded motor mounting holes.

© BUCYRUS AMERICA, INC.

WARNING! You can be seriously injured or killed by a falling load. Follow the safe working load limits of all blocking devices.  2. Insert the four bolts through the motor mounting holes (Fig. 162) and hand tighten them into the boom’s threaded motor mounting holes  3. Torque the four bolts to approximately 1,800 ft-lbs (see bolt installation procedure in this chapter) to secure the drive motor to the boom.  4. Attach rear support mount to motor with bolts and lock washers (Fig. 161). Torque bolts to proper setting (see Torque tables in Chapter 6).  5. Install the two motor cooling water fittings into the front and rear cooling water ports of the motor.  6. Attach the two motor cooling water hoses to the fittings (Fig. 161).  7. Using a socket wrench, remove the four hex head capscrews and lock washers that secure the junction box cover.  8. Remove the cover and O-ring.

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Replacement of wear parts _____________________________________

  9. Insert the three lugs of the power cable (with gland and stuffing box already installed) into the motor’s junction box.  10. Replace the stuffing box’s half-moon clamp in its channel to secure the stuffing box in the junction box.  11. Tighten the two socket head capscrews to secure clamp to the junction box.  12. Inside the junction box, locate the motor’s lug connections.  13. Match the motor lug connections to the corresponding power cable lugs.  14. Attach the first motor lug to its corresponding power cable lug by inserting a hex head capscrew through the motor lug, through the power cable lug, through a flat washer, and through a lock washer. Secure the capscrew with a hex nut.

 16. When all three connections have been secured, wrap each of the three connections with a layer of rubber tape, then a layer of black tape and then a layer of glass tape.  17. Replace the junction box O-ring and cover.  18. Insert the four hex head capscrews and lockwashers to secure the junction box cover and tighten using a socket wrench.  19. An MSHA certified electrician must inspect all work and check for permissibility.  20. Replace the top motor cover.  21. Tighten the hex head capscrews and lock washers to secure the top cover.  22. Replace the side motor cover.  23. Install the drum drive shaft and the cutter head drum drive torque limiting clutch (see Drum drive torque limiting clutch removal and installation procedure in this chapter).  24. Replace the debris guard (optional) under the retaining strap.

The holes of the guard and strap should align with the threaded holes in the motor top cover.  25. Tighten the hex head capscrews and lock washers to secure the debris guard and its retaining strap to the top motor cover.

_________________________________________________________________ 5.209 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

 15. Repeat this step for the other two lugged connections.

Replacement of wear parts _____________________________________ Drum drive gear case removal and installation drum drive gear case removal

To remove the drum drive gear case:  1. Remove the cutter head center drum (See Center cutter drum removal procedure in this chapter).  2. Remove the covers, water spray manifolds, hosing and cutter motor power leads.  3. Remove the cutter head end drum (See End cutter drum removal procedure in this chapter).  4. Carefully lower the cutter head assembly (now with the cutter drum drive gear case exposed) onto blocking.

 5. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine lockout/tagout regulations.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.  6. Remove the strapping from the capscrews securing the gear case to the boom using a cutting torch. 

 7. Remove the sixteen hex head capscrews (Fig. 162) that secure the cutter drum drive gear case to the cutter drum.

Fig. 162: Capscrews

Capscrews

 8. Remove the cutter motor.  9. Connect electrical power to the miner.  10. Slowly tram the miner in reverse away from the blocked gear case.  11. Remove the two keys and store for installation.

_________________________________________________________________ 5.210 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

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

____________________________________ Replacement of wear parts drum drive gear case installation

To install the drum drive gear case:  1.

Securely block the gear case so that the miner’s boom can be trammed forward into position behind it.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all blocking devices.  2.

Install the gear case’s two alignment keys.

 3. Connect the trailing cable to energize the miner. 

 4. Slowly tram the miner in forward toward the blocked gear case.

WARNING! Use extreme caution when tramming the miner forward to position the boom face against the gear case.

© BUCYRUS AMERICA, INC.

 5. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine lockout/tagout regulations.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.  6. Install the cutter motor.  7. Install the hex head capscrews into the cutter drum drive gear case mounting brace and into the threaded holes in the cutter boom face.  8. Using a torque wrench with 20 to 1 multiplier, tighten all twentyone hex head capscrews to 1,900 ft-lb.  9. Install the strapping (Fig. 163) onto the capscrews securing the gear case to the boom.

Fig. 163: Capscrew strapping Strapping

Strapping

 10. Install the cutter motor power leads, hosing, water spray manifolds and covers.  11. Install the cutter drums. ______________________________________________________________ A6474X332 VSSV/00 5.211

Replacement of wear parts _____________________________________ Gathering head assembly The gathering head assembly (Fig. 164) consists of the gathering pan, the continuous loading arms (CLAs), lift cylinders, and drive motors.

Continuous loading arms (CLA) (2) Lift cylinder location

Gear case (under CLA)

Foot shaft location

gathering head assembly removal

CLA key

To remove the gathering head assembly

  1. Lower the conveyor tail section until it is level with the floor.

Lower the gathering head until it rests on the floor. Place blocking under the rear of the gathering head to stabilize its position during and after removal of the pivot pins and disconnection of the lift cylinders.  2. Raise the cutter head to its highest point and place blocking underneath it. Lower the cutter head onto the blocking.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of blocking devices.  3. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.

_________________________________________________________________ 5.212 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.



Fig. 164: Gathering head assembly

____________________________________ Replacement of wear parts  4. Double check that the cutter head is securely blocked.   5. Separate the conveyor chain and remove the foot shaft (see Foot shaft removal procedure in this chapter).  6. Remove the hex head capscrews and lock washers that secure each of the front rub rails to the tractor frame and open both front rub rails. 7. Remove the electrical power cables from the gathering head.  8. Disconnect, tag, and cap the motor cooling water and scrubber spray water hoses from the gathering head.

© BUCYRUS AMERICA, INC.

WARNING! You could be seriously injured or killed by falling loads. Do not remove the gathering head pivot pins unless the gathering head is securely blocked into a stationary position. Use extreme caution when removing the pivot pins.  9. Remove the hex head capscrews and lockwashers that secure the right gathering head pivot pin retaining plate to the tractor frame (Fig. 165).  10. Remove the hex head capscrews and lock washers that secure the pin retaining plate to the gathering head pivot pin and remove the retaining plate.

Fig. 165: Gathering head pivot pin Hex head capscrews (retaining plate to tractor frame)

Pivot pin retaining plate

Gathering head pivot pin

Hex head capscrews (retaining plate to pivot pin)

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Replacement of wear parts _____________________________________

  11. Using a slide hammer, pull the pivot pin.  12. Repeat steps 9 through 11 for the left gathering head pivot pin.

WARNING! You can be seriously injured or killed by falling loads. Do not disconnect the gathering head cylinder unless the gathering head is securely blocked. Use extreme caution when disconnecting the gathering head lift cylinder.  13. Remove the hex head capscrews and lock washers that secure the piston pin retaining bar on the right gathering head lift cylinder to the gathering head side panel and remove the retaining bar (Fig. 166).  14. Repeat step 13 for the left gathering head lift cylinder.

Fig. 166: Gathering head lift cylinder piston pin retaining bar

Lock washer

Retaining bar

Gathering head lift cylinder Hex head capscrew 

 15. Connect the trailing cable to energizer the miner.

WARNING! Stand clear of the blocked cutter head and gathering head assemblies during the contraction of the gathering head lift cylinders.  16. Slowly contract the lift cylinders until the piston ends come free from their gathering head clevises.

CAUTION! When separating the gathering head from the tractor frame, ensure that the disconnected ends of the conveyor chain smoothly slide out of the gathering head.  17. Lift the cutter head off the blocking and slowly tram the miner in reverse until the cutter head clears the backboard of the gathering head. _________________________________________________________________

5.214

Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

Piston pin

____________________________________ Replacement of wear parts gathering head assembly installation

To install the gathering head assembly:  1. Position the gathering head assembly at the front of the tractor frame. Block up the rear of the gathering head so that it’s pivot points are at the level of the tractor frame clevises.

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

CAUTION! When tramming the miner toward the gathering head, be careful that the conveyor chain and gathering head lift cylinders do not become pinched between the tractor frame and the gathering head.  2. Raise the cutter head assembly to its highest point.

© BUCYRUS AMERICA, INC.

 3. Slowly tram the miner forward until it is close to the gathering head head assembly.  4. Thread the lower end of the conveyor chain into the gathering head assembly return pan so that the end appears on the footshaft return plate. Place the upper end of the conveyor chain down the front of the gathering head entrance pan.  5. Place blocking underneath the cutter head and lower the cutter head onto the blocking.  6. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel. 

7. Connect the trailing cable to energize the miner.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of blocking and lifting devices and stand clear of the blocked cutter head and the gathering head during the gathering head lift extension. 

8. Extend the gathering head lift cylinders so that the piston end bearings can be inserted into the gathering head lift cylinder clevises.

 9. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel. ______________________________________________________________ A6474X332

VSSV/00

5.215

Replacement of wear parts _____________________________________

  10. Insert the piston end bearing of the right gathering head lift cylinder into the gathering head clevis.  11. Using the hammer, insert the piston end pin through the aligned clevis bushings and the rod end bearing.

IMPORTANT! Insert the pin far enough to avoid obstructing the placement of the pin retaining bar.  12. Place the pin retaining bar over the end of the pin and insert and tighten the two hex head capscrews and lock washers that secure the piston pin retaining bar to the gathering head side panel.  13. Repeat steps 10 through 12 on the left gathering head lift cylinder.

 14. Use the gathering head lift cylinders and tractor frame stabilizer to align the tractor frame clevis and the gathering head pivot points to make inserting pivot pins easier.  15. Gently tap the right gathering head pivot pin through the aligned tractor frame clevis and gathering head pivot bushings.

IMPORTANT! The pin must be inserted far enough so that it does not obstruct positioning of the retaining plate flat against the tractor frame.  16. Place the pivot pin retaining plate so that edge with two cutouts located in the corners is positioned against the backup strip.

The edge of the plate with two cutouts and a hole for the pin’s grease fitting must be positioned over the pivot pin.  17. Insert and tighten the two hex head capscrews and lock washers to secure the pivot pin retaining plate to the gathering head pivot pin.  18. Insert and tighten the hex head capscrews and lock washers to secure the pivot pin retaining plate to the tractor frame.  19. Repeat steps 16 through 18 for the left gathering head pivot pin.  20. Replace the motor cooling water and scrubber spray water hoses onto the gathering head assembly.  21. Replace the electrical power cables onto the gathering head assembly.

_________________________________________________________________ 5.216 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

CAUTION! Use caution when using the lift cylinders and stabilizer to adjust the alignment of the clevis and pivot pins.

____________________________________ Replacement of wear parts

  22. Close the front rub rails and insert and tighten a hex head capscrew and lock washer to secure the front rub rail closed against the tractor frame.

© BUCYRUS AMERICA, INC.

 23. Replace the foot shaft into the gathering head (see Foot shaft removal and installation procedure in this chapter) and reconnect the conveyor chain.

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Replacement of wear parts _____________________________________ Gathering head drive motor removal and installation gathering head drive motor removal

To remove the gathering head drive motor:  1. Lower the gathering head completely until it touches the floor.

Lower the conveyor tail assembly until it is level with the floor.  2. Raise the cutter head assembly to its highest position. Place blocking underneath the cutter head assembly. Lower the cutter head assembly onto the blocking.

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

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.  4. If necessary, remove the CLA to allow access to the motor mouting bolts. (See CLA removal and installation procedure in this chapter).  5. Remove the hex head capscrews and lock washers that secure the upper deck cover (Fig. 167) to the gathering head assembly.  6. Remove the upper deck cover. The gear case and drive shaft end of the motor should be exposed.  7. Locate the side cover of the gathering head motor and remove the hex head capscrews and lock washers that secure the side cover to the gathering head assembly.  8. Remove the cover to expose the end of the motor.

Fig. 167: Upper deck cover

Upper deck cover

_________________________________________________________________ 5.218 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

 3. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

____________________________________ Replacement of wear parts

  9. Remove the square-headed pipe plug on the end of the gathering head motor.  10. Remove the retaining ring that secures the shaft end plug inside the motor housing (Fig. 168).  11. Using a slide hammer, pull the drive shaft end plug out.  12. Pull the drive shaft from the motor and store in safe place.

© BUCYRUS AMERICA, INC.

Fig. 168: Drive shaft and end plug removal

Drive shaft end plug

O-ring

Retainer ring Drive shaft

 13. Use the adjustable wrench to replace the pipe plug into the end of the motor. Remove water hosing from motor and cap, and move to sides.  14. Remove the hex head capscrews and lock washers that secure the motor junction box cover.  15. Remove the cover and its o-ring.  16. Locate the three taped power connections inside the junction box and strip the tap covering each lug connection.  17. Tag each connection and remove the hex head capscrew, flat washer, lock washer, and hex head nut that secures each of the power cable lugs.  18. Remove the socket head capscrews and lock washers that secure the stuffing box’s half-moon clamp to the junction box.  19. Remove the clamp and slide the stuffing box out of the junction box. The power cable should be completely disconnected from the motor.

WARNING! While the power cable is detached from the motor, the trailing cable should not be reconnected to the miner. Damage to the machine or injury or death to personnel could result.

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Replacement of wear parts _____________________________________  20. To prevent damage to the power cable lugs, stuffing box, and gland assembly, cover and secure the power cable to the miner in a safe location.  21. Replace the junction box o-ring and cover and secure with the hex head capscrews and lock washers to protect the motor’s electrical connections.  22. Tag, disconnect, and cap the two cooling water hoses (with elbow and adapter) from the two motor cooling water fittings on the gear case end of the motor.  23. Remove the two motor cooling water fittings from the motor and store in a clean place.

WARNING! The next steps disconnect the gathering head drive motor from the adapter that links it to the gathering head gear case. The gathering head drive motor is extremely heavy. Be prepared to support this weight before performing the following steps.  25. Remove the socket head capscrews that secure the motor to the gear case adapter plate.  26. The gathering head drive motor should now be detached from the gear case and able to be removed from the gathering head assembly through the motor side cover opening. gathering head drive motor installation

To install the gathering head drive motor:  1. Insert the gear case to motor seal between the adapter plate and the gear case (Fig. 169). When the motor is inserted, the seal should be located between the surfaces of the motor and the gear case.  2. Insert the gathering head motor through the slide cover opening, attachment bolt holes first. The junction box of the motor should be positioned toward the front of the gathering head.

Fig. 169: Gear case to motor seal installation Gear case to motor seal

Gear case adapter plate

Motor

_________________________________________________________________ 5.220 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

 24. Plug the two motor cooling water ports to keep them clean.

____________________________________ Replacement of wear parts

© BUCYRUS AMERICA, INC.

  3.

Position the motor against the gear case adapter plate and align the four attachment bolt holes on the gear case side of the motor with the four holes on the corners of the adapter plate.

 4.

Apply Loctite 242 (blue) to the four socket head capscrews.

 5.

Insert and tighten the socket head capscrews to secure the motor to the gear case adapter plate.

 6.

Using an adjustable wrench, insert the two motor cooling water fittings into the gathering head drive motor’s cooling water ports, which are located on the gear case end of the motor.

 7.

Attach the two motor cooling water hoses (with elbow and adapter) to the fitting.

 8.

Remove the hex head capscrews and lock washers that secure the junction box cover.

 9.

Remove the cover and its o-ring.

 10. Insert the three lugs of the power cable (with gland and stuffing box already installed) into the motor’s junction box.  11. Replace the stuffing box’s half-moon clamp in its channel to secure the stuffing box in the junction box.  12. Insert and tighten the two socket head capscrews and lock washers to secure clamp to the junction box.  13. Locate the motor’s lug connections inside the junction box and match the motor lug connections to the corresponding power cable lugs.  14. Attach the first motor lug to its corresponding power cable lug by inserting a hex head capscrew through the power cable lug, through the motor lug, through a flat washer, and through a lock washer. Secure the capscrew with a hex nut.  15. Repeat this step with the other two power cable and motor lugged connections.  16. When all three connections have been secured, wrap each of the three connections with a layer of rubber tape, then a layer of electrical (black) tape, and finally a layer of glass tape.  17. Replace the junction box o-ring and junction box cover and secure the cover with hex head capscrews and lock washers to secure the junction box cover.

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Replacement of wear parts _____________________________________  18. Remove the pipe plug from the end of the motor (Fig. 170).   19. Slide the drive shaft through the gathering head motor and into the gathering head gear case (the drive shaft end without the threaded hole should be inserted first). The shaft may require some adjustment so that its end fits into the gear case.  20. Install the o-ring into the channel on the shaft end plug.  21. Insert the drive shaft end plug into position in the center of the motor.  22. Insert the retaining ring to secure the shaft end plug inside the motor housing.  23. Replace the pipe plug into the end of the motor.

O-ring Retainer ring

Pipe plug

Drive shaft Drive shaft end plug

 24. Reconnect water hosing.  25. Replace the gathering head motor side access cover. Secure the cover to the gathering head by inserting and tightening the hex head capscrews.  26. Replace the upper deck cover and secure to the gathering head by inserting and tightening the hex head capscrews.  27. If removed, install the CLA over the motor (see CLA removal and installation procedure in this chapter).

_________________________________________________________________ 5.222 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

Fig. 170: Drive shaft installation

____________________________________ Replacement of wear parts Gathering head gearcase removal and installation gathering head gear case removal

To remove the gathering head gear case:  1. Lower the conveyor tail section until it is level with the floor.

Lower the gathering head until it touches the floor.  2. Raise the cutter head assembly to its highest position. Place blocking underneath the cutter head assembly. Lower the cutter head assembly onto the blocking.

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

© BUCYRUS AMERICA, INC.

 3. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.  4. Remove the gathering head motor’s side cover by removing the hex head capscrews and lock washers that secure the side cover to the gathering head assembly.  5. Remove the cover to expose the end of the motor.  6. Remove the square-headed pipe plug on the end of the gathering head motor.  7. Remove the retaining ring that secures the shaft end plug inside the motor housing (Fig. 171).  8. Using a slide hammer, pull out the drive shaft end plug.  9. Pull the drive shaft from the motor and store in a safe place.  10. Replace the pipe plug into the end of the motor.

Fig. 171: Motor shaft removal

Drive shaft end plug

O-ring

Retainer ring Drive shaft

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Replacement of wear parts _____________________________________  11. Remove the CLA to expose the gathering head gear case (see CLA removal and installation procedure in this chapter).  12. Remove the hex head capscrews and lock washers that secure the upper deck cover (Fig. 172) to the gathering head assembly. Remove the upper deck cover to expose the gear case and the drive shaft end of the motor.  13. Remove the hex head capscrews and lock washers that secure the lower deck cover (Fig. 172) to the gathering head assembly and remove the lower deck.

Upper deck cover

Lower deck cover

 14. Loosen tension on the conveyor chain as much as possible (see Conveyor chain adjustment in the Adjustment procedures section of this chapter).  15. Separate the conveyor chain and remove the gathering head foot shaft (see the Foot shaft removal and installation procedure in this chapter).  16. Connect the trailing cable to energize the miner.  17. Raise the gathering head to its highest position. Place blocking underneath the gathering head and lower the gathering head onto the blocking.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of blocking devices.  18. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.

_________________________________________________________________ 5.224 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

Fig. 172: Deck covers

____________________________________ Replacement of wear parts  19. Remove the drain plugs from the underside of the gathering head gear case and completely drain the gear case lubricant.  20. Replace the drain plugs into the underside of the gear case.  21. Connect the trailing cable to energize the miner.  22. Raise the gathering head off the blocking, remove the blocking, and lower the gathering head until it touches the floor.  23. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.

© BUCYRUS AMERICA, INC.

 24. Disconnect, tag, and cap the four lubrication connections from the gathering head gear case.  25. Remove the socket head capscrews (Fig. 173) that secure the motor to the gear case adapter plate.  26. Remove the motor and clean out the cavity.  27. Remove the hex head capscrews that secure the gathering head gear case pot to the mounting plate.  28. Remove four wedge bolts and remove four wedge blocks.  29. The gathering head gear case is now unattached and can be removed from its position in the gathering head.

Fig. 173: Gear case removal Plugs

Lubrication lines

Socket head capscrews (gear case to adapter plate)

Adapter plate

Hex head capscrews (gear case to mounting plate)

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Replacement of wear parts _____________________________________ gathering head gear case removal

To install the gathering head gear case:  1. Insert a new gear case-to-motor seal between the adapter plate and the gear case (Fig. 174). When the gear case is inserted into the gathering head and the transfer case is positioned against the gathering head motor, the seal should be located between the surfaces of the motor and the gear case.  2. Carefully insert the gathering head gear case into position in the gathering head assembly.  3. Insert and tighten the hex head capscrews and lock washers to secure the gear case pot to its mounting plate.

Fig. 174: Gear case mounting

Gear caseto-motor seal

Hex head capscrews

 4.

Install the motor and align the four holes on the corners of the adapter plate with the four attachment bolt holes on the gear case side of the motor.

 5.

Apply Loctite 242 (blue) to the four socket head capscrews.

 6.

Insert and tighten the four socket head capscrews to secure the gear case adapter plate to the motor.

 7.

Attach the four lubrication connections to the gathering head gear case.

 8.

Attach the rose gun to the lower ports located adjacent to the gathering head side cover and fill the gathering head gear case to the proper level with lubricant. Check the gear case lubricant level.

IMPORTANT! The bottom ports on the high speed input cases are the fill lines.

The top ports on the high speed input cases are the check lines.  9.

Examine the gathering head gear case in various places for signs of leaking lubricant that identify improper installation or gear case damage.

_________________________________________________________________ 5.226 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

Gear case adapter plate

____________________________________ Replacement of wear parts  10. Install the gathering head foot shaft and reconnect the conveyor chain (see Foot shaft installation procedure in this chapter).  11. Tighten the conveyor chain to the proper tension (see Con veyor chain adjustment in the Adjustment procedures section of this chapter).

IMPORTANT! Improper conveyor chain tension can lead to excessive wear, mechanical problems, and miner downtime. Always keep the conveyor chain at proper tension.  12. Replace the lower deck cover (Fig. 175) onto the gathering head assembly and secure to the gathering head assembly by inserting and tightening the hex head capscrews and washers.

© BUCYRUS AMERICA, INC.

 13. Replace the upper deck cover (Fig. 175) onto the gathering head assembly and secure by inserting and tightening the hex head capscrews and washers.

Fig. 175: Deck covers

Upper deck cover

Lower deck cover

  14. Install the CLA onto the gathering head gear case turntable (see CLA removal and installation procedure in this chapter).  15.. Remove the pipe plug from the end of the motor.  16. Slide the drive shaft through the gathering head motor and into the gathering head gear case (the drive shaft end without the threaded hole should be inserted first.) The shaft may require some adjustment so that its end fits into the gear case.

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Replacement of wear parts _____________________________________  17. Install the o-ring into the channel on the shaft end plug (Fig. 176).  18. Insert the drive shaft end plug into position in the center of the motor.  19. Insert the retaining ring to secure the shaft end plug inside the motor housing.

Fig. 176: Drive shaft installation

O-ring

Pipe plug

Drive shaft Drive shaft end plug

 20. Replace the pipe plug into the end of the motor.  21. Install fittings and re-hose water supply.  22. Replace the side cover onto the gathering head assembly.  23. Insert and tighten the hex head capscrews and lock washers to secure the side cover to the gathering head assembly.

_________________________________________________________________ 5.228 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

Retainer ring

____________________________________ Replacement of wear parts Gathering head foot shaft removal and installation gathering head foot shaft removal

To remove the gathering head foot shaft:  1. Lower the gathering head until it touches the floor.  2. Position the conveyor tail section directly behind the miner so that it is level with the floor.  3. Raise the cutter head assembly to its highest position. Place blocking underneath the cutter head assembly and lower the cutter head assembly onto the blocking.

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

© BUCYRUS AMERICA, INC.

 4. Slowly advance the conveyor chain until a connecting link appears on the gathering head entrance pan.  5. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.  6. Loosen tension on the conveyor chain as much as possible (see Conveyor chain adjustment procedure in the Adjustment procedures section of this chapter).  7. With conveyor chain tension removed, remove the connecting link pins and the connecting link.  8. The conveyor chain should now be separated. Move the two pieces of the conveyor chain out of the way to allow for easier removal of the gathering head foot shaft.  9.

Remove the hex head capscrews and lock washers that secure the foot shaft cover to the gathering head and remove the foot shaft cover.

 10. Locate the two collars on the foot shaft and remove the hex head capscrews that secure each of the collars to the foot shaft. When the capscrews are removed, the flex lock nuts will fall free from the other side of the collar. Retrieve these nut and hand tighten them onto their capscrews for safe keeping.

Remove both collars from the foot shaft.

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Replacement of wear parts _____________________________________  14. Slide the foot shaft couplings (Fig. 177) from the ends of the foot shaft toward the sprocket in the center. Once the couplings have been moved, the foot shaft is disconnected from the gear case bevel pinions.  15. The foot shaft can now be removed from the gathering head.

Fig. 177: Foot shaft removal Hex head capscrews

Gear case bevel pinion

Flex lock nuts

Foot shaft coupling

gathering head foot shaft installation

To install the gathering head foot shaft:  1. Slide a coupling onto each end of the foot shaft (Fig. 177).  2

Inspect the snap rings on both output shaft seal retainers.

 3. Insert the gathering head foot shaft into position between the two gathering head gear case bevel pinions.

IMPORTANT! Position the foot shaft so its sprocket will engage the conveyor chain links when the chain is reconnected.  4. Align the foot shaft splines with the bevel pinions’ splines.  5. Slide the right coupling over the foot shaft spline onto the bevel pinion splines until it touches the gear case seal carrier. Repeat with the left coupling.  6. Place a collar onto each end of the foot shaft so that the collars keep the couplings secure against the gear case seal carriers, bridged between the foot shaft and bevel pinion.  7. Insert and tighten the hex head capscrews through both halves of each collar and into the flex lock nuts to secure the collars to the foot shaft.  8. Replace the foot shaft cover.  9. Insert and tighten the hex head capscrews and lock washers to secure the foot shaft cover to the gathering head.

_________________________________________________________________ 5.230 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

Foot shaft collar

____________________________________ Replacement of wear parts  10. Reattach the two ends of the conveyor chain by replacing the connecting link. Secure the link.  11. Tighten the conveyor chain to the proper tension (see Conveyor chain adjustment procedure in the Adjustment procedure section of this chapter).

© BUCYRUS AMERICA, INC.

IMPORTANT! Improper conveyor chain tension can lead to excessive wear, mechanical problems, and miner downtime. Always keep the conveyor chain at proper tension.

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Replacement of wear parts _____________________________________ Gathering head lift cylinder removal and installation gathering head lift cylinder removal

To remove a gathering head lift cylinder:  1. Lower the conveyor tail section so that it is level with the floor.  2. Completely raise the cutter head and gathering head assemblies.  3. Place blocking under the cutter head and gathering head assemblies and lower the assemblies onto the blocking.

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

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.  5. Remove the hex head capscrews and lock washers that secure the lift cylinder piston pin retaining bar to the gathering head side panel and then remove the retaining bar (Fig. 178).

Fig. 178: Gather head lift cylinder piston pin retaining bar Piston pin

Lock washer

Retaining bar Gathering head lift cylinder Hex head capscrew

_________________________________________________________________ 5.232 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

 4. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

____________________________________ Replacement of wear parts  6. Use a slide hammer to pull the pin from the clevis bushings.  7. Connect the trailing cable to energize the miner.

WARNING! Stand clear of the blocked cutterhead and gathering head assemblies during gathering head lift cylinder contraction.  8. Slowly contract the lift cylinder until the piston end comes free from its clevis.  9. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

© BUCYRUS AMERICA, INC.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.  10. Check the blocking that supports the cutter head and gathering head assemblies.  11. Move the gathering head lift cylinder control lever up and down to release any pressure from the gathering head lift cylinders.  12. Disconnect and plug the hydraulic hose from the gathering head lift cylinder’s hydraulic fitting.  13. Remove the hydraulic fitting from the gathering head lift cylinder and store it in a clean place.  14. Attach a lifting device to the gathering head lift cylinder. Take up any slack in the lift device so that the weight of the cylinder rests on the left device.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all lifting devices and stay clear of suspended loads.  15. Remove the two hex head capscrews and lock washers that secure the pin retaining plate on the gathering head lift cylinder to the tractor frame and remove the retaining plate.  16. Using a slide hammer, remove the rod end pin from the frame clevis bushing. The cylinder should now be able to be removed from the miner.

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Replacement of wear parts _____________________________________ gathering head lift cylinder installation

To install the lift cylinder:  1. Insert the piston end bearing of the gathering head lift cylinder into the gathering head assembly clevis.  2. Insert the piston end through the aligned clevis bushings and piston end bearing.

WARNING! This procedure involves the alignment of hydraulic cylinder end bearings within their clevises to allow for insertion of the retaining pins. DO not test this alignment using your fingers. Shifting of the aligned pieces could cause serious injury.  3. Place the pin retaining bar over the piston end pin and secure to the gathering head side panel with hex head capscrews and lock washers.

 5. Attach the hydraulic hose to the gathering head cylinder hydraulic fitting.  6. Connect the trailing cable to energize the miner.

WARNING! Stand clear of the blocked cutterhead and gathering head assemblies during the gathering head lift cylinder extension.  7. Slowly extend the cylinder so that its rod end bearing can be inserted into the gathering head cylinder frame clevis.  8. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.  9. Position the gathering head cylinder rod and bearing into the gathering head cylinder frame clevis.  10. Insert the rod end pin into the aligned clevis bushings and rod end of the cylinder.

IMPORTANT! The pin should be inserted so that its retaining channel remains outside of the bushings.  11. Insert the pin retaining plate in the pin’s channel to secure the pin in the clevis.  12. Insert and tighten the two hex head capscrews and lock washers that secure the pin retaining plate to the tractor frame. _________________________________________________________________ 5.234 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

 4. Insert the hydraulic fitting into the gathering head lift cylinder hydraulic port.

____________________________________ Replacement of wear parts CLA removal and installation Fig. 179: Continuous loading arms (CLAs)

© BUCYRUS AMERICA, INC.

CLA tip

Socket head capscrews

Continuous loading arm (CLA)

Hog rings

CLA removal

To remove a CLA:   1. Lower the conveyor tail section until it is level with the floor.

Lower the gathering head until it touches the floor.  2. Raise the cutter head assembly to its highest position. Place blocking under the cutter head assembly. Lower the cutter head assembly onto the blocking.

WARNING! You can be seriously injured or killed by falling loads. Observe the safe working load limits of all blocking devices.  3. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.  4. Remove the hog rings (Fig. 179) from around each of the CLA’s socket head capscrews.  5. Remove the socket head capscrews located where the arms meet the CLA hub.  6. Remove the capscrews located in the center of the CLA hub.

The CLA should now be free and able to be removed.

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Replacement of wear parts _____________________________________

  7. Remove the four CLA alignment keys (Fig. 180) from the exposed gathering head gear case turntable and store the keys in a safe place.

Fig. 180: CLA alignment key removal

Alignment key

CLA installation

To install the CLA:  1.

On the CLA exterior, mark the bolt hole (outer set of three holes) located directly adjacent to a key cut-out.

 2.

Place an alignment dowel (Fig. 181) in the gathering head gear case turntable bolt hole (outer set of three holes) that is directly adjacent to a key cut-out.

 3.

Place the four keys into their cutouts on the gathering head gear case turntable.

Fig. 181: Alignment dowel placement Alignment dowel placement location Alignment key

Inner hub

Gear case turn table

_________________________________________________________________ 5.236 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

Inner hub

____________________________________ Replacement of wear parts

  4. Place the CLA onto the gear case turntable so that the dowel extends through the marked CLA hole. Adjust the CLA as necessary to fit the turntable keys into the CLA cut-outs.  5. Insert two socket head capscrews into the CLA outer holes not blocked by the dowel.  6

Remove the alignment dowel and insert the last socket head capscrew into the CLA hole.

 7. Tighten the three capscrews to secure the CLA to the gear case turntable.  8. Use the hammer to install three hog rings into the counterbore around each of the three outer socket head capscrews of the CLA.. The rings should be tapped down until they are below the chamfer of the socket head capscrews.

© BUCYRUS AMERICA, INC.

IMPORTANT! Hog rings should be installed so that their sharp points are directed clockwise.  9. Insert the socket head capscrews into CLA hub bolt holes and tighten.  10. Use the hammer to install hog rings into the counterbore around each of the socket head capscrews of the CLA hub (Fig. 182). The rings should be tapped down until they are below the chamfer of the socket head capscrews.

Fig. 182: Hog ring installation

Capscrew chamfer

Hog ring

Hog ring

Bottom of hog ring counterbore

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Replacement of wear parts _____________________________________ Continuous loading arm tip replacement  1. Lower the conveyor tail section until it is level with the floor.

Lower the gathering head until it touches the floor.  2. Raise the cutter head assembly to its highest position. Place blocking under the cutter head assembly, both on the floor and on the gathering head. Lower the cutter head assembly onto the blocking.

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

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.  4. Locate the CLA tip which requires replacement.  5. Remove the hex head capscrews that secure the tip to the CLA.  6. Use force as necessary to remove the tip from the CLA..  7. Slide the new tip onto the CLA..  8. Insert and tighten the hex head capscrews through the tip and the CLA.

_________________________________________________________________ 5.238 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

 3. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

____________________________________ Replacement of wear parts Tram motor removal and installation tram motor removal

To remove the tram motor:  1. Lower the conveyor tail section until it is level with the floor.  2. Lower the gathering head and cutter head assemblies until they touch the floor.  3. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.

© BUCYRUS AMERICA, INC.

 4. Remove the two rub ail pins that secure the tram rub rail to the two rub rail sections adjacent to it.  5. Remove the tram rub rail to expose the tram gear case and locate the tram drive motor inside the gear case (Fig. 183).

Fig. 183: Tram drive motor location

Tram drive motor

 6. Remove the hex head capscrews and hi-collar lock washers that secure the input shaft access cover to the motor housing.

Note that the cooling water hose support clamp is secured by one of the capscrews.  7. Remove the input shaft access cover and its o-ring.  8. Remove the retaining ring that secures the shaft plug in position.  9. Remove the shaft plug with o-ring that secures the input shaft in the motor (Fig. 184).

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Replacement of wear parts _____________________________________ Fig. 184: Shaft plug removal

Shaft plug

O-ring

 10. Pull the input shaft from the motor and store in a safe place.  11. Replace the input shaft access cover on the motor housing and secure the cover with the hex head capscrews and hi-collar lock washers.  12. Tag, disconnect, and cap the cooling water hoses or fittings from the cooling water fittings located on the top left and right corners of the tram motor.  13. Remove the cooling water fittings from the bottom left and right corners of the tram motor and store in a safe place.  14. Remove the hex head capscrews and disc lock washers that secure the tram motor bracket to the tram case.  15. Remove the socket head set screws that secure the tram motor bracket to the tram motor.  16. Remove the tram motor bracket from the tram motor.  17. Carefully slide the tram motor out from the tram case until the motor’s electrical connection and hand hole cover are accessible.  18. Remove the socket head capscrews and hi-collar lockwashers that secure the hand hole cover to the motor housing.  19. Remove the hand hole cover and its o-ring from the motor housing. 

 20. Remove the socket head capscrews and lock washers that secure the stuffing box's half moon clamp to the junction box.  21. Remove the clamp and slide the stuffing box out of the junction box. The power cable should be completely disconnected from the motor.

_________________________________________________________________ 5.240 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

Retaining ring

____________________________________ Replacement of wear parts WARNING! Do not reconnect the trailing cable to the miner while the power cable is detached from the motor. Serious injury or death or damage to the machine may result.  22. To prevent damage to the power cable lugs and gland assembly, cover the power cable and secure it to the miner in a safe location. Bucyrus also recommends replacing motor gear case input seals for all motors.  23. To protect the motor’s electrical connections, replace the motor hand hole cover and o-ring and secure using the socket head capscrews and hi-collar lock washers. 24. Carefully remove the tram motor from the tram case and slide onto blocking. Clean out tram motor housing.

© BUCYRUS AMERICA, INC.

 25. Remove the tram motor cooling water bypass hose that connects the two cooling water fittings on the rear of the tram motor and store in a safe place.  26. Clean out tram motor housing.

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

To install the tram motor:  1. Replace the seal on the motor adapter plate, which is positioned against the primary planetary (Fig. 185).  2. Install fittings and install tram motor bypass hose on the rear of motor.  3. Slide the tram motor into the tram case, leaving the motor’s hand hole cover and stuffing box accessible outside the tram case.

Fig. 185: Tram motor installation

Tram case Tram motor

Drain plug

Motor-toadapter seal

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Replacement of wear parts _____________________________________

  3. Remove the socket head capscrews and hi-collar lock washers that secure the hand hole cover to the motor housing.  4. Remove the hand hole cover and its o-ring.  5. Insert the four lugs of the power cable (with gland and stuffing box already installed) into the tram motor’s junction box.  6. Replace the stuffing box’s half-moon clamp in its channel to secure the stuffing box in the junction box.  7. Tighten the socket head capscrews to secure the clamp to the junction box.  8. Match the power cable lugs to the corresponding terminal strip posts and secure each lug to the corresponding post with a flat washer, lock washer, and hex nut.

 10. Carefully slide the tram motor into position in the tram case.

The end of the motor must be completely flush against the primary planetary adapter plate.  11. Position the tram motor bracket (Fig. 186) against the motor.

The lower half of the bracket must be flush against the motor and upper bracket must be flush against the tram case. Reposition the tram motor until the bracket can be properly positioned.  12. Insert and tighten the socket head capscrews to secure the tram motor bracket to the tram motor.  13. Insert and tighten the hex head capscrews and disc lock washers to secure the tram motor bracket to the tram case.

Fig. 186: Motor bracket installation Disc lock washer

Hex head capscrew

Motor bracket Socket head capscrew

_________________________________________________________________ 5.242 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

 9. Replace the motor hand hole cover and o-ring, and secure it with socket head capscrews and hi-collar lockwashers.

____________________________________ Replacement of wear parts

  14. Insert the two cooling water fittings into the cooling water ports located on the top left and right corners of the tram motor.  15. Attach the cooling water hoses to the two cooling water fittings located on the top left and right corners of the tram motor.  16. Remove the hex head capscrews and hi-collar lock washers that secure the input shaft access cover to the motor housing.  17. Remove the input shaft access cover and its O-ring.  18. Slide the input shaft through the tram motor and into the tram planetary primary gear (the input shaft end without the threaded hole should be inserted first). The shaft may require some adjusting so that its splined end fits into the gear.

© BUCYRUS AMERICA, INC.

 19. When the drive shaft is correctly positioned in the motor, install the o-ring onto the input shaft plug and then insert the plug into the motor.  20. Insert the retaining ring to secure the input shaft plug inside the tram motor.  21. Replace the input shaft access cover and its O-ring on the motor housing. When replacing the input shaft access cover and its capscrews, carefully insert the tram motor cooling water bypass hose into the bypass hose clamp. The clamp is secured to the tram motor by the access cover’s lower capscrew. Secure the cover with hex head capscrews and hi-collar lock washers.  22. Replace the tram rub rail between the two adjacent rub rails and secure it with the two rub rail pins.

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Replacement of wear parts _____________________________________ Tram primary planetary gear removal and installation primary planetary gear removal

To remove the primary planetary gear:  1. Lower the conveyor tail section until it is level with the floor.  2. Lower the gathering head and cutter head assemblies until they touch the floor.  3. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.

 5. Remove the tram motor (see Tram motor removal and installation procedure in this chapter).  6. Remove the socket head capscrews that secure the motor adapter plate to the primary gear ring (and also secure the primary planetary carrier assembly to the tram case) (Fig. 187).  7. Remove the motor adapter plate from the tram case.  8. Carefully slide the primary planetary carrier assembly out of the primary gear ring and remove the assembly from the tram case.  9. Carefully slide the primary gear ring out of the tram case.

Fig. 187: Tram primary gear removal Tram case Motor adapter plate

Socket head capscrews

Primary planetary gear ring Primary planetary carrier assembly

_________________________________________________________________ 5.244 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

 4. Remove the two rub rail pins that secure the tram rub rail to the two rub rail sections adjacent to it and remove the tram rub rail to expose the tram gear case.

____________________________________ Replacement of wear parts primary planetary gear installation

To install the tram primary planetary gear:  1. Insert alignment dowels into four of the sixteen capscrew holes in the tram case (Fig. 188).  2. To facilitate gear ring insertion, mark the mounting holes of the primary planetary gear ring that corresponds to the holes in which dowels were placed.  3. Slide the primary planetary gear ring onto the alignment dowels so the dowels appear through the marked holes.

Fig. 188: Alignment dowels and gear ring mounting Alignment dowels

Tram case

© BUCYRUS AMERICA, INC.

Primary planetary gear ring

Tram drive pinion gear

Mounting marks (match with alignment dowels)

 4. Carefully insert the primary planetary gear assembly into the gear ring, ensuring that the extension of the sun gear faces out from the centerline of the miner and that the internal gear teeth of the primary carrier are seated securely onto the tram drive pinion gear.  5. Place the two adapter plate dowels into two 1” holes on the bottom left and right corners of the adapter plate.  6. Orient the adapter plate with the adapter dowels along the bottom edge.  7. Slide the adapter plate onto the four alignment dowels.  8. Insert and tighten twelve socket head capscrews into the holes in the adapter plate not blocked by the alignment dowels.  9. Remove the four alignment dowels and insert and tighten the final four socket head capscrews to secure the adapter plate and gear ring to the tram case.

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Replacement of wear parts _____________________________________

  10. Torque the sixteen socket head capscrews to the appropriate amount (see Torque tables in Chapter 6 of this manual).  11. Install the tram motor in the tram case (see Tram motor removal and installation procedure in this chapter).  12. Replace the tram rub rail between the two adjacent rub rails and secure it with the two rub rail pins.

© BUCYRUS AMERICA, INC.

 13. Refill the tram gear case with oil.

_________________________________________________________________ 5.246 Bucyrus – Model 25M0 Continuous Miner

____________________________________ Replacement of wear parts Tram secondary planetary gear removal/installation secondary planetary gear removal

To remove the tram secondary planetary gear:  1. Lower the conveyor tail section until it is level with the floor.  2. Lower the gathering head and cutter head assemblies until they touch the floor.  3. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.

© BUCYRUS AMERICA, INC.

 4. Remove the two rub rail pins that secure the tram rub rail to the two rub rail sections adjacent to it and remove the tram rub rail.  5. Remove the plug from the bottom of the tram secondary planetary gear cover and drain the lubricant from the gear case.  6. Replace the oil drain plug in the gear cover (Fig. 189).  7. Remove the sixteen socket head capscrews that secure the secondary planetary gear cover to the tram case and carefully remove the secondary planetary gear cover.

Fig. 189: Tram secondary planetary gear cover and drain plug

Tram secondary planetary gear cover

Socket head capscrews

Drain plug

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Replacement of wear parts _____________________________________ WARNING! The next step removes the secondary planetary gear ring from the secondary planetary gear assembly. The secondary planetary gear ring is extremely heavy. Be prepared to support its weight before removing it from the secondary planetary assembly.  8. Carefully slide the secondary planetary gear ring off the secondary planetary gear assembly.  9. Insert eight hex head capscrews into the sprocket bearing carrier to secure it to the tram case.  10. Carefully pull the secondary tram drive shaft from the gear and sprocket and store in a safe place.  11. Carefully slide the secondary planetary assembly out of the sprocket bearing carrier.

Ring gear

Secondary planetary gear assembly

Thrust washer

Hex head capscrew

Secondary planetary gear assembly

Secondary tram drive shaft

Sprocket bearing carrier

Secondary planetary gear assembly

_________________________________________________________________ 5.248 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

Fig. 190: Secondary planetary assembly removal

____________________________________ Replacement of wear parts secondary planetary gear removal

To install the tram secondary planetary gear:  1. Carefully insert the secondary planetary gear assembly into the sprocket bearing carrier (Fig. 191), ensuring that the splined extension of the planetary carrier seats securely in the interior teeth of the sprocket.

Fig. 191: Planetary carrier installation Sprocket bearing carrier

Sprocket teeth Secondary planetary gear assembly

© BUCYRUS AMERICA, INC.

Splined extension

 2. Slide the secondary tram drive shaft through the secondary planetary gear assembly and into the tram drive sprocket and reach gear set (the drive shaft end without the threaded hole should be inserted first). The shaft may require some adjustment so that the end fits into the reach gears.  3. Insert four alignment dowels into the holes in the sprocket bearing carrier not blocked by the eight hex head capscrews (Fig. 192).  4. To facilitate gear ring insertion, mark the mounting holes of the secondary planetary gear ring that corresponds to the holes in which the dowels were placed.  5. Remove the eight hex head capscrews that secure the sprocket bearing carrier to the tram.

Fig. 192: Gear ring installation Sprocket bearing carrier

Secondary planetary gear assembly Gear ring

Thrust washer Hex head capscrews Alignment marks

Alignment dowels

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Replacement of wear parts _____________________________________

  6. Apply silicon sealant to the ring gear.  7. Carefully slide the secondary planetary gear ring onto the four alignment dowels so that the dowels appear through the marked holes. The planetary gear teeth should slide smoothly and securely into the gear teeth should slide smoothly and securely into the gear ring teeth.  8. Place the thrust water into the secondary planetary carrier directly behind the secondary tram drive shaft. The side of the thrust washer with the inscribed circles should face away from the drive shaft.  9. Apply silicon sealant to the cover.

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

IMPORTANT! The flat edge of the cover located adjacent to the lubrication fitting is the top of the cover. Orient the cover so that the lubricant level check plug is on the motor side of the cover and the drain plug is on the bottom.  12. Insert and tighten the twelve socket head capscrews into the holes in the gear case cover not blocked by the alignment dowels.  13. Remove the four alignment dowels.  14. Insert and tighten the remaining four socket head capscrews to secure the cover, the gear ring, and the sprocket bearing carrier to the tram case.  15. Using a torque wrench, torque all sixteen socket head capscrews to the proper torque (see Torque tables in Chapter 6 of this manual).  16. Using the lubrication fitting at the top of the gear cover (Fig. 193), fill the secondary planetary gear case to the proper level with lubricant.  17. Examine the secondary planetary gear case in various places for signs of leaking lubricant that identify improper installation or gear case damage.

_________________________________________________________________ 5.250 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

 10. To facilitate gear cover replacement, mark the mounting holes of the secondary planetary gear cover that corresponds to the holes in which alignment dowels are placed.

____________________________________ Replacement of wear parts

 Fig. 193: Gear case fill and check plugs

Fill plug

Check plug

© BUCYRUS AMERICA, INC.

 18. Replace the tram rub rail between the two adjacent rub rails and secure it with the two rub rail pins.

______________________________________________________________ A6474X332 VSSV/00 5.251

Replacement of wear parts _____________________________________ Tram case removal and installation tram case removal

To remove the tram case:  1. Lower the conveyor tail section until it is level with the floor. 2. Raise the gathering head and cutter head and place a small stack of blocking under these two assemblies.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all blocking devices.  3. Lower the gathering head and cutter head onto the blocking so that the front end of the miner lifts off the floor.

 5. Place blocking in multiple locations under the miner tram track.

When the miner is lowered, the tram track should be secured between the blocking and the tractor frame.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all blocking devices.  6. Raise the stabilizer and the gathering head and cutter head assemblies so the weight of the miner rests on the blocking.  7. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.  8. Remove the two rub rail pins that secure the tram rub rail to the two rub rail sections adjacent to it and remove the tram rub rail to expose the tram case.  9. Remove the hex head capscrew and lock washer that secure the front rub rail to the tractor frame and open the front rub rail cover.  10. Attach the grease gun to the front idler take-up cylinder fitting (Fig. 194) and pump grease into the take-up cylinder to extend the cylinder and remove pusher plate pressure on the idler shims.

_________________________________________________________________ 5.252 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

 4. Extend the stabilizer completely so that the rear end of the miner lifts off of the floor.

____________________________________ Replacement of wear parts  11. Remove all the idler adjustment shims and store the shims in a safe place.  12. Open the pressure release valve for the front idler take-up jack and allow the cylinder to contract.

Fig. 194: Idler take-up cylinder Idler take-up cylinder

Pressure release valve

© BUCYRUS AMERICA, INC.

Grease fitting

Idler adjustment shims

 13. Locate a tram track link near the track entry opening at the bottom of the tram case (Fig. 195) and, using a hammer and punch, remove the two roll pins that secure the tram track pin between the links. Store the roll pins in a safe place.  14. Using the hammer and punch, remove the tram track pin to disconnect the links and separate the track. Store the track pin in a safe place.

Fig. 195: Tram track removal

Roll pins

Separate track here

Tram track pin

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Replacement of wear parts _____________________________________

  15. Attach guide wires to the end of the tram track that passes through the tram case.  16. Connect the trailing cable to energize the miner.  17. Use the tram motor to slowly rotate the sprocket so that the end of the tram track that passes through the case is pulled up through the case and rolls off the sprocket.  18. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.

 20. Remove the tram motor (see Tram motor removal and installation procedure in this chapter).  21. Remove the bolts and washers from the sprocket and motor sides of the tram case.  22. Place a stack of blocking in front of the tram case onto which the case can be removed.

WARNING! The next step removes the tram case from the tractor frame. The tram case (with sprocket and reach gears) is extremely heavy. Be prepared to support the tram case before removing it from the tractor frame.

WARNING! Ensure that the electrical cables and cooling water hoses for the tram motor are free from the tram cases before attempting to remove the tram case from the tractor frame.   23. Carefully slide the tram case out from the tractor frame and onto the blocking.

WARNING! You can be seriously injured or killed by falling loads. Observe the safe working load limits of all blocking devices.  24. Pull the tram track guide wires out of the tram case exit opening and secure the wires to the tractor frame.

_________________________________________________________________ 5.254 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

 19. Pull on the tram track from the front of the miner (near the idler) so that the free end of the tram track is pulled clear of the tram case exit opening.

____________________________________ Replacement of wear parts tram case installation

To install the tram case:  1. Block up the tram case adjacent to its tractor frame position at a level that makes it easy to slide the case into the tractor frame.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all blocking devices.  2. Thread the guide wires through the tram case exit opening, between the sprocket gears, and out the tram case entry opening.  3. Slide the tram case into position in the tractor frame.

IMPORTANT! The guide wires will be used to pull the tram track links onto the tram case sprocket after the tram case is installed.

© BUCYRUS AMERICA, INC.

WARNING! Before attempting to slide the tram case into the tractor frame, ensure that the tram motor electrical and water connections are out of the way. Failure to do so may result in damage to the electrical and water connections.  4. Slide the tram case into position in the tractor frame.  5. Install the bolts that secure the motor side of the tram case to the tractor frame.  6. Install the bolts that secure the sprocket side of the tram case to the tractor frame.  7. Replace the tram motor (see Tram motor removal and installation procedure in this chapter). 

 8. While feeding the tram track from the front of the miner (near the idler), pull on the tram track guide wires until a link of the tram track engages the sprocket.  9. Connect the trailing cable to energize the miner.

WARNING! Stand clear of the miner when using the motor to pull the tram track through the tram case.  10. Use the tram motor to slowly rotate the sprocket and pull the tram track through the case until the end appears out the bottom.

WARNING! Double check that the links of the tram track are correctly seated onto the tram drive sprocket. Improper engagement of the tram track links onto the sprocket can cause serious mechanical damage. ______________________________________________________________ A6474X332

VSSV/00

5.255

Replacement of wear parts _____________________________________  11. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.  12. Remove the guide wires from the tram track.  13. Connect the two ends of the tram track and using the hammer and punch, insert the track pin to secure the two track links together.  14. Using the hammer and punch, insert the two roll pins into the track pin to secure the pin in the links.

 16. Close the front rub rail cover and replace the hex head capscrews and lock washers that secure the front rub rail to the tractor frame.  17. Replace the tram rub rail between the two adjacent rub rails and secure it with the two rub rail pins.  18. Connect the trailing cable to energize the miner.  19. Remove blocking.  20. Fill gear case to proper level with lubricant.

WARNING! You could be seriously injured or killed by falling loads. Follow mine procedure to remove blocking devices and use caution.

_________________________________________________________________ 5.256 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

 15. Adjust the tram track tension (see Tram track adjustment procedure in the Adjustment procedures section of this chapter).

____________________________________ Replacement of wear parts Tram reach gear set removal and installation tram case removal

To remove the tram reach gear set:  1. Lower the conveyor tail section until it is level with the floor.  2. Raise the gathering head and cutter head assemblies and place a small stack of blocking under each.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of blocking devices.  3. Lower the gathering head and cutter head onto the blocking so that the front end of the miner lifts off the floor.

© BUCYRUS AMERICA, INC.

 4. Extend the stabilizer completely so that the rear end of the miner lifts off the floor.  5. Place blocking in multiple locations under the miner tram track to securely support the tractor frame off the floor.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of blocking devices.  6. Raise the stabilizer and the gathering head and cutter head assemblies so the weight of the miner rests on the blocking.

When the tractor frame is lowered, the tram track should be secured between the blocking and the tractor frame.  7. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.   8. Double-check the tractor frame support blocking now that the weight of the tractor frame is completely upon it.  9. Remove the two rub rail pins that secure the tram rub rail to the two rub rail sections adjacent to it and remove the tram rub rail to expose the tram case.  10. Remove the tram case (see Tram case removal and installation procedure in this chapter).  11. Remove the plug from the motor end of the reach gear case bottom and drain the lubricant from the gear case.  12. When the lubricant has been completely drained, replace the plug.

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Replacement of wear parts _____________________________________  13. Remove the hex head capscrews and lock washers (Fig. 196) that secure the reach gear case cover to the gear case and remove the cover.

Fig. 196: Reach gear case cover removal Hex head capscrews Lock washers Reach gear case cover

Rear side of tram case

Drain plug

 14. Locate the cap bearing carrier that secures the tram drive pinion inside the reach gear case.  15. Using retaining ring pliers, remove the retaining ring located outside the cap bearing carrier on the tram drive pinion (Fig. 197).  16. Using the wire cutters, cut and remove the wire securing the cap bearing carrier capscrews in position.  17. Remove the four drilled head capscrews and lock washers that secure the cap bearing carrier to the tram case and remove the cap bearing carrier.

Fig. 197: Cap bearing carrier removal Drilled head capscrews

Cap bearing carrier

Retaining ring

Tram drive pinion

_________________________________________________________________ 5.258 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

Reach gear case

____________________________________ Replacement of wear parts

  20. Remove the three steel shims and the bearing found under the shims (Fig. 198).  21. Carefully pull the tram drive pinion out of the reach gear case through the cap bearing carrier opening.

Fig. 198: Tram drive pinion removal Bearing carrier opening Cap bearing carrier

© BUCYRUS AMERICA, INC.

Tram drive pinion Bearing cup and cone set

Shims

 22. Cut and remove the wire securing the idler shaft capscrews in position.  23. Remove the drilled hex head capscrews that secure the idler shaft cap to the tram case and remove the idler shaft and three steel shims located under the cap.  24. Carefully slide the idler shaft out of the reach gear case through the idler shaft cap opening.  25. Remove the idler reach gear through the top opening of the reach gear case (Fig. 199).  26. Remove the bearing cup and cone sets from the center indentions of the idler reach gear.

______________________________________________________________ A6474X332 VSSV/00 5.259

Replacement of wear parts _____________________________________ Fig. 199: Idler reach gear and idler shaft removal Idler reach gear

Bearing cup and cone set Reach gear case

Rear side of tram case

Shims

Hex head capscrews

 27. Remove the hex head capscrews and lock washers that secure the sprocket reach gear bearing cap to the reach gear case (Fig. 200).  28. Remove the bearing cap and the three steel shims under the cap.  29. Remove the bearing cone and cup set from the end of the splined sleeve.  30. Carefully slide the splined sleeve out of the sprocket reach gear.  31. Remove the sprocket reach gear through the top opening of the reach gear case.

Fig. 200: Sprocket reach gear removal Sprocket reach gear Splined sleeve Shims

Bearing cup and cone set Reach gear case

Sprocket reach gear bearing cap

Hex head capscrews

_________________________________________________________________ 5.260 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

Idler shaft cap

____________________________________ Replacement of wear parts  32. Remove the second splined sleeve bearing cone and cup set from the rear of the reach gear case, located behind the sprocket reach gear. tram reach gear set installation

To install the tram reach gear set:  1. Insert one of the bearing cup and cone sets (cone side facing out) into the cut-out inside the reach gear case adjacent to the tram case sprocket (Fig. 201).

Fig. 201: Bearing cup and cone set installation

© BUCYRUS AMERICA, INC.

Bearing cup and cone set

 2. Insert the sprocket reach gear into the top of the reach gear case and position it against the bearing cup and cone set adjacent to the tram case sprocket (Fig. 202).

Fig. 202: Sprocket reach gear installation

Sprocket reach gear set

 3. Insert the splined sleeve into the reach gear case (Fig. 203), through the sprocket reach gear and through the bearing cup and cone set until it is positioned against the tram sprocket.  4. Slide the second bearing cup and cone set (cup side facing out) onto the end of the splined sleeve.  5. Replace the three steel shims over the bearing set.  6. Replace the sprocket reach bearing cap.  7. Insert and tighten the hex head capscrews and lock washers to secure the sprocket reach gear bearing cap to the reach gear case.

______________________________________________________________ A6474X332 VSSV/00 5.261

Replacement of wear parts _____________________________________ Fig. 203: Splined sleeve and bearing cap installation Sprocket reach gear Splined sleeve Shims

Bearing cup and cone set

Sprocket reach gear bearing cap

Hex head capscrews

 8. Insert two cup and cone bearing sets into the central cut-outs on either side of the idler reach gear (Fig. 204). The cone side of the bearing sets should face out of the gear on both sides.  9. Insert the idler reach gear through the top opening of the reach gear case and position it against the sprocket reach gear, ensuring that the gear teeth securely mesh.  10. Insert the idler shaft through the bearing sets in the idler reach gear until it is positioned against the tractor frame.  11. Replace the three steel shims over the idler shaft.  12. Replace the idler shaft cap.

Fig. 204: Idler reach gear and idler shaft installation Idler reach gear

Bearing cup and cone set Reach gear case

Rear side of tram case

Shims

Hex head capscrews

Idler shaft cap

_________________________________________________________________ 5.262 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

Reach gear case

____________________________________ Replacement of wear parts

  13. Insert and tighten the ten drilled hex head capscrews to secure the idler shaft cap.  14. Insert the tram drive pinion through the cap bearing carrier opening (located on the inside of the tram case tram motor bay) into the reach gear case. Ensure that the teeth of the pinion securely mesh with the idler reach hear teeth.  15. Replace the pinion bearing.  16. Replace the three steel shims over the pinion bearing.  17. Replace the cap bearing carrier over the pinion end.  18 Insert and tighten the drilled hex head capscrews and lock washers to secure the cap bearing carrier to the tram case.

© BUCYRUS AMERICA, INC.

 19. Install the retaining ring on the tram drive pinion.  20. Double check that the tram drive pinion, idler reach gear and sprocket reach gear teeth are properly meshed and the gears rotate smoothly.  21. Tighten the sprocket reach gear bearing cap capscrews to correct torque (see Torque tables in Chapter 6 of this manual).  22. Tighten the idler shaft cap capscrews to correct torque (see Torque tables in Chapter 6 of this manual).  23. Lock wire the idler shaft cap capscrews to secure their positions.  24. Tighten the tram drive pinion cap bearing carrier capscrews to correct torque (see Torque tables in Chapter 6 of this manual).  25. Lock wire the tram drive pinion cap bearing carrier capscrews to secure their positions.  26. Replace the reach gear case cover onto the top of the reach gear case.  27. Insert and tighten fourteen hex head capscrews and lock washers to secure the reach gear case cover to the gear case.  28. Remove the plug from the sprocket side of the reach gear case cover.  29. Fill the reach gear case to the proper level with lubricant (Spec.

100-14).  30. Replace the fill plug.  31. Replace the tram case into the tractor frame (see Tram case removal and installation procedure in this chapter).

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Replacement of wear parts _____________________________________ IMPORTANT! The re-installation procedure for the tram case includes reinstallation of the primary and secondary planetary gears and the tram motor, and reconnection of the tram track.  32. Replace the tram rub rail between the two adjacent rub rails and secure it with the two rub rail pins.  33. Reconnect the trailing cable to energize the miner.  34. Raise the tractor frame by lowering the stabilizer and the gathering head and cutter head assemblies.  35. Carefully remove the support blocking from under the tractor frame.

© BUCYRUS AMERICA, INC.

 36. Lower the tractor frame onto the floor by raising the stabilizer and the gathering head and cutter head assemblies.

_________________________________________________________________ 5.264 Bucyrus – Model 25M0 Continuous Miner

____________________________________ Replacement of wear parts Tram sprocket removal and installation tram sprocket removal

To remove the tram sprocket:  1. Lower the conveyor tail section until it is level with the floor.  2. Raise the gathering head and cutter head and place a small stack of blocking under these two assemblies.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all blocking devices.  3. Lower the gathering head and cutter head onto the blocking so that the front end of the miner lifts off the floor.

© BUCYRUS AMERICA, INC.

 4. Extend the stabilizer completely so that the rear end of the miner lifts off the floor.  5. Place blocking in multiple locations under the miner tram track.

When the miner is lowered, the tram track should be secured between the blocking and the tractor frame.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all blocking devices.  6. Raise the stabilizer and the gathering head and cutter head assemblies so the weight of the miner rests on the blocking.  7. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.  8. Double check the tractor frame support blocking now that the weight of the tractor frame is completely upon it.  9. Remove the two rub rail pins that secure the tram rub rail to the two rub rail sections adjacent to it and remove the tram rub rail to expose the tram case.  10. Remove the hex head capscrew and lock washer that secures the front rub rail to the tractor frame and open the cover.  11. Attach the grease gun to the fitting on the grease take-up cylinder (Fig. 205) and pump grease to extend the cylinder and remove pusher plate pressure on the idler shims.

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Replacement of wear parts _____________________________________

  12.

Remove all the idler adjustment shims and store the shims in a safe place.

 13.

Open the pressure release valve for the front idler take-up jack and allow the cylinder to contract.

Fig. 205: Idler adjustment shim removal Idler take-up cylinder

Pressure release valve

Idler adjustment shims

 14. Locate a tram track link near the track entry opening at the bottom of the tram case (Fig. 206) and, using the hammer and punch, remove the two roll pins that secure the tram track pin between the links. Store the roll pins in a safe place.  15. Using the hammer and punch, remove the tram track pin to disconnect the links and separate the track. Store the track pin in a safe place.

Fig. 206: Tram track removal

Roll pins

Separate track here Tram track pin

_________________________________________________________________ 5.266 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

Grease fitting

____________________________________ Replacement of wear parts



 16. Attach guide wires to the end of the tram track that passes through the tram case.  17. Connect the trailing cable to energize the miner.  18. Use the tram motor to slowly rotate the sprocket so that the end of the tram track that passes through the case is pulled up through the case and rolls off the sprocket.  19. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.

© BUCYRUS AMERICA, INC.

 20. Pull on the tram track from the front of the miner (near the idler) so that the free end of the tram track is pulled clear of the tram case exit opening.

WARNING! Ensure that the end of the tram track is out of the tram case exit opening before attempting to remove the tram case from the tractor frame.  21. Remove the plug from the bottom of the cover and drain the lubricant from the gear case (Fig. 207).  22. Replace the oil drain plug in the gear cover.  23. Remove the Secondary planetary gear assembly (see Secondary planetary gear assembly removal and installation procedure in this chapter).

Fig. 207: Tram secondary planetary gear cover and drain plug

Tram secondary planetary gear cover

Socket head capscrews

Drain plug

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Replacement of wear parts _____________________________________

  24. Remove the bearing carrier (Fig. 208).

Fig. 208: Sprocket bearing carrier removal

Bearing/seal sleeve assembly

Sprocket

WARNING! The next step removes the sprocket from the tram case. The sprocket is extremely heavy. Be prepared to support its weight before removing it from the tram case.  25. Remove the sprocket from the tram case (Fig. 209).  26. Remove the bearing/seal sleeve assembly from the rear of the sprocket bay of the tram case.

Fig. 209: Tram sprocket removal Bearing/seal sleeve assembly Tram case

Sprocket

_________________________________________________________________ 5.268 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

Sprocket bearing carrier

____________________________________ Replacement of wear parts tram sprocket installation

To install the tram sprocket:  1. Bucyrus recommends ordering a pre-assembled sprocket. If you choose to order a pre-assembled sprocket, go directly to step 16. Consult your Bucyrus service representative to order a pre-assembled sprocket.  2. Install a spherical bearing into one of the bearing sleeves (Fig. 210).  3. Install the o-ring into the outside channel of the bearing sleeve.

IMPORTANT! When the bearing sleeve is inserted into position, the o-ring forms a seal between the sleeve and the piece that holds it.  4. Install a Duo-Cone seal into the seal sleeve (see Duo-cone seal installation notes in this chapter). The rubber side of the seal should face toward the sleeve; the metal ring of the seal should face outward.

© BUCYRUS AMERICA, INC.

Fig. 210: Bearing/seal sleeve assembly Spherical bearing Seal sleeve

Duo-cone seal

O-ring Bearing sleeve

Metal ring

Rubber seal

 5. Insert the seal sleeve into the bearing sleeve. 

 6. Insert and tighten the three set screw into the bearing sleeve to secure the seal sleeve in the bearing sleeve.  7. Insert the bearing/seal sleeve assembly into position at the rear of the sprocket bay of the tram case.  8. Install the two Duo-Cone seals into the channel in each end of the sprocket. The rubber side of the seals should face into the sprocket channel; the metal rings of the Duo-Cone seals should face outward.  9. Insert the end of the sprocket into the seal sleeve so that it seats into the spherical bearing. Push the sprocket until the metal rings of the Duo-Cone seals are securely against each other.  10. Install the other spherical bearing into the remaining bearing sleeve.

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Replacement of wear parts _____________________________________

  11. Install the o-ring into the outside channel of the bearing sleeve.  12. Install a Duo-Cone seal into the remaining seal sleeve. The rubber side of the seal should face toward the sleeve; the metal ring of the seal should be facing outward.  13. Insert the seal sleeve into the bearing sleeve.  14. Insert and tighten the three set screws into the bearing sleeve to secure the seal sleeve in position.  15. Slide the bearing/seal sleeve assembly onto the end of the sprocket. Push the sleeve assembly until the end of the sprocket seats into the spherical bearing and the metal rings of the Duo-Cone seals are securely against each other.  16. Install the assembled sprocket assembly.

 18. Apply anti-seize to all the bearing fits on the sprocket, then use the planetary shaft to support the weight of the sprocket during installation. Start the sprocket bearing in evenly, then install the bearing carrier and start the front bearing in evenly.  19. Install the Secondary planetary gear assembly (see the Secondary planetary gear assembly removal and installation procedure in this chapter).  20. While feeding the tram track from the front of the miner (near the idler), pull on the tram track guide wires until a link of the tram track engages the sprocket.  21. Connect the trailing cable to energize the miner.

WARNING! Stand clear of the miner when using the motor to pull the tram track through the tram case.  22. Use the tram motor to slowly rotate the sprocket and pull the tram track through the case until the end appears out the bottom.

WARNING! Double check that the links of the tram track are correctly seated onto the tram drive sprocket. Improper engagement of the tram track links onto the sprocket can cause serious mechanical damage.  23. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.  24. Remove the guide wires from the tram track. _________________________________________________________________ 5.270 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

 17. Replace the bearing carrier over the bearing sleeve and end of the bearing sleeve and end of the sprocket.

____________________________________ Replacement of wear parts

  25. Connect the two ends of the tram track and using the hammer and punch, insert the track pin to secure the two track links together.   26. Using the hammer and punch, insert the two roll pins into the track pin to secure the pin in the links.  27. Adjust the tram track tension (see Tram track adjustment procedure in the Adjustment procedures section of this chapter).  28. Close the front rub rail cover and replace the hex head capscrews and lock washers that secure the front rub rail to the tractor frame.  29. Replace the tram rub rail between the two adjacent rub rails and secure it with the two rub rail pins.  30. Connect the trailing cable to energize the miner.

© BUCYRUS AMERICA, INC.

 31. Remove blocking.

WARNING! You could be seriously injured or killed by falling loads. Follow mine procedure to remove blocking devices and use caution.

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Replacement of wear parts _____________________________________ Tram track front idler removal and installation tram track front idler removal

To remove the tram track front idler:  1. Raise the gathering head and cutter head assemblies to their highest points and place blocking underneath. Lower the assemblies onto the blocking. The gathering head and cutter head must be blocked high enough to allow the idler assembly to be removed from the tractor frame’s idler slide channel.

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

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.  3. Remove the hex head capscrew and lock washer that secure the front rub rail to the tractor frame and open the front rub rail cover.  4. Attach the grease gun to the front idler take-up cylinder fitting (Fig. 211) and pump grease into the take-up cylinder to extend the cylinder and remove pusher plate pressure on the idler shims.  5. Remove all the idler adjustment shims and store the shims in a safe place.  6. Open the pressure release valve for the front idler take-up jack and allow the cylinder to contract.

Fig. 211: Idler take-up cylinder

Pressure release valve

Idler take-up cylinder

Grease fitting

Idler adjustment shims

_________________________________________________________________ 5.272 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

 2. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

____________________________________ Replacement of wear parts

  7. Locate a tram track link near the near the idler and remove roll pins and link pin.  8. Using the hammer and punch, remove the tram track pin to disconnect the links and separate the track. Store the track pin in a safe place.

Fig. 212: Tram track removal

Roll pins

Separate track here

© BUCYRUS AMERICA, INC.

Tram track pin

 9. Slide the front idler assembly out of the idler slide channel (Fig. 213).

Fig. 213: Front idler assembly removal

Pressure relief valve

Take-up cylinder

Idler slide channel Front idler assembly

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Replacement of wear parts _____________________________________

  10. Slide the pusher plate and the spacer pusher out of the idler slide channel to inspect for damage (Fig. 214).

Fig. 214: Pusher plate removal Take-up cylinder

Spacer pusher

Pressure relief valve

Idler slide channel

tram track front idler installation

To install the tram track front idler:  1. Insert the pusher spacer (Fig. 215) into the tractor frame’s idler slide channel so that it rests on the slide block support and is positioned against the take-up jack.  2. Ensuring that the channel guides face away from the take-up jack, insert the pusher plate into the idler slide channel until it touches the pusher spacer.

Fig. 215: Pusher plate installation Take-up cylinder

Pusher spacer

Pressure relief valve Pusher plate

Idler slide channel

_________________________________________________________________ 5.274 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

Pusher plate

____________________________________ Replacement of wear parts

  3. Insert the block slides of the front idler assembly (Fig. 216) into the idler slide channel. The relief valve of the slide blocks must be oriented toward the front of the miner. The grease fittings must be oriented to the outside of the miner.  4. Push the front idler assembly into the slide channel until the block slides are against the pusher plate channel guides.

Fig. 216: Front idler installation Take-up cylinder Front idler assembly

© BUCYRUS AMERICA, INC.

Pressure relief valve

Idler slide channel Pusher plate channel Block slide

Relief valve

 5. Connect the two ends of the tram track and using the hammer and punch, insert the track pin to secure the two track links together.  6. Using the hammer and punch, insert the two roll pins into the track pin to secure the pin in the links.  7. Adjust the tram track tension (see Tram track adjustment procedure in the Adjustment procedures section of this chapter).  8. Close the front rub rail cover and replace the hex head capscrews and lock washers that secure the front rub rail to the tractor frame.

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Replacement of wear parts _____________________________________ Front idler take-up cylinder removal and installation front idler cylinder removal

To remove the front idler take-up cylinder  1. Lower the conveyor tail section until it is level with the floor.  2. Lower the gathering head and cutter head until these two assemblies touch the floor.  3. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.

 5. If installed, remove the hex head capscrews that secure the fill plate to the frame and remove the fill plate. The cylinder may have to be collapsed before the fill plate can be removed.  6. Locate the front idler take-up cylinder bracket assembly (Fig. 217) which is mounted to the rear of the idler shim channel.

Fig. 217: Front idler take-up cylinder bracket Bracket assembly

Idler shim channel

_________________________________________________________________ 5.276 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

 4. Remove the hex head capscrew and lock washer that secures the front rub rail to the tractor frame and open the front rub rail cover.

____________________________________ Replacement of wear parts

  7. Pull the flip pin (Fig. 218) from the half link to release the takeup cylinder bracket from the tractor frame.  8. Lower the end of the bracket until it clears the half link and pull the bracket straight out to remove it from the tractor frame. If necessary, collapse the take-up cylinder.

Fig. 218: Front idler take-up cylinder removal Idler take-up cylinder assembly

Bracket assembly

© BUCYRUS AMERICA, INC.

Flip pin

front idler cylinder installation

Flip pin

Tractor frame

To install the front idler take-up cylinder:  1.

Replace the take-up cylinder bracket assembly into the tractor frame and secure it by inserting the flip pin through the half link.

 2.

Replace the fill plate and secure with capscrews.

 3.

Close the front rub rail cover and secure to the tractor frame with a hex head capscrew and lock washer to secure the front rub rail to the tractor frame.

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Replacement of wear parts _____________________________________ Hydraulic pump removal  1. Lower the conveyor tail section until it is level with the floor.  2. Lower the gathering head and cutterhead assemblies until they rest on the floor.  3. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.

There are two alternative locations and instructions for the removal of the hydraulic pump: in front of the demister box or behind the operator’s case.

 4. Locate the rub rail directly behind the tram case on the scrubber exhaust side of the miner (Fig. 219). Remove the two rub rail pins that secure the rub rail to the two rub rail sections adjacent to it and remove the rub rail.

Fig. 219: Pump located behind demister Hydraulic pump

Scrubber exhaust Rub rail

 5. Locate the hydraulic pump and motor assembly (Fig. 220).  6. Using the adjustable wrench, disconnect the inlet hose from the pump. Plug the hose end to keep it clean.  7. Using the adjustable wrench, disconnect the pilot and valve hoses from the pump fittings. Plug the hose ends to keep them clean.

_________________________________________________________________ 5.278 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

When located in front of the demister box:

____________________________________ Replacement of wear parts

  8. Remove the hose fittings from the pump and store in a safe place.  9. Remove all hex head capscrews and lockwashers that secure the pump assembly to the motor assembly and save for reinstallation.  10. Carefully remove the pump assembly by sliding it out of the pump motor.

When located behind the operator’s case:  4. Locate the rub rail directly behind the tram case on the operator’s side of the miner. Remove the two rub rail pins that secure the rub rail to the two rub rail sections adjacent to it and remove the rub rail.  5. Locate the hydraulic pump and motor assembly.

© BUCYRUS AMERICA, INC.

 6. Using the adjustable wrench, disconnect the inlet hose from the pump. Plug the hose end to keep it clean.  7. Using the adjustable wrench, disconnect the pilot and valve hoses from the pump fittings. Plug the hose ends to keep them clean.

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Replacement of wear parts _____________________________________ Hydraulic pump installation  1. Slide the pump assembly into the pump motor (Fig. 220).  2. Insert and tighten, all hex head capscrews and lockwashers to secure the pump assembly to the motor.

Fig. 220: Hydraulic pump installation Motor

Pump

Lockwasher

 3. Insert the hydraulic hose fittings into the pump assembly and tighten.  4. Attach and tighten the exit pilot and valve hoses to the pump fittings.  5. Attach the inlet hose to the pump.  6. Replace the rub rail between the two adjacent rub rails and secure it with the two rub rail pins.  7. Check the hydraulic fluid level.  8. Jog pump motor on and off a few times to prime the pump before starting.

_________________________________________________________________ 5.280 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

Hex head capscrew

____________________________________ Replacement of wear parts Hydraulic pump motor removal  1. Lower the conveyor tail section it is level with the floor.  2. Lower the gathering head and cutter head until they touch the floor.  3. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.  4. Remove the hydraulic pump (see Hydraulic pump removal procedure in this chapter).

© BUCYRUS AMERICA, INC.

 5. Remove the two hex head capscrews that secures the motor to the pump stand (Fig. 221).  6. Remove the two hex head capscrews and lockwashers that secure the pump stand to the tractor frame and remove the pump stand.

Fig. 221: Hydraulic pump stand removal Hex head capscrew (2) Pump stand

Motor

Hex head capscrew (2)

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Replacement of wear parts _____________________________________

  7. Tag, disconnect, and cap the two cooling water hoses from the cooling water fittings on the pump motor.  8. Remove the cooling water fittings from the top left and right surface of the pump motor and store in a safe place.  9. Remove the cover and its o-ring from the motor’s junction box by removing four hex head capscrews and lockwashers.  10. Locate the three taped power connections inside the junction box.  11. Strip off the three layers of tape covering each of the three lug connections inside the junction box.  12. Tag the three lugs to facilitate reconnection during motor installation.

 14. Remove the two socket head capscrews and lockwashers that secure the stuffing box’s half-moon clamp to the junction box.  15. Remove the clamp and slide the stuffing box out of the junction box. The power cable should be completely disconnected from the motor.  16. To prevent damage to the power cable lugs and gland assembly, cover the power cable and secure it to the miner in a safe location.  17. To protect the motor’s electrical connections, replace the motor junction box cover and secure it using four hex head capscrews and lockwashers.

WARNING! The hydraulic pump motor is now detached from the tractor frame and can be removed. The hydraulic pump motor is extremely heavy. Prepare to support its weight before removing it from the tractor frame.  18. Carefully slide the hydraulic pump motor out of the tractor frame.

_________________________________________________________________ 5.282 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

 13. Remove the hex head capscrew, flat washer, lockwasher, and hex head nut that secures the three power cable lugs to the three motor lugs.

____________________________________ Replacement of wear parts

 Hydraulic pump motor installation  1. Slide the hydraulic pump motor into position in the tractor frame.  2. Remove the four hex head capscrews and lockwashers that secure the junction box cover and remove the cover and its oring.  3. Insert the three lugs of the power cable (with gland and stuffing box already installed) into the motor’s junction box.  4. Replace the stuffing box’s half-moon clamp in its channel to secure the stuffing box in the junction box.

© BUCYRUS AMERICA, INC.

 5. Tighten the two socket head capscrews to secure the clamp to the junction box.  6. Inside the junction box, locate the motor’s lug connections.

Match the motor lug connections to the corresponding power cable lugs (refer to the wiring diagram supplied in your Bucyrus America, Inc. parts manual).  7. Attach the first motor lug to its corresponding power cable lug by inserting a hex head capscrew through the motor lug, through the power cable lug, through a flat washer, and through a lockwasher. Secure the capscrew with a hex nut.

Repeat this step for the other two lugged connections.  8. When all three connections have been secured, wrap each of the three connections with a layer of rubber tape, then a layer of black tape and finally a layer of glass tape.  9. Replace the junction box O-ring and cover.  10. Insert the four hex head capscrews and lockwashers to secure the junction box cover and tighten. 11. Insert the two motor cooling water fittings into the pump motor cooling water ports.  12. Attach the two motor cooling water hoses to the fittings.  13. Position the pump stand against the motor and attach to the motor with two hex head capscrews.  14. Insert and tighten the two hex head capscrews and lockwashers to secure the pump stand to the tractor frame.  15. Install the hydraulic pump (see hydraulic pump installation procedure in this chapter).

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Replacement of wear parts _____________________________________ Scrubber fan/motor removal  1. Lower the conveyor tail section until it is level with the floor.  2. Lower the gathering head and cutter head assemblies until they rest on the floor.  3. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.  4. Locate the rub rail on the fan exhaust side at the rear of the miner (Fig. 222) and remove the pin that secures the rear rub rail to the rail adjacent to it. Open both rub rails.

© BUCYRUS AMERICA, INC.

Fig. 222: Scrubber fan/motor location

Scrubber fan/motor

 5. Remove the four capscrews and lockwashers that secure the rub rail hinge post to the tractor frame and remove the post.  6. Locate the scrubber fan motor junction box and remove the four hex head capscrews and lockwashers that secure the junction box cover. Remove the cover and o-ring.  7. Locate the three taped power connections inside the junction box.  8. Strip off the three layers of tape covering each of the three lug connections inside the junction box.  9. Tag the three lugs to facilitate reconnection during motor installation.

_________________________________________________________________ 5.284 Bucyrus – Model 25M0 Continuous Miner

____________________________________ Replacement of wear parts

  10. Remove the hex head capscrew, flat washer, lockwasher, and hex head nut that secures the three power cable lugs to the three motor lugs.  11. Remove the two socket head capscrews and lockwashers that secure the stuffing box’s half-moon clamp to the junction box.  12. Remove the clamp and slide the stuffing box out of the junction box. The power cable should be completely disconnected from the motor.  13. To prevent damage to the power cable lugs and gland assembly, cover the power cable and secure it to the miner in a safe location.

© BUCYRUS AMERICA, INC.

 14. To protect the motor’s electrical connections, replace the motor junction box cover and secure it using four hex head capscrews and lockwashers.  15 Remove the twelve hex head capscrews and lock-washers to secure the scrubber fan/motor assembly to the tractor frame.

WARNING! The scrubber fan/motor is now detached from the tractor frame and can be removed. The hydraulic pump motor is extremely heavy. Prepare to support its weight before removing it from the tractor frame.  16. Carefully slide the scrubber fan/motor out of the tractor frame.

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Replacement of wear parts _____________________________________ Scrubber fan/motor installation  1. Carefully insert the scrubber fan/motor assembly into the tractor frame so the motor face is toward the scrubber’s mist eliminator box.  2. Orient the scrubber fan/motor so the motor drain is directly at the bottom of the assembly. Ensure that the scrubber fan/motor is positioned correctly for airflow out the rear vent of the miner. 3. Insert and tighten the twelve hex head capscrews and lockwashers to secure the scrubber fan/motor assembly to the tractor frame.  4. Remove the four hex head capscrews and lockwashers that secure the junction box cover and remove the cover and its oring.

 6. Replace the stuffing box’s half-moon clamp in its channel to secure the stuffing box in the junction box.  7. Tighten the two socket head capscrews to secure the clamp to the junction box.  8. Inside the junction box, locate the motor’s lug connections.

Match the motor lug connections to the corresponding power cable lugs (refer to the wiring diagram supplied in your Bucyrus America, Inc. parts manual).  9. Attach the first motor lug to its corresponding power cable lug by inserting a hex head capscrew through the motor lug, through the power cable lug, through a flat washer, and through a lockwasher. Secure the capscrew with a hex nut.

Repeat this step for the other two lugged connections.  10. When all three connections have been secured, wrap each of the three connections with a layer of rubber tape, then a layer of black tape and finally a layer of glass tape.  11. Replace the junction box O-ring (optional) and cover.  12. Insert the four hex head capscrews and lockwashers to secure the junction box cover and tighten.   13. Replace the rub rail hinge post.  14. Insert and tighten the four hex head capscrews and lockwashers to secure the rub rail hinge post to the tractor frame.  15. Close both rub rails and secure with the rub rail pin.

_________________________________________________________________ 5.286 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

 5. Insert the three lugs of the power cable (with gland and stuffing box already installed) into the motor’s junction box.

____________________________________ Replacement of wear parts Stabilizer cylinder removal WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all blocking devices.   1. Raise the conveyor tail assembly to its highest position.  2. Raise the cutter head and gathering head assemblies. Place a small stack of blocking under the cutter head and gathering head assemblies.

© BUCYRUS AMERICA, INC.

 3. Lower the cutter head and gathering head assemblies onto the blocking so that the front of the tractor frame lifts off the floor.

Place blocking under the front of the tractor frame. Raise the cutter head and gathering head assemblies slightly so that the tractor frame lowers onto the blocking.  4. Completely extend the stabilizer so that the rear of the tractor frame lifts off the floor. Place blocking under the rear of the tractor frame. Raise the stabilizer slightly so that the tractor frame lowers onto the blocking.  5. Place blocking under the conveyor tail assembly and lower the tail assembly onto the blocking.  6. Extend the stabilizer so that it touches the floor. The stabilizer should not support any miner weight.  7. Double check that the tractor frame and the conveyor tail are securely blocked.  8. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.  9. Locate the rod end bearing pin of the stabilizer cylinder (Fig. 223). Remove the socket head capscrew that passes through the rod end bearing pin and retaining collar and remove the pin securing the stabilizer cylinder rod end bearing in its clevis.  10.

Connect the trailing cable to energize the miner.

______________________________________________________________ A6474X332 VSSV/00 5.287

Replacement of wear parts _____________________________________ Fig. 223: Stabilizer cylinder rod end bearing Retaining collar

Rod end, right stabilizer cylinder

Bearing pin

Nut Socket head capscrew

WARNING! Stand clear of the blocked tractor frame during contraction of the stabilizer cylinder.  12.

Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.  13.

Raise and lower the stabilizer cylinder lever to release any pressure from the conveyor lift cylinder.

WARNING! The next steps require crawling under the block supported conveyor tail section. Verify that this tail section is adequately secured before proceeding.  14. Tag, disconnect, and cap the hydraulic hoses from the stabilizer cylinder’s fittings.  15. Remove the hydraulic fittings from the stabilizer cylinder and store in a clean place.

WARNING! Each stabilizer cylinder is extremely heavy. The next steps will remove the cylinder from its tractor frame mounting. Be prepared to support the weight from its tractor frame mounting. Be prepared to support the weight of the cylinder when it becomes free from the mounting.

_________________________________________________________________ 5.288 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

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

____________________________________ Replacement of wear parts

 16. Locate the bearing pin that secures the stabilizer cylinder to its tractor frame mounting.  17. Remove the two cotter pins that secure the bearing pin inside the stabilizer cylinder’s piston bearing and tractor frame mounting.

© BUCYRUS AMERICA, INC.

18. Slide the washers off both ends of the pin and Remove the pin from the cylinder’s piston end bearing and tractor frame mounting. The cylinder is now free and can be removed.

______________________________________________________________ A6474X332 VSSV/00 5.289

Replacement of wear parts _____________________________________ Swivel pin assembly removal Reference Fig. 224:   1. Lower the cutter head and gathering head assemblies until they touch the ground.  2. Position the conveyor tail section to the extreme right or left of the miner so that the chain is drawn to one side as far as possible and the conveyor swivel pin is exposed.  3. Lower the conveyor tail section until it is level with the floor. 4. Insert blocking between the conveyor tail section and the floor.

 5. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.

Fig. 224: Conveyor swivel Dowel pin

Grease fitting

Set screw

Swivel pin

Socket head capscrews

Retainer

View A-A _________________________________________________________________ 5.290 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

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

____________________________________ Replacement of wear parts

  6. Remove the socket head capscrews from the upper swivel pin.   7. Remove the center setscrew from the center of the upper conveyor swivel pin.  8. Use a slide hammer to remove the upper conveyor swivel pin.  9. Remove the center setscrew from the center of the lower conveyor swivel pin.  10. Remove the socket head capscrews from the lower conveyor swivel pin.  11. Use a slide hammer to remove the lower conveyor swivel pin.  12. Reach into the conveyor chain return channel and retrieve both upper and lower swivel pin retainers.

© BUCYRUS AMERICA, INC.

Swivel pin assembly installation Reference Fig. 229:   1. Working first on the upper swivel pin assembly, insert the dowel pin, center setscrew, and the grease fitting into the swivel pin.  2. Lower the swivel pin into the hole in the conveyor bed making sure the dowel pin is positioned in the notch and the top of the swivel pin is flush with the top surface of the conveyor bed.  3. Holding the swivel pin retainer with the flanged side downward, reach into the conveyor chain return channel and fit the swivel pin retainer into the hole.  4. Insert the socket head capscrews and tighten.  5. Working on the lower swivel pin assembly, insert the dowel pin, center setscrew and the grease fitting into the swivel pin.  6. Lift the swivel pin into the hole in the lower side of the conveyor making sure the dowel pin is positioned in the notch and the lower side of the swivel pin is flush with the lower surface.  7. Holding the swivel pin retainer with the flanged side upward, reach into the conveyor chain return channel and fit the swivel pin retainer into the hole.  8. Insert the socket head capscrews and tighten.

______________________________________________________________ A6474X332 VSSV/00 5.291

Replacement of wear parts _____________________________________ Tail roller removal Reference Fig. 225:   1. Lower the gathering head and cutter head assemblies until they rest on the floor.  2. Slowly advance the conveyor chain until a connecting link moves onto the conveyor tail section slide pan.  3. Using the procedure outlined in Chain Tension, Loosen tension on the conveyor chain as much as possible (see Conveyor chain adjustment procedure I n this chapter).  4. Lower the conveyor tail section onto blocking so it is level with the floor.

 5. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.  6. With conveyor chain tension removed, remove the retaining rings, or “T” pins, from the connecting link.  7. Remove the connecting link and its strap. The conveyor chain should now be separated. Move the two pieces of the conveyor chain out of the way to allow for easier removal of the conveyor tail roller assembly.  8. Remove the socket head capscrews that secure the tail roller assembly to the slide pan.  9. Remove the tail roller assembly from its location in the slide pan.

_________________________________________________________________ 5.292 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

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

____________________________________ Replacement of wear parts Fig. 225: Tail roller

Tail roller

Socket head capscrew

© BUCYRUS AMERICA, INC.

Tail roller installation  1. Insert the tail roller assembly into the proper location in the slide pan (Fig. 225).  2. Insert and tighten the socket head capscrews through the holes in the tail roller shaft and into the threaded holes in the slide pan (Fig. 225).  3. Reattach the two ends of the conveyor chain by replacing the connecting link.  4. Secure the connecting link by replacing the side strap and the retaining rings onto the ends of its pins.  5. Tighten the conveyor chain to the proper tension (see Conveyor chain adjustment procedure in this chapter).

IMPORTANT! Improper conveyor chain tension can lead to excessive wear, mechanical problems and miner downtime. Always keep the conveyor chain at the proper tension.

______________________________________________________________ A6474X332 VSSV/00 5.293

Replacement of wear parts _____________________________________ Chain replacement  1. Lower the cutter head and gathering head assemblies until they touch the ground.  2. Position the conveyor tail section directly behind the miner and raise it. Insert the blocking under the tail section and lower the tail section onto the blocking.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all blocking devices.  3. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

 4. Loosen the tension of the conveyor chain as much as possible (see Conveyor chain adjustment procedure in this chapter).  5. Remove the two retaining rings from a connecting link located near the rear of the conveyor bed.  6. Remove the connecting link. The chain is now separated.  7. Connect the come-along to the end of the chain on the conveyor bed.  8. Connect the new chain to the end of the lower chain and allow the new chain to extend behind the miner on the floor.  9. Use the come along to pull the old chain out of the miner. The new chain will follow the old through the conveyor return channel around the gathering head foot shaft and out onto the conveyor tail section.  10. When the entire length of old chain has been pulled through the miner and the replacement chain is in position, disconnect the old chain from the new and remove the come along.  11. Connect both ends of the new chain by replacing the connecting link, pins and retaining rings.  12. Tighten the conveyor chain (see Conveyor chain adjustment procedure in this chapter).

_________________________________________________________________ 5.294 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.

____________________________________ Replacement of wear parts Duo-cone seals Duo-Cone seals consist of a pair of matched sets. Each set is made up of a metal seal ring and a rubber toric (see Fig. 226).

The special seal rings are precision lapped to ensure positive sealing at the mating surfaces. The torics position the seal rings and furnish the floating action that allows for shaft deflection and end play. They also provide a constant sealing face pressure, seal the back sides of the sealing rings to adjacent parts, and transmit the force needed to turn one metal ring, while holding the other stationary.

The faces of the mated sealing rings form a sealing band 0.8 mm (1/32") wide that retains the oil lubricant and keeps out dirt. As wear occurs, the contact band broadens, moving slowly inward until the inside diameter is reached. Thus, a simple visual check will show the amount of remaining life.

Fig. 226: Duo cone seal sets © BUCYRUS AMERICA, INC.

1

2 3 4

6 7

9

5

1-Seal Ring 2-Rubber Toric 3-Housing Retainer Lip 4-Housing Ramp 5-Seal Ring Housing 6-Seal Ring Face 7-Seal Ring Ramp 8-Seal Ring Retaining Lip 9-Installation Tool

8

mating pairs

Duo-Cone seals must always be installed in mated pairs; two new seals together or two seals that have previously run together. Never assemble one new seal and one used seal together, or two used seals that have not previously run together.

handling

Proper handling and installation of these seals is vital to get maximum life and positive sealing protection given by these precision units. Special attention was given during shipping to ensure absolute For maximum service, keep seals clean during installation and with oil.

housing preparation

The housing components that contact the rubber toric rings (3 and 4 Fig. 226) must be free from foreign material (oil, grease, dirt, metal chips, dust or lint particles, etc.) before installing the seal. This should be done with a lint-free wipe and a non-petroleum based solvent. The solvent recommended is trichloroethane. Dry with a clean wipe.

______________________________________________________________ A6474X332 VSSV/00 5.295

Replacement of wear parts _____________________________________ IMPORTANT! To obtain maximum performance, the seals must be installed accurately to insure uniform loading at the mating faces and achieve a stable running position. Misalignment or cocking of seal rings during assembly can produce non-uniform loading and wobbling of the seals in their housings resulting in leakage due to scoring and/or pumping of debris past the toric rings. Improper installation can also result in breakage of the metal seal rings.

Put the torics (Item 1, Fig. 227) onto the metal seal rings. They should be positioned on the tail of the metal seal ring (2) and seat uniformly.

Be sure that the torics are not twisted and rest uniformly against the lip.

This can be done by checking the mold flash line on the toric outer diameter for even tracking around the seal. Remember that a twisted rubber ring will allow the face load to be uneven. If a toric is twisted, it can be straightened by gently pulling a section away from the metal ring and allowing it to snap back. Do this at several sections until the twist is corrected.

Fig. 227: Toric Care 3

1 2

1

2

5

8

2

Check the retaining lip (Item 3, Fig. 227) and metal seal for rough tool marks or nicks. Smooth any nicks or scratches and re-clean. seal assembly

Install the toric so that it seals uniformly on the sealing ring. Be sure the toric is not twisted and rests uniformly against the lip that prevents it from falling off the metal seal ring. Press with fingers on the rubber ring only, seating the ring inside the lip.

Use when possible the special seal installer tools provided with the miner. DO NOT use a screwdriver or any sharp instrument to seat the ring. Always install new rubber torics on new or used metal rings. Both metal rings must be replaced if one is defective.

Special attention is given during manufacturing and shipping to ensure absolute cleanliness. To obtain maximum service, cleanliness during installation and while filling with oil must be the rule. Lack of care can cause premature seal failure.

Getting full performance also requires proper installation procedures be followed. This results in even loading on the faces and a stable running position. One seal cocked, or a ring out of alignment when reassembling may cause the load to be uneven. The seals may end up wobbling in their housings. This would produce leakage from scoring or debris pumped across the rings. Another result of incorrect installation could be the breakage of the metal rings themselves.

_________________________________________________________________ 5.296 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

1

7

____________________________________ Replacement of wear parts NOTICE! Improper care and installation can result in immediate leakage or reduced service life. seal preparation

Remove any foreign material from the rubber torics (Item 2 in Fig. 228) and the ramps (Item 7, Fig. 228) and lips (Item 8, Fig. 233) of both seal rings. This should also be done with a lint-free wipe and a nonpetroleum based solvent. Dry with a clean wipe.

Place the rubber torics on the metal seal ring at the bottom of the seal ring ramp and against the retaining ring (see Figure ). Make sure the rubber toric is straight on the seal ring and not twisted. Be careful not to nick or cut the torics during this assembly, as this can cause leaks.

Put the installation tool onto the metal seal ring and rubber toric (see Figure ). Lightly dampen the lower half of the rubber toric with the appropriate assembly lubricant. Techniques to dampen the toric include wiping with a lint-free towel, lubricating using a clean foam brush, or dipping in a container lined with towels saturated in the as-

© BUCYRUS AMERICA, INC.

Fig. 228: Seal Preparation 9

1

2

using installer tools

After the torics are on the seal rings, they can be put into the housing assembly. Simple installer tools are available that will facilitate installation while protecting the seals from damage. The tool is made to locate on the toric ring and slide it past the retaining lip on the housing. The lip on the installer tool permits uniform pressure to be exerted directly onto the toric and provides protection on the sealing surface.

A hinged installer tool is used for the smaller seals. This tool closes over the metal seal ring so that the lip of the tool will force the rubber toric into its seat.

The larger seals use a one piece installer tool which snaps around the seal ring. When the installer tool is in place on the metal seal ring, hand pressure is applied to push the toric into its seat. The toric must be seated uniformly relative to both seal ring and seat.

Dipping the seal assembly into a shallow pan of solvent is highly recommended. The solvent recommended is trichloroethane. This facilitates assembly by reducing friction between the toric and seat thus allowing the toric to slip easier past the remaining lip on the housing and sealing evenly in the housing nose radius. ______________________________________________________________ A6474X332

VSSV/00

5.297

Replacement of wear parts _____________________________________ After dipping the assembly in solvent, shake off the excess fluid and then promptly pop the seal into the housing with a push from the tool.

Remove the tool and check the standout height at several spots.

Make certain that the seal is straight in the bore and inside the lip on the ramp. The dimension must be uniform around the entire circumference of the seal. If the seal is at an improper height, check for twisting or bulging. The seal can be somewhat adjusted by gently pushing the toric into place by hand. If this does not result in proper placement, remove the seal and repeat installation.

After proper height is obtained, allow the assembly to rest for a couple minutes to allow the solvent to dry. This is done so that when the housings are reassembled, the torics will roll rather than slide in the housing as the face load is increased. If the torics slide, they can result in an uneven load.

Insufficient lubrication can cause improper sealing. Again, the use of quick evaporating trichloroethane solvent will not leave an oil residue or cause corrosion of the metal parts. Other lubricants that leave a residue can allow the toric to slide, rather than roll in the seat. This will cause bad seal efficiency. reassembling housings

After reassembling the torics into the housings and just before assembling the housings, a thin film of light oil should be put onto the faces of the seals. A disposable tissue, cotton applicator or a clean finger can be used to spread the oil evenly.

IMPORTANT! Do not get any oil onto the rubber torics!

Check the seal faces one more time to ensure that there is no dust, dirt or other objects on either face. Be sure that all solvent has dried off of the housing.

IMPORTANT! Even a small piece of lint can hold the faces apart and cause leakage!

_________________________________________________________________ 5.298 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

IMPORTANT! The toric must lie uniformly in the seal with the sealing ring and parallel to the seat face. Be sure that the toric is not twisted and that it rests uniformly against the retaining lip or not deeper in one side of the seat than the other.

____________________________________ Replacement of wear parts seal test

After the entire unit is reassembled, it may be a good practice to test the seals. A vacuum test is more sensitive than a pressure test and can be performed during a vacuum fill operation.  Carefully fill the compartment to the correct fluid level.  Slowly rotate the assembly several revolutions to seat the seals.  A vacuum test will catch severe seal damage such as broken seal rings or cut torics that may be damaged in the last phases of assembly. The torics are not designed to seal air. Some leakage can be expected using such a procedure.

Fig. 229:Installation issues

© BUCYRUS AMERICA, INC.

Toric sliding on retainer ramp.

Toric caught on housing retainer lip.

Toric sliding on seal ramp. installation process

With the lower half of the rubber toric seal still wet, use the installation tool to position the seal ring and the rubber toric squarely against the housing (Fig. 230). For smaller diameter seals, use sudden and even pressure to push the rubber toric under the retaining lip of the housing.

For larger diameter seals which will not press in with sudden and even pressure, it is acceptable to work the toric past the retaining lip by starting on one side and tapping the opposite side of the installation tool with a rubber mallet until it is engaged past the retaining lip of the housing.

Check the assembled height (height “A”, Fig. 230) in at least four places, 90° apart, using a caliper, tool makers' rule or any other calibrated measuring device. The difference in height around the ring must not be more than 1mm. If small adjustments are necessary, do not push or pull directly on the seal ring. Use the installation tool to push down and your fingers to pull up uniformly on the rubber toric and seal ring.

The rubber toric can twist if it is not wet all around during installation or if there are burrs or fins on the retaining lip of the housing. Twists, misalignment, and bulges of the toric will result in seal failure. If correct installation is not obvious, remove the seal from the housing and repeat the process.

The rubber torics must never slip on the ramps of either the seal ring or the housing. To prevent slippage, allow adequate evaporation time for the lubricant before proceeding with further assembly. Once correctly in place, the rubber toric must roll on the ramp only.

______________________________________________________________ A6474X332 VSSV/00 5.299

Replacement of wear parts _____________________________________ Wipe the face of each seal ring using a lint-free wipe. No particles of any kind are permissible on the sealing surfaces. (Even a hair can hold the seal surfaces apart and cause a leak.) Apply a thin film of oil on the entire seal face of one or both seals using a clean finger or a lint-free applicator. Oil must not contact surfaces other than the sealing faces.

Fig. 230: Installation process 9

1

2 11 9

3

final assembly

1

While completing the final assembly of the unit (Fig. 231), make sure that both housings are in correct alignment and are concentric. Slowly bring the two housings together. High impact can scratch or break the seal components.

If the rubber toric slips at any location, it will twist, causing the seal rings to cock. Cocked seals create uneven pressure on the seal faces, resulting in galling, scoring and leakage. Any wobbling action can cause dirt to enter by pumping mud past the torics.

Fig. 231: Final Assembly Max. Variation 0.04 in. (1.00 mm)

Seal Ring Locator Toric Ring Locator

_________________________________________________________________ 5.300 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

5

____________________________________ Replacement of wear parts Bearings

© BUCYRUS AMERICA, INC.

handling of bearings

The most important single factor in obtaining good service and long life from bearings is to keep dirt and foreign particles out of the bearing.

■

Use only clean grease/oil from clean containers.

■

Keep the grease/oil containers closed.

■

Handle the grease/oil so as to keep it clean.

■

Clean all dirt from adjacent surfaces before opening a bearing housing.

■

Always protect an exposed bearing with a lint free protective cover.

cleanliness

Try to prevent chips or dirt from getting between the bearing face and the shaft or housing shoulder. Contamination keeps the bearing from seating properly. The dirt may then work out and cause the bearing to work back against the shoulder, resulting in the bearing adjustment being excessively loose. Chips or dirt on one side of the shoulder could cock the bearing on the shaft, causing a misaligned condition similar to an off square shoulder.

proper protection

Bearings are originally packed in cardboard cartons, tubes or spiral wrapping at the factory to give the proper protection against dirt and moisture. Leave bearings in these containers and store in a clean, dry place until ready to be used. Bearings should not be removed from cartons and left in open trays, pans or in open cabinets exposed to dirt, dust or moisture. Keep bearings clean and dry!

It is not necessary to wash new bearings to remove the slushing grease put on at the factory for rust protection. This grease has little lubricating value, but it will not harm to the lubricant used in the bearings.

In special cases, it is necessary to wash bearings before assembly because they become dirty. Use a clean solution; kerosene is recommended. Cover bearings with a lubricant as soon as possible after washing to prevent rust.

cleaning bearings

When bearings are removed, examine each one for wear. If the bearing is in good condition, it should be cleaned with a suitable cleaner and then dried. When drying a bearing that has just been cleaned, never rotate the bearing at high speed; there is no lubricant in the bearing to protect it. Id the bearing is being dried with an air hose, direct the airstream so that rotation does not occur. After the bearings have been cleaned and dried, they should be coated immediately with light oil and covered with a lint-free cloth.

IMPORTANT! A mixture of marking compound and spindle oil is good lube for the gears under light loads for 2-3 revolutions only. Check tooth patterns all round to make sure the pattern/markings are uniform.

______________________________________________________________ A6474X332 VSSV/00 5.301

Replacement of wear parts _____________________________________ bearing assembly

Bearing cones and cups can be assembled in many ways. Smaller bearings can be pressed onto shaft or into housings. Bearing cones can be heated and shrunk onto shafts. Cups can be frozen and contracted to slip into housings easier. Proper bearing operation hinges upon correct mounting. With any method used, a number of factors should be considered.

■

Do not drop or roughly handle the bearings.

■

Do not subject bearings to sudden, large temperature changes.

This could cause condensation onto the bearing surfaces.

■

Do not handle the bearings more than necessary. Finger prints can be a starting point for rust.

■

When installing, be sure the cone or cup is solidly seated against its shoulder. After the part has been pressed, shrunk, or cooled on, check with a thickness gauge to make sure it is properly seated.

■

Be sure the bearing being installed is Original Equipment Manufacturer (OEM) . This ensures that an exact duplicate is put on. Bearings and shafts are designed for each other, and changes can cause failure, loss of warranty, and extended downtime.

■

Be sure the bearing fit is not too loose or too tight. A loose bearing will creep, slip and cause it to overheat and be subjected to abrasive wear on the bore or shaft.

■

On a tight bearing, the inner ring of the cup will be stretched to where there is no room for the rollers or balls to revolve freely.

■

The bearing should be supported properly and pressure should be applied to the correct ring of the bearing.

There are generally three basic methods to mounting bearings: cold mounting, temperature mounting, and hydraulic mounting.

Bearings up to 4" (102 mm) in diameter can be cold mounted, using a sleeve and a hammer or press. Soft-metal hammers, while less likely to cause damage, have a tendency to chip and send metal flying into the bearing.

The end faces of a driving sleeve should be flat, parallel, and free of burrs. The bearing seating on the shaft and in the housing should be lightly smeared with thin oil.

_________________________________________________________________ 5.302 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

Mount in a relatively clean environment. Dirt and debris affect internal clearances and fits. Dust can keep two mating surfaces from being tight, causing out-of -round bores. Dirt on a shaft contact area can cause seal wear. Debris mixing with gear oil forms a lapping compound that wears the bearing. Keep the bearing in its container until ready to mount it.

____________________________________ Replacement of wear parts micronized graphite for bearing assembly

drivers for bearing cups and cones

Micronized graphite can be used on shafts, cone seats, and in the cone bores to facilitate the assembly and removal of bearing cones on the shaft. Considerably less pressure is needed to press on a cone if micronized graphite is used. Removal is easier too, since it reduces or eliminates oxidizing on the cone seat (fretting corrosion).

Drivers should be used wherever possible to assemble cups and cones. They save time, ease installation by driving/pressing cups onto cones straight, prevent damage to bearing cages and nicks in bearing parts, and in general assure better assembly.

© BUCYRUS AMERICA, INC.

Do not damage the cage of the bearing cone by pressing or driving against it. This will distort and loosen it. Distortion causes skewing of the rollers and early failure of the bearings. Loosening the cage will cause cage and rollers to fall off the cone.

Drivers can be hardened for longer life. If they are not available, mild steel bars can be used, although they are not preferred. Use mild steel, not hardened drifts or brass bars. Hardened bars damage the bearing.

Brass will chip easily and get into the bearing or behind the bearing face, preventing it from becoming seated against the shoulder.

When bars are used as drivers, take care to see that they are tapered to clear the bearing cage, and hit only against the bearing race. Drivers should be used wherever possible as they save time.

Heating bearings Temperature mounting is done by one of three ways: ■

heating one part

■

cooling one part

■

heating one and cooling another

Heating is recommended for larger bearings. Cooling is suitable for any size, straight or tapered, although if temperature mounting is to be done to smaller assemblies, cooling is preferred. Be absolutely sure that no bearings are ever heated over 135°C - 150°C (275° - 300°F). If they are, they will begin to draw, or soften.

Heating bearings in oil is common. Before heating, the oil and the container should be clean. Quenching oils with a minimum flash point of 150°C (300°F) should be used. The oil quantity should be large in relationship to the bearing being heated. A smaller volume heats and cools too rapidly. Where oil is heated in a pan or metal container over an open flame, there should be a screen on which the bearings will rest. It should be raised an inch from the bottom of the pan.

The bearing must not rest on the bottom, since heat would be transferred directly from the flame through the pan to the bearing. This temperature will be very high and will draw the bearing. A wire rack can be installed about 3" from the bottom. This will keep the bearing away from the direct heat, and also out of contamination. Another method is to suspend the bearing in the bath.

______________________________________________________________ A6474X332 VSSV/00 5.303

Replacement of wear parts _____________________________________ Once the bearing is heated, wipe the bore clean, place the assembly immediately on the shaft, and lock it in place. If there is no locking device, use a mounting tool to hold the inner ring in place until it has cooled. Oil baths are not recommended for sealed bearings. induction heating

Induction heating is not recommended. Surface temperatures will get too high and will draw the bearings.

freezing/shrinking bearing cups

Where cups are to be assembled in housings with a press fit, they can be shrunk in a deep freeze unit or an alcohol bath cooled with dry ice.

In some cases, you must also heat the housing to get the cup to slip into place readily.

tapered roller bearing adjustment

The accurate location and mating of rotating parts depends on the internal running clearance and stability of the support bearings. Running clearance of tapered roller bearings can be readily adjusted to meet a variety of operation conditions. This is through the axial adjustment of either the cone (inner race) or cup (outer race).

Proper initial adjustment should compensate for thermal changes and/ or deflections produced by normal operation. Tapered roller bearings operate well over a relatively wide adjustment range. The optimum initial bearing adjustment results in an operating adjustment of almost "metal to metal", or no appreciable end play within the bearings.

WARNING! Check a heated bearing for assembly after cooling a proper shoulder seating.

adjustment for wear

Though the surface hardness of bearings resists abrasion, dirt in the lubricant accelerates wear. After extended periods of operation, this wear results in the loss of the original adjustment and increases running clearance or end play.

The adjustable feature of a tapered assembly allows readjustment to compensate for this condition. This readjustment increases life to bearings, seals, gears, and other rotating parts. These general recommendations for adjusting tapered roller bearings cover most applications.

thermal expansion

Thermal expansion reduces end play. As a bearing rotates, heat is generated, causing successive thermal expansions. Usually the cone and roller assembly expands first, followed by the cup. When the cup is in a rigid housing with a tight fit, it cannot expand until the housing itself heats and expands.

In a typical gear drive or transmission, the operating temperature of the cup is lower than the cone and roller assembly. This is due to the cooling effect of the housing, since normally it can more effectively dissipate heat than can the shaft on which the cone is mounted.

_________________________________________________________________ 5.304 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

WARNING! When bearings are heated for assembly, the part heated should be checked after cooling to see that it is seated properly against the shoulder. Bearings have a tendency to pull away from the shoulder.

____________________________________ Replacement of wear parts Under operating conditions, the component parts of the bearing do not expand uniformly. When a single-row tapered roller bearing is used at each end of a shaft, consider the axial expansion of the shaft and housing in determining the proper initial bearing adjustment.

Lubrication is important in the thermal characteristics. Bearings rotating at high speed partially or completely submerged in oil may cause a high degree of heat from their churning action of bearings in the lubricant.

Bearings usually are first adjusted with slight running clearance or end play. On applications such as gear cases, initial end play will be about .001" to .003" (.025mm - .076mm) on the small sizes and proportionately greater as the bearings size increases. Generally, running bearings at higher speeds and temperatures increases the amount of initial end play or running clearance required.

© BUCYRUS AMERICA, INC.

torque for zero end play

The following recommended procedure for adjusting tapered roller bearings is used in most applications. Pull up on the end cap or bearing cup carrier, or end plate, without shims in place, until bearings bind slightly in rotation. Then the gap between the cap flange and housing or the end of the shaft, can be measured with a thickness gauge. The measured gap plus the end play desired will give the total shim pack required.

Another good way is to put a lead wire where the shims go and then pull up until all end play is taken up. The wire, which has to be larger than the original gap, is then flattened and can be measured with micrometers and the shim pack made up in the same manner as when thickness gauges are used. The shaft should then be tapped with a hammer so that the adjusted bearing member (cup or cone) is likewise backed off and seated against the adjusting device.

Where large tapered roller bearings are adjusted, it may be hard to manually feel when a "metal to metal" setting is reached. In such cases, a simple torque measuring device is commonly used. With this method, as the bearings are being adjusted, an increase in bearing torque can be detected which indicates that a close setting has been reached.

Do not confuse this torque with torque generated by gears and seals.

When bearings are being set for desired initial end play, check the axial movement of the shaft as the bearings rotate. Rotating bearings ensures that the rollers will align and seat against the cone rib, resulting in a true end play measurement.

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Replacement of wear parts _____________________________________ bearing testing

After the bearings have been installed and the machine reassembled, it should be tested. Running the machine without a load or a short time will ensure that all components are installed correctly.

Check the bearings for noise, excessive heat and vibration. Any of these signs could indicate damage which may have occurred during the installation procedure (Fig. 232) . Interference or overload will produce a high-pitched whine. Bearing misalignment will cause a medium or low-pitched noise and poor shaft finish or out-of-round housings will create a rumbling noise. Excessive heat is frequently caused by the presence of too much lubricant.

bearing removal

If the bearing is designed to be installed with an arbor press, then use an arbor press to remove the bearing. If the bearing or shaft is too long to fit in a press, use a bearing puller.

CAUTION! Be careful not to set fire to any grease or lubricant!

Make sure the heating torch is the proper type and that it is set for heating, not cutting or burning.

IMPORTANT! Observe all applicable fire and safety regulations!

Remember to provide proper support for the bearing and shaft during disassembly.

Fig. 232: Wear patterns in failed bearings Wide worn area

Wavy wear pattern

_________________________________________________________________ 5.306 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

If the bearing does not come off the shaft easily, a different approach must be tried. One possible method is to heat the bearing with a torch, thereby increasing the clearance between the shaft and the bearing.

____________________________________ Replacement of wear parts Bevel gear adjustment Straight bevel gears connect shafts having perpendicular axes. The alignment of bevel gears is more critical than that of spur gears or helical gears. An Adjustment on all bevel gear sets corrects any tooth contact errors.

Straight bevel gears are produced to run with a localized tooth contact.

Since the area of contact does not cover the whole tooth, slight tolerance in positioning the gears in assembly and some displacement under operating loads is possible without concentration of the loads on the ends of the teeth.

Regarding tooth contact pattern, the contact length is usually about half the tooth length and toward the inner end of the tooth (small end). Under a heavy load, the tooth contact will spread out and shift toward the heel (large end of the tooth). The resulting contact is called “central toe contact”.

© BUCYRUS AMERICA, INC.

To check the tooth pattern, paint the gear teeth with gear marking compound and run the gears briefly under a light load two or three revolutions.

IMPORTANT! A mixture of marking compound and spindle oil is suitable for lubricating the gears under light loads for two or three revolutions only. Check tooth pattern all around gear to make sure that the pattern is uniform.

Fig. 233 shows examples of recommended tooth contact patterns for straight bevel gears. Also shown are typical examples of incorrect contact patterns due to errors in gear assembly and the changes necessary to correct them. To check tooth pattern, paint gear teeth with a gear marking compound, and run gears briefly under light load two or three revolutions.

Fig. 233: Tooth contact patterns

Low Contact: To correct, move out on pinion cone ERROR

High Contact: To correct, move in on pinion cone

Preferred contact pattern on a completed gear run on a test machine under a light load with a control gear.

ERROR

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Replacement of wear parts _____________________________________ Gears and gear failure The three (3) most common gear failures are tooth breakage, pitting and scoring.

Breakage happens because an unexpectedly high load is applied to a gear or because of bending fatigue that occurs through repetition of loading as the gear rotates. A gear tooth will frequently break at its base.

Pitting is fatigue at the surface occurring when the stress exceeds the endurance limit of the surface material. After sufficient repetitions, bits of surface metal will drop off. Insufficient lubricant usually causes pitting to start.

Gear maintenance tips Lubrication is the first line of defense against gear failure. Be sure all gear cases are filled to the proper level with the specified lubricant.

Check the lubricant level regularly and be on the alert for unusual noises or excessive heating in the gear cases.

After some gears have been running for several years, hairline cracks may develop in the body or teeth. The teeth may also become chipped or broken. These minor maintenance problems should not be ignored, but should be corrected as soon as possible after they are discovered.

Some of the ways to correct such problems include welding, drilling and tapping and tooth resurfacing or metal spraying.

CAUTION! Because these maintenance techniques are specialized, they should be performed only by qualified personnel.

When a gear case is rebuilt, all gears should be replaced with a new set. The old set should be tested with magnaflux equipment or dye penetrant to detect any gears with hidden flaws or cracks. The old set can then be used as a spare after any bad gears are replaced. Sometimes magnafluxing is not possible, but it remains a desirable goal since it finds flaws that are sometimes invisible to the human eye.

The wear pattern on gear teeth can show how the gears are meshing.

Abnormal wear patterns will appear on gear teeth (Fig. 234). Shimming can sometimes be used to adjust the meshing of gears to prevent premature gear failure.

_________________________________________________________________ 5.308 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

Scoring occurs under heavy loads with insufficient lubrication. The oil film breaks down, resulting in metal to metal contact and high temperatures. The high spots on the two metal surfaces weld together, but the weld breaks at once. This action causes the gear teeth to wear very rapidly.

____________________________________ Replacement of wear parts Fig. 234: Examples of worn gear teeth

Improper type of lubricant

Bent or broken teeth

Contaminated lubricant

© BUCYRUS AMERICA, INC.

Shock loading

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Replacement of wear parts _____________________________________ Lock wiring fasteners single wire

Insert the wire through the fastener from inside the bolt circuit toward outside the bolt circle, advancing in clockwise direction (Fig. 235).

wired in pairs

Establish the left and right hand fasteners as viewed from center of the bolt circle. Insert left hand fastener from inside to outside of the bolt circle. Insert the right end of the wire through right hand fastener from outside of the bolt circle (Fig. 235).

Special fasteners Various types of self- locking bolt and nut fasteners are in use. They are to be used in the same manner as standard fasteners with regard to tensile strength and torque; but they provide better locking qualities and reduce the number of parts used in fastening. Most special fasteners, once used, should not be re-used because of the locking material retention limitations.

Self-locking screws This socket head screw has a number of threads with wide, offset sections, which produce the self-locking effect by causing a high friction bind against the matting threads. This type fastener is identified by a triangle at the base of the socket. Because of this self- locking feature, the use of washers is usually not necessary. It is suitable in assemblies subjected to high vibration. installation

The self- locking screw (Fig. 236) is generally used where measured torque is required. When this is specified, hand wrench only - do not power wrench. This is to obtain an accurate reading and not due to structural limitations of the screw.

The top performance of this screw is reduced with each use. Re-use of this fastener should be limited to twice. For assemblies that require shims with self- locking screws, establish the shim set using standard fasteners. For final assembly, remove the standard fasteners and install the self- locking type, then torque down as required.

_________________________________________________________________ 5.310 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

Fig. 235: Lock wiring fasteners

____________________________________ Replacement of wear parts Fig. 236: Self-locking screws 2 to 4 pitches

4 pitches min.

Screw locking feature 6 thread pitches max.

See Detail A

Wider Thread Sections

Triangle at bottom of socket identifies self-locking screw

DETAIL A

© BUCYRUS AMERICA, INC.

Locknuts Locknuts reduce use of (but do not replace) cotter pins, jam nuts, lock tabs and safety wire. These latter methods are usually more suitable for certain applications where permanent fastening is required, or in areas inaccessible or hidden after final assembly.

Locknuts with nylon or fiber inserts should not be re-used. A locknut with unlimited reuse contains a spring steel lock ring in the head. The locking feature is an elliptical insert, which is permanently bonded to the nut. installation

Be sure bolt or stud has a 35-45 degree chamfer on threaded end and the end is flat. The flat diameter should be 1/32" below root diameter of thread on bolt or stud. These features are necessary to allow the lock ring to thread on for maximum grip without damage.

CAUTION! Do not power wrench the lead thread of the lock ring insert until it is engaged by hand turning. Then tighten normally.

Make sure the bolt or stud threads extend at least 2 1/2 threads beyond the top of the insert.

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Replacement of wear parts _____________________________________ Component substitution IMPORTANT! Anti-seizing compounds may be used with this type of locknut.

Washers are not normally required here, but if assembly does, include them as they are needed due to high stress torque.

When parts need changed, OEM equipment is recommended.

This includes less obvious components such as hydraulic hoses, couplings, and valves, as well as the more obvious ones such as relays, gears, and torque shafts.

WARNING! Components not meeting specifications can fail, cause serious injury, and damage equipment.

IMPORTANT! When performing maintenance on the machine, remember that fabrication, installation, modifications or adjustments must be according to OEM specifications.

_________________________________________________________________ 5.312 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

WARNING! Do not substitute materials or compounds not complying with OEM. Use of non-OEM supplies may void warranties.

_____________________________________________ Troubleshooting Troubleshooting procedures The following section lists possible problems encountered when servicing the Continuous Miner and can aid in locating and correcting these problems.

This section covers basic components, with each listed in a troublecause-remedy format.

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

© BUCYRUS AMERICA, INC.

For maintenance procedures and tests that DO NOT require the controller to be energized, these precautions include: ■

Before removing the controller cover, remove power from the system by disconnecting the trailing cable. Follow all mine, local, State, and Federal lockout/tagout procedures.

■

Use insulated gloves and tools where possible.

■

All connections must be tight and care must be taken to pre vent bolts, nuts, washers and other small metal fasteners from being dropped or lost inside the controller. These lost fasteners could cause electrical shorts inside the controller.

For procedures that DO require that the controller be energized while the cover is off: ■

At no time should you reach inside the controller while it is energized. If it becomes necessary to make adjustments or to replace parts inside the controller, the machine circuit breaker must be turned to the “OFF” position. Once the circuit breaker is in the “OFF” position, adjustments or parts replacements can be made.

■

Use insulated gloves and tools where possible.

■

All connections must be tight and care must be taken to pre vent bolts, nuts, washers and other small metal fasteners from being dropped or lost inside the controller. These lost fasteners could cause electrical shorts inside the controller.

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Troubleshooting ______________________________________________ WARNING! Never disconnect a hydraulic hose if the circuit is pressurized or there is a load on the circuit. If a hose is disconnected while the cylinder is supporting a load, the load will fall.

Typical hydraulic problems

■

contaminated oil or poor oil quality

■

low or insufficient oil in the system

■

using the wrong type of oil or wrong viscosity grade

■

air in the hydraulic system

■

internal or external leakage of the hydraulic system

■

improper mechanical adjustments, such as reliefs

■

mechanical or structural damage leading to component failure

■

components by-passing (internal leaking or inability to hold pressure) which leads to erosion of bushings, valve spools, and other costly, critical components

The greatest aid to troubleshooting a hydraulic system is the confidence that comes with knowing the intended operation of the system, along with a fundamental understanding of basic hydraulic principles. Every component in the system has an intended purpose. The construction and operating characteristics of each of these components should be clearly understood before attempting to troubleshoot the machine. For example, understanding that a solenoid controlled directional valve can be manually actuated will save considerable time in isolating a defective solenoid. Please familiarize yourself with the operational descriptions of the hydraulic circuits given in the Hydraulics section of this chapter.

It is also important to know the capabilities of the system. Each component in the system has a maximum rated speed, flow, torque, or pressure. If the system is loaded beyond the specifications, the possibility of failure is greatly increased. The correct operating pressures of a system must be known and must always be checked and set with a pressure gauge. Refer to the hydraulic schematic in the Bucyrus America, Inc. parts manual supplied with your machine for the correct operating parameters. When in doubt, always assume that the correct pressure is the lowest pressure that will allow adequate performance of the system function (s) while remaining below the maximum rating of the machine’s components.

_________________________________________________________________ 5.314 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

The most common causes for improper function are:

_____________________________________________ Troubleshooting The ability to recognize trouble indicators in a specific system is usually acquired with experience. the gaining of this experience can be greatly enhanced by developing a logical sequence for determining the cause of a hydraulic problem and implementing the proper remedy.

© BUCYRUS AMERICA, INC.

Refer to the general troubleshooting charts in this section that illustrate the logical sequence for shutdown, troubleshooting, and restarting the machine. The charts cover: ■

general safety procedure for shutting down the machine

■

troubleshooting excessive noise

■

troubleshooting excessive heat

■

troubleshooting incorrect flow

■

troubleshooting incorrect pressure

■

troubleshooting faulty movement/operation

■

general restart checklist and procedure

This general information is intended to enhance the understanding of basic hydraulic principles which will lead to the development of a logical troubleshooting procedure. Specific troubleshooting checklists for each hydraulic circuit are given directly after the very important section entitled “Contaminants in hydraulic systems”.

Contaminants in hydraulic systems SYSTEM CONTAMINATION is the primary cause of hydraulic component failure! Cleanliness must be a high priority when servicing the hydraulic system. Even very small particles can damage system components by scoring valves, clogging orifices, and wearing seals prematurely. It is not the intent of this operation manual to outline a contamination control program but some of the most effective steps that have been identified in successful programs are given below: 1. Ensure that bulk oils are at acceptable cleanliness levels.

Areas where Bucyrus America, Inc. customers have made improvements in the past include: –

implement ISO Cleanliness Code standards for bulk hydraulic oils

–

evaluate bulk oil shipments for cleanliness by conducting particle counts and maintain records

–

minimize drum usage by utilizing tote tanks and five gallon pails

–

utilize plastic versus steel storage tanks, if possible

______________________________________________________________ A6474X332 VSSV/00 5.315

Troubleshooting ______________________________________________ –

install desiccant breathers on all bulk tanks

–

use sealed plastic containers for adding oil to small sumps

–

locate bulk tanks near equipment and pump directly to reservoirs

–

utilize filter carts to maintain oil cleanliness standards

–

properly train personnel on the importance of clean oil and best practices for storage and handling

–

monitor your program closely and look for continuous improvement

This is best achieved by understanding the primary sources of contamination during maintenance and troubleshooting which are given below: –

always clean the area around the component that is to be removed and inspected

–

store components in a plastic bag after inspection and prior to replacement on machine

–

cap off all open hoses/fittings

–

never touch a filter with bare hands when installing it back onto the machine

–

pay close attention to the filler/breather cap and replace it when damaged or in the recommended time frame

Contact your Bucyrus America, Inc. representative for more information on implementing an effective program to ensure that your oil and maintenance practices are not contributing to your equipment failure.

Specific hydraulic circuit troubleshooting Multi-function failure If more than one function fails to operate on the machine, check the output of the pumps. Since this is an “open center” circuit, the normal pressure (with all directional control valves in the center position) should be less than 100 psi. This pressure reading illustrates the necessary pressure to circulate the oil through the system. If the pressure reading under these conditions is significantly greater than 100 psi, it is likely that one of the control valves is trying to direct oil to one (or more) of the circuits on the machine.

_________________________________________________________________ 5.316 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

2. Eliminate contamination source through “clean” maintenance practices.

_____________________________________________ Troubleshooting The next step in troubleshooting a multi-function failure is to check the pilot pressure on the main control valve manifold. This pressure should be between 400 - 500 psi. If the pilot pressure is significantly below 350 psi, start with the General Troubleshooting Flow Chart IV - Incorrect Pressure.

Another step to resolve multi-function failure is to have an electrician check for power to the solenoid circuits.

Individual hydraulic circuit failures Perform the following checks on the individual circuits in conjunction with the general troubleshooting: Oil tank fill  Check the venturi ejector for blockage.  Check for low oil in the new oil supply.

Cutter head raise © BUCYRUS AMERICA, INC.

Check the directional control valve for proper operation.  Check to see that hosing has not been crossed, especially if the problem occurs after maintenance or repair work.  Check that the "in-line" counterbalance holding valve is piloted and shifting to direct retract port cylinder oil flow back to tank.  Check to see that there is no mechanical bind.  Check cylinders for bypassing.  Check for pilot pressure on the cutter head cylinder’s holding valves. Also check that the valves are shifting to send (extend port) oil back to the tank.

Cutter head lower  Check the direction control valve for proper operation.  Check to see that hosing has not been crossed, especially if the problem occurs after maintenance or repair work.  Check to see that there is no mechanical bind or hydraulic block.  Check flow control valve cartridge.  Check cylinders for bypassing.  Check for pilot pressure on the cutter head cylinder's holding valves. Also check that the valves are shifting to send (extend port) oil back to the tank. Note: Cylinder removal will be required to safely achieve this.

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Troubleshooting ______________________________________________ Gathering head raise  Check the directional control valve for proper operation.  Check to see that piping has not been crossed, especially if the problem occurs after maintenance or repair work.  Check pressure at the LH pressure gauge on scrubber.  Check to see that there is no mechanical bind.  Check cylinders for bypassing.  Check accumulator for 500 psi pre-charge, and that the bladder is functioning properly, depending on system installed.  Check needle valve on pilot circuit to verify that it is not open or leaking off.

Gathering head float  Check the control valve for proper operation.  Check to see that hosing has not been crossed, especially if the problem occurs after maintenance or repair work.  Check to see that there is no mechanical bind.  Check accumulator for 400 psi pre-charge, and that the bladder is functioning properly, depending on system installed.  Check cylinders for bypassing (they will leak out the top).  Check needle valve on pilot circuit to verify that it is not open or leaking off.  Check counterbalance valve for proper operation (See the schematic in the Bucyrus America, Inc. parts book supplied with your machine for the proper setting).

Conveyor raise  Check the directional control valve for proper operation.  Check to see that hosing has not been crossed, especially if the problem occurs after maintenance or repair work.  Be sure that the built-in atmospheric-vented reliefs on the cylinders are not dumping oil.  Check to see that there is no mechanical bind.  Verify that cylinders are not bypassing.

_________________________________________________________________ 5.318 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

 Check in-line counterbalance valve for proper operation or blockage.

_____________________________________________ Troubleshooting Conveyor lower  Check the directional control valve for proper operation.  Check to see that hosing has not been crossed, especially if the problem occurs after maintenance or repair work.  Verify that pilot pressure is being applied to open the piloted builtin checks.  Verify that cylinders are not bypassing.

Conveyor swing  Check the directional control valve for proper operation.

© BUCYRUS AMERICA, INC.

 Check for any mechanical bind or any obstruction blocking movement, either to the cylinder itself, the main pivot area, or to some point along or under the discharge conveyor itself. Also check to ensure that the pivot bushings have not frozen up from lack of lubrication.  Verify that the cylinder is not bypassing.

Stabilizer raise  Check the directional control valve for proper operation.  Check to see that hosing has not been crossed, especially if the problem occurs after maintenance or repair work.  Check for bound bushings.  Check for any mechanical bind or any obstruction blocking movement.  Check cylinder for bypassing.

Stabilizer lower  Check the control valve for proper operation.  Check to see that hosing has not been crossed, especially if the problem occurs after maintenance or repair work.  Check for bound bushings.  Check for any mechanical bind or any obstruction blocking movement.  Check cylinder for bypassing.

______________________________________________________________ A6474X332 VSSV/00 5.319

Troubleshooting ______________________________________________ General safety procedure for shutting down machine When shutting down the machine for maintenance:  lower or mechanically secure (block) all suspended loads  exhaust any pressure locked in the system  drain down all accumulators  isolate the electrical control system  isolate the electrical power supply

© BUCYRUS AMERICA, INC.

Follow all procedures listed in the Shutdown procedure in this chapter.

_________________________________________________________________ 5.320 Bucyrus – Model 25M0 Continuous Miner

_____________________________________________ Troubleshooting Table 3: Flow chart I for troubleshooting excessive noise Pump Noisy Cause

Motor Noisy Remedy

Cavitation

A

Air in fluid

B

Coupling misaligned

C

Pump worn or damaged

E

Cause

Relief/Counterbalance Valve Noisy Remedy

Cause

Remedy

C

Setting too low or too close to another valve setting

D

Worn poppet and seat

E

Motor or coupling worn or damaged

Remedies A. Any or all of the following:

© BUCYRUS AMERICA, INC.

 replace dirty filters  wash strainers in solvent compatible with system fluid  clean clogged inlet line  clean reservoir breather vent  change system fluid  change to proper pump drive motor speed  check fluid temperature B. Any or all of the following:  tighten leaky inlet connections  fill reservoir to proper levels: with few exceptions, all return lines should be below fluid level in the reservoir  bleed air from system  replace pump shaft seal; also replace shaft if worn at seal journal C. All of the following:  align unit  check condition of seals, bearings, and coupling D.  install and/or adjust pressure gauge E.  overhaul or replace defective parts

______________________________________________________________ A6474X332 VSSV/00 5.321

Troubleshooting ______________________________________________

Pump Heated

Motor Heated Cause

Fluid Heated

Cause

Remedy

Cause

Remedy

See Fluid Heated

System pressure too high

D

Cause

Remedy

Fluid heated

See Fluid Heated

Cavitation

A

Relief valve set too high

D

Valve setting incorrect

D

Unloading valve set too high

D

Air in fluid

B

Excessive load

C

Worn or damaged valve

E

Fluid dirty or low supply

F

Relief valve set too high

D

Worn or damaged motor

E

Incorrect fluid viscosity

F

Excessive load

C

Worn or damaged pump

E

Worn pump, valve motor, cylinder, or other component

E

Fluid heated

Remedy

Relief Valve Heated

See Fluid Heated

Fluid heated

Remedies  locate and correct mechanical binding A. Any or all of the following:  check for workload in excess of circuit design  replace dirty filters  clean clogged inlet line

D.  install and/or adjust pressure gauge; keep at least 125 psi difference between valve settings

 clean reservoir breather vent

E.  overhaul or replace defective parts

 change system fluid

F.  change filters

 change to proper pump drive motor speed

 check system fluid viscosity; change if necessary

B. Any or all of the following:  fill reservoir to proper level  tighten leaky inlet connections  fill reservoir to proper levels: with few exceptions, all return lines should be below fluid level in the reservoir  bleed air from system  replace pump shaft seal; also replace shaft if worn at seal journal C. All of the following:  align unit  check condition of seals, bearings, and coupling

_________________________________________________________________ 5.322 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

Table 4: Flow chart II for troubleshooting excessive heat

_____________________________________________ Troubleshooting Table 5: Flow chart III for troubleshooting incorrect flow No Flow

© BUCYRUS AMERICA, INC.

Cause

Low Flow Remedy

Cause

Excessive Flow Remedy

Cause

Remedy

Pump not receiving fluid

A

Flow control set too low

D

Flow control set too high

D

Pump drive motor not operating

E

Relief or unloading valve set too low

D

RPM of pump drive motor incorrect

H

Pump to drive coupling sheared

C

Flow by-passing thru partially open valve

E of F

Improper size pump used for replacement

H

Pump drive motor turning in wrong direction

G

External leak in system

B

Directional control set in wrong position

F

RPM of pump drive motor incorrect

H

Entire flow passing over relief valve

D

Worn pump, valve, motor, cylinder, or other component

E

Damaged pump

C

Pilot filter clogged

A

Improperly assembled pump

E

Pilot filter clogged

A

Remedies A. Any or all of the following:  replace dirty filters  clean clogged inlet line

F. Any or all of the following   check position of manually operated controls  check electrical circuit on solenoid operated controls

 clean reservoir breather vent  repair or replace pilot pressure pump  fill reservoir to proper level G.  reverse rotation B. Any or all of the following: H.  replace with correct unit  tighten leaky inlet connections  bleed air from system C. All of the following:  check for damaged pump or pump drive  replace coupling D.  adjust setting on valve E.  overhaul or replace part

______________________________________________________________ A6474X332 VSSV/00 5.323

Troubleshooting ______________________________________________ Table 6: Flow chart IV for troubleshooting incorrect pressure Low Pressure

Cause

Remedy

Cause

No flow

See Table 5 Pressure relief path exists

Erratic Pressure

Remedy See Table 5

Cause

Excessive Pressure

Remedy

Cause

Remedy

Air in fluid

B

Pressure reducing, relief valve misadjusted

D

Pressure recuing, relief valve worn or damaged

E

Pressure reducing valve set too low

D

Worn relief valve

E

Pressure reducing valve damaged

E

Contamination in fluid

A

Damaged pump, motor, or cylinder

E

Accumulator defective or has lost charge

C

Worn pump, motor, or cylinder

E

Remedies A.  replace dirty filters and system fluid B.  tighten leaky connections  fill reservoir to proper level and bleed air from system C.  gas valve for leakage  pre-charge to correct pressure  overhaul if defective D.  adjust valve E.  overhaul or replace part

_________________________________________________________________ 5.324 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

No Pressure

_____________________________________________ Troubleshooting Table 7: Flow chart V for troubleshooting faulty operation No Movement Cause

© BUCYRUS AMERICA, INC.

No flow or pressure

Slow Movement

Remedy

Cause

See Table Low flow 5

Erratic Movement

Excessive Speed or Movement

Remedy

Cause

Remedy

See Table 5

Erratic pressure

See Table Excessive flow 6

See Table 5

Air in fluid

See Table Feedback 3 transducer malfunctioning

E

Limit or sequence device (mechanical, electrical, or hydraulic) inoperative or misadjusted

E

Fluid viscosity too high

A

Mechanical bind

B

Insufficient control pressure for valves

See Table 6

No lubrication of machine ways or linkage

G

No command signal to valve or amplifier

F

No lubrication of machine ways or linkage

G

Erratic command signal

F

Inoperative or misadjusted valve amplifier

C

Misadjusted or malfunctioning valve amplifier

C

Misadjusted or malfunctioning valve amplifier

C

Inoperative solenoid or proportional valve

E

Sticking valve

D

worn or damaged cylinder or motor

E

Worn or damaged cylinder or motor

E

Sticking valve

D

Pilot filter clogged

See Table 5

Worn or damaged cylinder or motor

E

Cause

Overriding work load

Remedy

H

Remedies A.  check fluid temperature  check system fluid viscosity; change if necessary B.  locate bind and repair C.  adjust, repair, or replace part D.  clean and adjust or replace part  check condition of system fluid and filters E.  overhaul or replace part F.  repair command console or interconnecting wires G.  lubricated H.  adjust, repair, or replace counterbalance valve

______________________________________________________________ A6474X332 VSSV/00 5.325

Troubleshooting ______________________________________________ Table 8: Restarting checklist Has the cause of the failure been remedied?

No

Carry out further investigation.

Yes

Clean or flush the system as required.

Yes Can dirt have entered the system by the unit failure or during replacement?

No Is the unit the correct one?

No

Modify or replace with correct unit.

No

Remedy installation.

No

Remedy installation.

Yes

Is the unit adjusted to a safe condition for start up?

Are all hydraulic connections correct?

Yes Are all electrical connections correct?

Yes Is the unit adjustable?

No

Adjust to a safe condition.

Yes No Have the cases of pumps and motors been filled?

No

Fill case.

Yes

Bleed or prime as necessary.

No

Remove safety interlocks.

No

Sound alarm or inform personnel.

Yes Will the system require bleeding or priming?

No Have all safety interlocks been removed

Yes Are all personnel aware the machine is restarting?

Yes Start machine (see Startup procedure in this chapter).

_________________________________________________________________ 5.326 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

Yes

_____________________________________________ Troubleshooting Water System including Circuits Table 9: Water system troubleshooting including circuits Trouble, symptom or cause

Probable cause

recommended water volume  Dynamic water pressure (psi) is not being supplied to the (gpm) cannot be maintained recommended psi.

Test, check and/or remedy  Change setting to the recommended psi.

 Water supply hose is not the minimum diameter

  Change hose to the recommended diameter size.

 Incoming supply of water has a problem.

 Check the water supply itself to see if there is an issue & fix.

damaged or clogged filter, con-  Dirt in the system. taminates in the water system

 Remove the filter and clean it thoroughly; flush the system as necessary.

© BUCYRUS AMERICA, INC.

 Change water filter frequently. plugged water nozzles are re-  Dirt in the system. stricting the flow of water or pressure fluctuates

 Remove the nozzles and clean thoroughly; flush the system as necessary.  Change water filter frequently.

pressure fluctuates and there is  Air in the system. extreme noise in the system  Pressure too high.

 Check for leaks.  Adjust the pressure.

excessive water blowing from  Excessive pressures on scrub-  Adjust psi setting. ber screen sprays. scrubber exhaust Pressure setting on jet pump too low.

 Adjust psi setting.

Damaged screen or mist eliminator.

Replace. 

Mist eliminator not sealing.

Replace seal.

Sump needs cleaned.

Remove mist eliminator and clean sump.  Remove mist eliminator and clean.

Mist eliminator baffles dirty. water function will not shut Hydraulic pilot operated water valve stuck open.

“OFF” with radio remote Faulty solenoid. Radio remote toggle switch faulty.

Clean or replace.   Replace.  Replace toggle switch.

______________________________________________________________ A6474X332 VSSV/00 5.327

Troubleshooting ______________________________________________ Table 9 (continued): Water system troubleshooting including circuits Probable cause

no water pressure on the  Water filter plugged. pressure gauge  Main water ball valve “OFF”.  No incoming water. water filter stopping up  Contaminated water supply frequently scrubber water will not turn  Faulty solenoid plug connection.

“ON” when scrubber motor is running  Faulty solenoid.  No hydraulic pilot pressure to water valve.

Test, check and/or remedy  Replace or clean.  Close valve.  Fix water supply issue.  Clean or filter the incoming water supply to the miner.  Check the connection.  Replace.  Check for pinched hose and check the hydraulic pilot valve.

scrubber water will not shut  Hydraulic pilot operated water valve stuck open.

“OFF” after scrubber motor stops  Faulty solenoid

 Clean or replaced valve.

jet pump not removing water  Incorrect pressure reducing valve setting. from sump

 Adjust psi.

Low water volume to scrubber circuit. Pressure reducing valve internal strainer dirty. Jet pump nozzle plugged with dirt.

 Replace.

 Check water volume gpm. Remove strainer and clean.  Backflush pump, remove nozzle and clean. Adjust psi.

Excessive pressure setting on scrubber screen sprays.  Suction hose from sump to jet pump plugged with sludge or hose has a loose connection.  Incorrect hose size from jet pump to manifold.  Manifold plugged.

scrubber screen dirty Incorrect pressure reducing valve setting. Low water volume to scrubber circuit. Pressure reducing valve internal strainer dirty. Spray nozzles clogged or incorrect nozzle size.

 Remove restriction or tighten hose connection. Check for correct hose size.   Clean. Adjust psi.   Check water volume gpm.   Remove strainer and clean.   Clean nozzles and check nozzle part size.

_________________________________________________________________ 5.328 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

Trouble, symptom or cause

_____________________________________________ Troubleshooting Bearings Table 10: Bearing troubleshooting Trouble, symptom or cause

Probable cause

overheating bearing  Wrong type of grease or oil.

© BUCYRUS AMERICA, INC.

 Low oil level; loss of lubricant through seal; excessive grease.

Test, check and/or remedy  Consult the lubrication chart for the proper lubricant.  Oil level should normally be at the center of lowest ball or roller in bearing; check seals for signs of leaking.

 Insufficient clearance in bearing.

 Replacement bearing should be identical to original equipment to ensure proper internal clearance.

 Housing bore out of round; housing warped; excessive distortion of housing; undersized housing bore.

 Check and scrape housing bore to relieve pinching of bearing; be sure pedestal surface is flat and shims cover entire area of pillow block base when applicable.

 Shaft out of line. noisy bearing  Insufficient clearance in bearing.

 Correct alignment and be sure shafts are coupled in a straight line.  Replacement bearing should be identical to original equipment to ensure proper internal clearance.

 Foreign matter acting as abrasive.

 Clean bearing housing and replace worn seals.

 Housing bore out of round; housing warped; excessive distortion of housing; undersized housing bore.

 Check and scrape housing bore to relieve pinching of bearing; be sure pedestal surface is flat and shims cover entire area of pillow block base when applicable.

 Shaft and other parts of bearing assembly distorted.

 Replace bearing, shaft and other parts as needed.

vibrating bearing  Enlarged housing bore causing spinning of outer ring in housing.

 Re-bore housing and press steel bushing in bore, then machine bore to correct size.

 Foreign matter acting as abrasive.   Unbalanced loading

unsatisfactory  Chip in bearing housing; insufficient clearance in bearing; Ball or roller performance dented from extreme loading.

 Clean bearing housing and replace worn seals.  Check balance of rotating parts and rebalance as needed.  Replace with OEM bearing; do not hammer on any part of bearing; clean housing and use fresh lube.

______________________________________________________________ A6474X332 VSSV/00 5.329

Troubleshooting ______________________________________________ Electrical System Table 11: Electrical system troubleshooting Probable cause

motor contact chatter  Low voltage

 Poor contact in control circuit.

 Broken shading coil. welding of motor contactor tips  Abnormal in rush current.

Test, check and/or remedy  Check supply voltage, especially during starting. Check coil voltage rating. Increase voltage or change coil rating as required.  Replace the contact or use holding-circuit interlock.

(3-wire control)  Replace magnet and armature assemblies.  Use the next larger size contactor or check for grounds, shorts or excessive motor current.

 Rapid jogging.

 Install larger device rated for jogging service.

 Insufficient contact pressure.

 Replace contacts and springs, check for contacts for abnormal wear or damage.

 Incorrect vacuum contactor gap.

 Use the over-travel gauge mounted on the front of the unit.

When the gap on the bottle goes below 0.010 inches, the unit should be replaced.   Check supply voltage to coil, especially for momentary voltage dip during starting.

 Low voltage preventing magnet from sealing.  Foreign matter preventing contacts from closing.

 Vibration in starter mounting.  Short circuit.

 Clean contacts with Freon. Contacts used at low current and voltage levels should be cleaned with Freon.  Insulate starter from shock and vibration.  Remove fault and check to be sure fuse or breaker size is correct.  For vacuum contactor: after a short circuit examine vacuum bottles, conductor bars, and cables for physical damage. Check overtravel on vacuum bottle.

_________________________________________________________________ 5.330 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

Trouble, symptom or cause

_____________________________________________ Troubleshooting Table 11 (continued): Electrical system troubleshooting Trouble, symptom or cause

Probable cause

chart contact life or  Filing or dressing. overheating of motor contactor  Interrupting excessively high currents.  

© BUCYRUS AMERICA, INC.

 Excessive jogging.

Test, check and/or remedy  Do not file silver contacts.

Rough spots or discoloration will not harm contacts or impair their efficiency.  Install larger unit. Check for grounds, shorts or excessive motor currents. 

 Install larger unit rated for jogging service.

 Short circuit or ground fault.

 Remove fault and check to be sure fuse or breaker size is correct.

 Loose connections in power circuit.

 Clean and tighten.

 Sustained overload.

 Check for excessive motor load current or install larger unit.

failure to pick-up and seal  Low voltage.

 Check system voltage and voltage dips during starting.

 Wrong coil or wrong connection.

 Check coil marking and wiring.

 Mechanical obstruction.

 With power off, check for free movement of armature and contacts.

 Coil open or overheated.

 Replace.

failure to drop out  Voltage not removed.

 Contacts welded.

open circuit  Mechanical damage.

 Check coil circuit or length of leads from supply voltage to coil. May be excessive.   See welding under contacts section.  Handle and store coils carefully.

______________________________________________________________ A6474X332 VSSV/00 5.331

Troubleshooting ______________________________________________ Table 11 (continued): Electrical system troubleshooting Probable cause

both cutter head motors do not  Three phase power not present at contactors. start

Test, check and/or remedy Check three phase input to contactors.

 Pump not running.

 Start pump.

 Failed control relay contacts.

 Check contacts

Cutter head motor start and stop switches, conveyor start switch, or pump start switch not working properly.

 Check for faulty switches.

 Overload relay.

 Check overload relays.

 Failed left cutter head motor contactor.

 Check contactor coil. Verify that contacts are free to move.

left cutter head motor starts but Auxillary contacts not closing. right cutter head motor does not   Time delay malfunction.    Failed vaccuum starter. 

Check contactor auxillary contacts and wiring.  Check coil and timed closed contacts and wiring.  Check contactor coil and contact tips and wiring.

both cutter head motors start but Problem with auxillary contacts. Check right cutter head motor contactor auxillary contacts and stop when pump start and cutter associated wiring. head start switches are released  Check overcurrent relays. Overcurrent relays.

_________________________________________________________________ 5.332 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

Trouble, symptom or cause

_____________________________________________ Troubleshooting Table 11 (continued): Electrical system troubleshooting Trouble, symptom or cause

Probable cause

Test, check and/or remedy

conveyor starts forward operation  Problem in holding circuit. but stops when conveyor start switch is released

 Check normally open conveyor forward auxiliary contact and associated wiring.

conveyor will not start in forward  Pump not running. or reverse. Contactor IS NOT pulling in contacts  Failed control relay contacts.

 Start pump.  Check contacts.

 Conveyor start and stop switches or conveyor forward/ reverse not working properly

 Check for faulty switches.

 Overload relay tripped/faulty/

 Check overload relays.

© BUCYRUS AMERICA, INC.

 Over current relay tripped/faulty.  Check over current relay.  Conveyor forward/reverse contactor failure.

 Check contactor coils. Verify that contacts are free to move.

conveyor will not start in forward  Three phase power is not present at contactors. or reverse. Contactor IS pulling in contacts  Contactor tips are damaged.

 Check three phase power input to the contactors.

conveyor operates in forward only  Reverse switch.

 Check that the Reverse switch is completing the circuit.

 Conveyor Forward auxiliary contacts.

conveyor operates in reverse only  Forward switch.  Conveyor Reverse auxiliary contacts.

 Check contactor tips.

 Verify that the conveyor forward auxiliary normally closed contacts have not failed to open.  Check that the Forward switch is completing the circuit.  Verify that the conveyor reverse auxiliary normally closed contacts have not failed to open.

______________________________________________________________ A6474X332 VSSV/00 5.333

© BUCYRUS AMERICA, INC.

Troubleshooting ______________________________________________

_________________________________________________________________ 5.334 Bucyrus – Model 25M0 Continuous Miner

_______________________________________________________________

Technical data

________________________________________________________________

________________________________________________________________

_________________________________________________________________

_______________________________________________ Technical data

Technical data This chapter contains the most important technical data on the 25M0 Continuous Miner. Further data can be found in the spare parts lists. At the end of this chapter you will find information on the bolt tightening torques, HFA fluids, greases, etc. Read this chapter through carefully and pay particular attention in particular to the safety instructions.

IMPORTANT! The technical data listed in this chapter is for stock machines only.

Customer specials may not be listed.

Components of the 25M0 Continuous Miner Technical data sheet

© BUCYRUS AMERICA, INC.

Note: All dimensions and rates are for a Miner with a 28” to 30” diameter cutter drum and 6” to 9” ground clearance. operating dimensions

Recommended mining range............................... approx. 38 - 76 in (965 - 1,219 mm) Maximum reach (w/ 9” ground clearance) ........... approx. 60 in (1,524 mm) Ground clearance ................................................ approx. 6 in (152 mm) with 3” lift kit installation ......................... approx. 9 in (229 mm) Length (rear bumper to bit tip) ......................... approx. 25 ft 2 in (7.77 m)

transport dimensions

Frame width (including rub rails) ......................... approx. 10ft 10 in (3.30 m) Overall length....................................................... approx. 35 ft 2 in (10.72 m) Weight (total)........................................................ approx. 105,000 lbs (47.6 metric tons)

cutter unit

dust suppression (optional)

Cutter drum diameter ........................................... approx. 28 - 30 in (711 - 762 mm) Cutter drum width................................................. approx. 12 ft (3.66 m) Cutter drum (continuous rating) ........................... 2X175 HP/130kW

Scrubber type....................................................... Wet bed Scrubber capacity ................................................ 4,500 cfm @10HP (2.1 cms @7 kW)

______________________________________________________________ A6474X332 VSSV/00 6.3

loading unit

Loading method ..........................................................4 finger CLA Conveyor width ...........................................................approx. 36 in (914 mm) Conveyor speed approx. 468 fpm (143 m/min) Conveyor depth...........................................................4 - 6 in (102 - 152 mm) Loading capacity .........................................................10 - 12 tpm (9 - 10 tones/min) Horse power On conveyor (continuous rating) ..........................2X40 HP (30kW) Through CLAs (one hour rating)...........................2X50 HP (37kW)

traction unit

Crawler chain width.....................................................20 in (508 mm) Crawler assembly length.............................................9 ft 7 in (2.92 m) Ground pressure .........................................................22 psi (152kPa) Crawler speed.............................................................0 - 85 fpm (0 - 26 m/min) Traction horse power Continuous rating .................................................2X50 HP (37 kW DC) One hour rating.....................................................2X60 HP (45 kW DC)

electrical system

Machine voltage..........................................................950 VAC Control system ............................................................Processor based/ radio remote control

hydraulic system

Hydraulic pump unit Tandem gear pump ..............................................3,200 psi (220 bar) Horse power Continuous rating...........................................1X40 HP (30 kW) One hour rating ..............................................1X50 HP (37 kW)

total installed horse power

Continuous rating (without scrubber)..........................570 HP (425 kW) One hour rating (without scrubber) .............................670 HP (500 kW)

_________________________________________________________________ 6.4 Bucyrus – Model 25M0 Continuous Miner

© Bucyrus America, Inc.

Technical data ________________________________________________

___________________________________________ Tightening torques Tightening torques IMPORTANT! Due to the application of fasteners being subject to great stresses and heavy or extreme vibration, it is imperative that all bolts be applied with an adequate amount of torque. For this reason this list of recommended torque settings for different types and sizes of fasteners used has been compiled. The tightening torques stated in the spare parts lists have to be observed, as well, for installation and maintenance.

IMPORTANT! Use a calibrated torque wrench for accuracy!

© BUCYRUS AMERICA, INC.

Table 17: Hex head bolts, Grade 8 (calculated at 75% proof load) Bolt size

Recommended torque setting (ft-lbs) (dry)

Recommended torque setting (ft-lbs) (wet)

1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1 1-1/8 1-1/4 1-3/8 1-1/2 1-3/4 2 2-1/4 2-1/2 2-3/4 3 3-1/4 3-1/2 3-3/4 4

12 25 44 70 107 154 212 376 606 909 1287 1875 2382 3161 4988 7500 10969 15000 17794 23507 30286 38266 47545 58100

6 12 22 35 53 77 106 188 303 454 644 938 1191 1581 2494 3750 5484 7500 8897 11753 15143 19133 23773 29085

______________________________________________________________ A6474X332 VSSV/00 6.5

Tightening torques ____________________________________________

Bolt size

#10 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1 1-1/8 1-1/4 1-3/8 1-1/2 1-3/4 2

Recommended torque setting (ft-lbs) (dry) 72 in-lb 180 in-lb 31 54 87 132 184 254 452 727 1090 1546 2181 2858 3794 5983 8994

Recommended torque setting (ft-lbs) (wet) 48 in-lb 120 in-lb 240 in-lb 35 56 86 120 165 293 473 709 1005 1417 1858 2466 3889 5846

_________________________________________________________________ 6.6 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

Table 18: Socket head bolts, Grade 8 (calculated at 75% proof load)

___________________________________________ Permissible media Permissible media Lubrication fluids and greases

© BUCYRUS AMERICA, INC.

NOTICE! Use only lubrication fluids and greases approved by Bucyrus America, Inc. ! These fluids and greases have been tested at Bucyrus America, Inc. and guarantee reliable operation of the mechanical and hydraulic functions of the machine.

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

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

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

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

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

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

IMPORTANT! As lubrication technology evolves, manufacturers continue to reformulate their products to obtain improved characteristics regarding wear, water dispersion, water absorption, environmental impact and a variety of other performance criteria. When an approved lubricant on this list has been superseded by a new formulation, it is recommended that the new formulation be tested to ensure compliance with the appropriate Bucyrus specification. At a minimum, a statement of conformance from the lubricant supplier should be obtained.

_____________________________________________________________ A6474X332 VSSV/00 6.7

Permissible media ____________________________________________ Approved lubricants

Supplier

Brand name

1

Amoco Oil Company

Amoco AW Oil No.68

2

Gulf Oil

Harmony 68 AW

3

Mobil Oil Corporation

Mobil DTE-16

4

Chevron U.S.A.

5

Sun Oil Company

Chevron Hydraulic Oil Aw ISO 68 Sunvis 868

6

Unocal 76

Unax AW 68

7

Shell Oil Company

Shell Hydraulic Oil #33

8

Century (Fuchs)

Hydraulic AW 68

9

Atlantic Richfield Company

Duro AW S-315 Oil

10

Texaco Lubricants Company

Texaco Rando Oil HD 68

11

Exxon

Nuto 68

12

Pennzoil

Pennzbell AW 68 Hydraulic Oil

13

14

Standard Oil Company Standard Oil Co. of Ohio Boron Oil Company BP Oil Inc. Lubricating Engineers

Industron 54 Industron 53 Energol HLP-C68 6120 Monolec Hydraulic Oil

15

Conoco Inc.

Super Hydraulic oil 68

16

Hydrotex

Systems 5K 68

17

Phillips

Maginus A Oils 81350

18

Miners Oil

Hydraulic Oil 68AW

_________________________________________________________________ 6.8 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

Table 19: Anti-wear hydraulic oil (Spec 100-1)

___________________________________________ Permissible media Approved lubricants

© BUCYRUS AMERICA, INC.

Table 20: Extreme pressure gear oils (Spec. 100-2) Supplier

Brand name

1

Amoco Oil Company

Amoco Permagear EP 460

2

Gulf Oil

EP Lubricant HD 460

3

Mobil Oil Corporation

4

Chevron U.S.A.

5

Sun Oil Company

Mobil Gear 634 Mobil Gear 636 Chevron Gear Compound EP ISO 460 Sunep 460

6

Unocal 76

7

Shell Oil Company

8

Century (Fuchs)

9 10

Texaco Lubricants Company Exxon

11

Pennzoil

12

Lubricating Engineers

13

Conoco Inc.

14

Hydrotex

15

Phillips

16

Miners Oil

Extra Duty NL Gear Lube 7 EP Extra Duty NL Gear Lube 8 EP Shell Omala 680 Hulbest EP-7 Powergear 460 Meropa 680 Spartan EP 460 Super Maxol EP 460 Gear Lube Super Maxol EP 460 Gear Lube 608 Almosal Vari-Purpose Gear Lubricant Gear Oil 460 933 Industrial Gear Lubricant All Purpose Gear Oil 85W-90 5EP Gear Oil EP460

_____________________________________________________________ A6474X332 VSSV/00 6.9

Permissible media ____________________________________________ Approved lubricants

1

Supplier Amoco Oil Company

2 3 4

Gulf Oil Mobil Oil Corporation Chevron U.S.A.

5 6 7 8

Sun Oil Company Unocal 76 Shell Oil Company Century (Fuchs)

9 10 11 12

Texaco Lubricants Company Exxon Pennzoil Lubricating Engineers

13

Conoco Inc.

14 15 16

Hydrotex Phillips Atlantic Richfield

Brand name Amolith Grease 2 EP Rykon Premium Grease 2 EP Gulfcrown Grease EP#2 Mobilux EP-2 Chevron Dura-Lith Grease EP-2 NLGI 2 Sun Prestige 742EP Multiplex EP2 Alvania EP-2 Hullith EP2 Multipurpose Grease or Replex2 or Uniwrl 2 or Uniwrl EMB or Hullith GP 2 or Hullith EP 2 Texaco Multifak EP 2 Lidok EP 2 Pennlith EP 712 Grease 3752 Almagard Vari-Purpose Lubricant EP Conolith grease No. 2 or Super Sta Grease No. 2 LC-65 Hyplex Philube EP Grease Litholine H EP-2 Grease

Approved lubricants Table 22: Semi-fluid grease (Spec. 100-4) 1 2 3 4 5 6

Supplier Texaco Lubricants Company Century (Fuchs) Hydrotex Pennzoil Unocal Exxon

Brand name Novatex EP 000 Joy Loader Semi-Fluid grease MPD-60 Ultra E.P. 000 Semi-Fluid 760 Grease MM Grease Lidok E.P. 000

_________________________________________________________________ 6.10 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

Table 21: Lithium based general lubrication grease (Spec. 100-3)

___________________________________________ Permissible media Approved lubricants Table 23: Invert emulsion hydraulic fluid (Spec. 100-5) 1 2 3 4

Supplier Unocal 76 Conoco Inc. Atlantic Richfield Company Brooks Oil Company

5 6

Cincinnati – Vulcon Company Cities Service Oil Company

7 8

Century (Fuchs) Fiske Bros. Refining Company Getty Oil company (Veedol, Tidewater) Gulf Oil Company E.F. Houghton

9

© BUCYRUS AMERICA, INC.

10 11 12 13 14 15 16 17 18 19 20 21

Century (Fuchs) Imperial Oil and Grease Mobil Oil Corporation National Oil and Chemical Co. Pennzoil Quaker Chemical Company Henery E. Sanson and Sons MFGE Company Southwest Grease and Oil Company, Inc. Southwest Petroleum Corp.

22 23

Standard Oil Company of Ohio (Boron Sohio) Sun Oil Company Tower Oil Company

24 25

Wynn Oil Company Lubrication Engineers

26

Hydrotex

Brand name FR Fluid FR Hydraulic Fluid Duro FR-HD Brooks Fire Resistant Hydraulic Fluid B Vulcon FR Fluid #1 Citgo Pacemaker Invert FR Fluid Aquacent Light Lubriplate HO-Retard Veedol Auburn FRH FR Fluid Houghto-Safe 5046 Houghto-Safe 5046W Hulsafe 600 Astrol 587 Pyrogard D Erifon 1, 2, and 3 Maxmul FRP/G Quintolubric 958 Series Quintolubric 958 Series Hydra-Mul Premium Emulsion Fluid Invert Emulsion Fire Resistant Hydraulic Fluid Swepco Fire Resistant Hydraulic Oil #718 Staysol FR

Sunsafe F Safoil Anti-Wear Hydraulic Fluid Hydra-Safe Heavy Medium 6455 Monolec Fire Resistant Hydraulic Fluid HY-Guard

_____________________________________________________________ A6474X332 VSSV/00 6.11

Permissible media ____________________________________________ Approved lubricants

1

Supplier Amoco Oil Company

Brand name Amoco Premagear EP 320

2

Gulf Oil

EP Lubricant HD 320

3

Mobil Oil Corporation

Mobil Gear 632

4

Chevron U.S.A.

5

Sun Oil Company

Chevron Gear Compound EP ISO 320 Sunep 320

6

Unocal 76

Extra Duty NL Gear Lube 6EP

7

Shell Oil Company

Omala 75

8

Century (Fuchs)

Hulbest EP-6

9

Texaco Lubricants Company

Meropa 320

10

Exxon

Spartan EP 320

11

Pennzoil

Super Maxol EP 220 Gear Lube

12

Lubricating Engineers

13

Conoco Inc.

605 Almasol Vari-Purpose Gear Lubricant Gear Oil 320

14

Hydrotex

932 Industrial Gear Lube

15

Phillips

16

Atlantic Richfield

Philube All Purpose Gear Oil 85W-90 Pennant NL S-1000

17

Cities Service

Citgo EP Compound 110

18

Pennzoil

Pen Gear #320

19

Miner Oil

Gear Oil EP220

20

Texaco, Lubricants Company

Texaco Multigear EP 80W-90

_________________________________________________________________ 6.12 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

Table 24: Extreme pressure gear oil, SAE 90 (Spec. 100-6)

___________________________________________ Permissible media Approved lubricants

© BUCYRUS AMERICA, INC.

Table 25: Medium-Heavy hydraulic and general purpose oil R&O inhibited (Spec. 100-7) 1

Supplier Amoco Oil Company

Brand name American Industrial Oil No. 68

2

Gulf Oil

Harmony 68

3

Mobil Oil Corporation

DTE Heavy – Medium

4

Chevron U.S.A.

5 6

Sun Oil Company Unocal 76

7

Shell Oil Company

Chevron Turbine Oil ISO 68 or Chevron Machine Oil R&O ISO 68 Sunvis 754 Unax RX68 or Turbine Oil 68 Turbo 68

8

Century (Fuchs)

Centraulic R&O 68

9

Texaco Lubricants Company

Regal Oil R&O N-68

10

Exxon

Tresstic 68

11

Pennzoil

Pennzbell RO 68

12

Lubricating Engineers

6120 Monolec Turbine Oil

13

Conoco Inc.

14

Hydrotex

Detol R&O 68 or Turbine Oil 68 Systems 1, System 5K 68

15

Atlantic Richfield

Duro 5.315

16

Cities Service

Citgo Pacemaker A/W68

17

Miner Oil

Hydraulic Oil AW68

18

Texaco, Lubricants Company

TDH 1893

_____________________________________________________________ A6474X332 VSSV/00 6.13

Permissible media ____________________________________________ Approved lubricants

Supplier

Brand name

1 2 3 4

Amoco Oil Company Gulf Oil Mobil Oil Corporation Chevron U.S.A.

5 6

Sun Oil Company Unocal 76

7 8 9

Shell Oil Company Century (Fuchs) Atlantic Richfield Company

10 11 12 13 14 15 16 17 18

Texaco Lubricants Company Exxon Pennzoil Cities Service Lubrication Engineers Conoco Inc. Hydrotex Phillips Miner Oil

American Industrial Oil No. 150 Harmony 150 DTE Oil EX. Heavy Chevron Machine Oil AW ISO 150M or Chevron Machine Oil R&O ISO 150 Sunvis 961 Unax RX 700 or Turbine Oil 700 Turbo 150 Centraulic R&O 150 Duro 600 or S-700 Regal Oil R&O 150 Teresstic 150 Pennzbell RO 150 Citgo Pacemaker 150 6405 Monolec Turbine Oil Dectol R&O 76 System 1 150, System 5k 150 Magnus Oils 700 ISO 150

Approved lubricants Table 27: Worm gear lubricant, compounded cylinder oil (Spec. 100-9) Supplier

Brand name

1 2 3

Amoco Oil Company Mobil Oil Corporation Chevron U.S.A.

4 5

Sun Oil Company Unocal 76

6 7 8 9 10 11

Century (Fuchs) Atlantic Richfield Company Texaco Lubricants Company Exxon Pennzoil Conoco Inc.

Cylinder Oil No. 1000 Extra Hecla Super Cylinder Oil Chevron Cylinder Oil W ISO 1000 Sun Steam Cylinder Oil Worm gear Lube 250 or Stevalc Garwal 680 Modoc 195 650 T Cylinder Oil 1000 Cylesstic TK-1000 Cylinder Oil #1000 Inca Oil 1000

_________________________________________________________________ 6.14 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

Table 26: Heavy hydraulic and general purpose oil/R&O inhibited (Spec. 100-8)

___________________________________________ Permissible media Approved lubricants

© BUCYRUS AMERICA, INC.

Table 28: Light gear oil, SAE 40 motor oil (Spec. 100-10) 1 2 3 4

Supplier Amoco Oil Company Gulf Oil Mobil Oil Corporation Chevron U.S.A.

5 6 7

Sun Oil Company Unocal 76 Shell Oil Company

8 9 10

Century (Fuchs) Texaco Lubricants Company Exxon

11 12 13

Pennzoil Lubricating Engineers Conoco Inc.

14 15

Hydrotex Phillips

Brand name Amoco 300 SAE 40 Super Duty 40 Delvac 1340 Chevron RPM Heavy Duty Motor Oil 15W-40 Sunoco Super C 40 Guardol Motor Oil SAE 40 Rotella Oil 40 (Automotive) Turbo Oil 150 (Industrial) Rimula CT40 (Foreign) Rotela SX40 (Foreign) Flexe SAE 40 Ursa Super Plus SAE 40 XD-3 Extra SAE 40 or XD-3 SAE 40 Long Life SAE 40 Motor Oil 8440 Monolex GFS Engine Oil Fleet Heavy Duty Motor Oil SAE 40 Hyfilm SAE 40 Super HD II Motor Oil SAE 15W-40

Approved lubricants Table 29: Synthetic EP gear lubricants (Spec. 100-11) 1

Supplier Century (Fuchs)

Brand name Synthetic EP Gear Lubricants

Approved lubricants Table 30: Multi-purpose tractor hydraulic fluid (Spec. 100-12) 1 2 3 4

Supplier Exxon / Mobil Century (Fuchs) Shell Chevron

Brand name Mobilfluid 424 Multitran Donax TD Tractor Hydraulic Fluid

5 6 7

BP Lubricants Quaker State Conoco

Tractran UTH Quaker State FCI HD Powertran Fluid

_____________________________________________________________ A6474X332 VSSV/00 6.15

Permissible media ____________________________________________ Approved lubricants Table 31: High emulsibility extreme pressure gear oil (Spec. 100-13) 1

Supplier Century (Fuchs)

Brand name Powergear H680

Approved lubricants Table 32: High temperature synthetic lithium complex grease (Spec. 100-14)

1

Supplier Mobil

Brand name Mobilith SHC 100

Approved lubricants

1

Supplier Conoco

Brand name GLW Gear Oil 220

_________________________________________________________________ 6.16 Bucyrus – Model 25M0 Continuous Miner

© BUCYRUS AMERICA, INC.

Table 33: High demulsibility extreme pressure gear oil (Spec. 100-15)

_______________________________________________________________

For your information

________________________________________________________________

________________________________________________________________

_________________________________________________________________

_________________________________________________ Our service

For your information Our service If you need to order spare parts or if technical problems occur, please contact our after-sales service personnel or contact us direct.

© BUCYRUS AMERICA, INC.

Service address Beckley, WV 351 Ragland Road Beckley, WV 25801 Phone: (304) 256-5927 Fax: (304) 256-5928

Craig, CO 400 Mack Lane Craig, CO 81625 Phone: (970) 824-3249 Fax: (970) 824-8851

Pulaski, VA 4041 Wurno Road Pulaski, VA 24301 Phone: 540-980-4530 Fax: 540-980-6211

Washington, PA 255 Berry Road Washington, PA 15301 Phone: (724) 743-1200 Fax: (724) 228-2177

Duffield, VA P.O. Box 847 6808 Fraley Avenue Duffield, VA 24244 Phone: (276) 431-7000 Fax: (276) 431-2464

Houston, PA 2045 West Pike Street Houston, PA 15342 Phone: (724) 743-1200 Fax: (724) 743-1201

Carrier Mills, IL 9580 State Route 13 West Carrier Mills, IL 62917 Phone: (618) 982-9000 Fax: (618) 982-9912

Oak Hill, WV P.O. Box 60 843 Lochgelly Road Oak Hill, WV 25901 Phone: (304) 469-3302 Fax: (304) 465-0450

Paonia, CO P.O. Box 566 719 Second Street Paonia, CO 81428 Phone: (970) 527-3151 Fax: (970) 527-6846

______________________________________________________________ A6474X332 VSSV/00 7.3

Our service __________________________________________________ Rebuild facility address Huntington, UT P.O. Box 1190 Route 10, 1Mile North Huntington, UT 84528 Phone: (435) 687-9831 Fax: (435) 687-2522

Norris City, IL 635 Illinois Highway 1 Norris City, IL 62869 Phone: (618) 378-3441 Fax: (618) 378-3106

© Bucyrus America Inc.

Pearisburg, VA P.O. Box 463 222 Industrial Park Drive Pearisburg, VA 24134 Phone: (540) 921-2111 Fax: (540) 921-2711

_________________________________________________________________ 7.4 Bucyrus – Model 25M0 Continuous Miner

Forced Potato TITO Remote Console (Bucyrus 25M Miner Version)

Operator’s Manual Issue: KN5602.C

Forced Potato Mining Electronics

Contents Contents ............................................................................................... 2 Preface ................................................................................................. 3 Introduction ........................................................................................... 4 Notice ............................................................................................ 4 Safety Notice ........................................................................................ 5 What’s New........................................................................................... 6 Remote Control Battery Charger .......................................................... 8 Remote Control Diagnostics ............................................................... 11 Notice .......................................................................................... 12 User Setup .......................................................................................... 13 Password Entry ........................................................................... 13 Options ........................................................................................ 14 1. Radio Channel ....................................................................... 15 2. Radio Timeout ....................................................................... 15 3. Tilt Switch .............................................................................. 16 4. ID Number ............................................................................. 16 5. Saving Changes .................................................................... 17 Maintenance ....................................................................................... 18 Inspection Frequency .................................................................. 18 Factory Service Frequency ......................................................... 18 Tools ............................................................................................ 19 Disassembly ................................................................................ 20 Cleaning ...................................................................................... 21 Reassembly ................................................................................. 22

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Forced Potato Mining Electronics

Preface This document is intended to provide reference to the Type KN Remote Console. This version of the TITO remote console has been developed for operation of Bucyrus continuous miners.

Forced Potato Inc. 640 Bizzell Drive Lexington, KY 40510 Telephone: +859 252 4439 Fax: +859 252 4641 Web: www.forcedpotato.com © Forced Potato Inc. Other than is permitted by law, no part of this document may be reproduced, stored in a retrieval system or transmitted in any form or process without prior written consent of Forced Potato Inc. Every effort has been made to ensure the accuracy and correctness of the information presented within this document. However, Forced Potato does not provide guarantee of its correctness or accuracy.

Other than is required by law, no warranty of any kind is expressed or implied.

Copies of this manual, and other documentation pertaining to Forced Potato control system products, may be obtained by contacting Forced Potato directly.

For all matters involving servicing or purchase of Forced Potato control system components used with machinery manufactured by Bucyrus, please contact your Bucyrus representative or local Bucyrus service center.

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Forced Potato Mining Electronics

Introduction The Type L0KN Remote Console (RC) is a self-contained battery powered remote control that has been specifically designed to provide a safer, more efficient means of operating mining machinery.

Notice This manual includes information specific to the following part: Part# L0KN5602

Description Bucyrus UHF

If this manual does not correspond to your equipment’s part number, please contact Forced Potato Inc. immediately to obtain a copy of the correct publication.

To obtain service of your TITO L0KN56 model remote control handset please contact your local Bucyrus representative or service center.

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Forced Potato Mining Electronics

Safety Notice The advent of remote control has afforded the operator a notable improvement in personal safety. However, the potential for injury or fatality still exists when operating heavy machinery remotely.

Thus, it is expressly important that the operator observe safe work practice when operating a remote control mining machine. This will be defined by mine management and should encompass MSHA recommendations where applicable.

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Forced Potato Mining Electronics

What’s New The Type KN Remote Console has been designed to meet the requirements of AS4240 / MDG5001. These requirements compel a number of design variations over existing equipment manufactured by Forced Potato Inc.

•

Size Whilst a similar physical layout has been retained to support transparent integration, the overall size has grown to support control spacing standards as specified by AS4240.

•

Visual Diagnostics A highly efficient LED display has been integrated to facilitate operating diagnostics. Information such as operating frequency, power and general operating status is available at all times.

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Forced Potato Mining Electronics •

Battery To improve operational readiness, a larger battery pack has been incorporated which affords a minimum 20 hours of continuous remote control operation.

•

Tilt Monitoring Dual tilt switches have been installed to allow detection of the angle of inclination relative to the horizontal plane. This feature can be enabled or disabled via the User Setup Options on the Remote Control Battery Charger. By default, this option is disabled.

•

Safety The most important design addition is single electrical fault tolerance. By incorporating dual-pole switch architecture and a new approach to switch sampling, a high level of fault tolerance has been achieved.

The KN56 TITO remote console also features a push-button stop button. This push-button makes the device compliant with MSHA P03-3 recommendations.

•

Ergonomics In an effort to improve operator comfort, stylish comfort knobs have been added to the most commonly used functions – traction and shear. These are entirely optional and can be removed if required.

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Forced Potato Mining Electronics

Remote Control Battery Charger Connect the Remote Control Battery Charger to your mains power outlet. During initial power-up, the firmware release information is displayed for 10 seconds.

After this period, the charger will then display the main screen which details the charge status.

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Forced Potato Mining Electronics Diagnostics The Remote Control Battery Charger permits the operator to verify that all switches are operating as expected. Similarly, it provides a secondary means of determining the operating frequency.

Power Up Turn the RC on by asserting and holding the ON [SHIFT] key for twoseconds. This startup requirement has been introduced to reduce the likelihood of incidental activation.

After the two-second period has expired, the RC will show the operating frequency via the LED display. The available operating frequencies for the L0KN5602 (Bucyrus UHF) are as follows: Indicated Frequency UHF1 UHF2 UHF3 UHF4 UHF5 UHF6 UHF7 UHF8

Actual Frequency 458.500MHz 458.525MHz 458.550MHz 458.575MHz 458.600MHz 458.625MHz 458.650MHz 458.675MHz

TITO Remote Console – Operator’s Manual Issue: KN5602.C

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Forced Potato Mining Electronics The Remote Control Battery Charger continually scans all 8 channels in an attempt to recognize a supported RC. On average, the Remote Control Battery Charger requires approximately 4 seconds to acquire a signal.

Upon detecting a valid signal, an identification screen is displayed for three seconds to allow classification of the type and frequency of the operating RC.

After this period has expired, the diagnostic screen is displayed.

Operators should be satisfied that all key functions operate as expected prior to taking the equipment underground. Similarly, operators should verify that the operating frequency corresponds to that displayed on the RC – See the Frequency Table on the previous page.

TITO Remote Console – Operator’s Manual Issue: KN5602.C

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Forced Potato Mining Electronics

Remote Control Diagnostics The RC supports a number of inbuilt diagnostics to aid operation. The following table details each of these messages and their implication.

Message UHF1, UHF2, UHF3, UHF4, UHF5, UHF6, UHF7, UHF8 ON

Meaning Operating on Frequency 1, 2, 3, 4, 5, 6, 7 or 8

ON

Power is ON and a command is being sent to the machine.

(Flashing)

Power is ON

OFF

Powering down whilst issuing PUMP OFF command.

STOP

Radio Stop Activated

TILT

The RC’s angle of inclination is beyond 45° relative to horizontal. The STOP command is issued continuously until the unit is righted.

The internal battery is low with and expected remaining operating time of approximately 30 minutes.

Indicating possible service requirements, a fault condition has been detected.

LOW (Flashing) SERV

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Forced Potato Mining Electronics

Notice The SERV message is displayed when a fault condition has been detected. There are a number of problems that can generate this fault and most of these would typically require the unit to be submitted for factory service.

However, this condition can be triggered if the operator asserts switches prior to turning the unit ON. If switches other than those allocated to User Setup are asserted prior to power up, it is assumed that these switches are faulty, consequently resulting in automatic power down.

TITO Remote Console – Operator’s Manual Issue: KN5602.C

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Forced Potato Mining Electronics

User Setup The RC supports a number of user programmable options that can be adjusted via the Remote Control Battery Charger. To engage User Setup and with the RC turned off, assert the following keys, in sequence, for two seconds: Assert Assert Assert

CONVEYOR ► SHEAR UP ON [SHIFT]

The RC will display SET on its LED display to indicate that User Setup has been selected.

Password Entry When the Remote Control Battery Charger has acquired the signal, the following password entry screen is displayed:

The password FORCED must be entered before access to User Setup is granted.

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Forced Potato Mining Electronics To enter characters, use the following keys: To change a character: Assert CONVEYOR UP or CONVEYOR DOWN To change cursor position: Assert CONVEYOR ► or CONVEYOR ◄ To check the password: Assert ON [SHIFT] After entering the password, assert ON [SHIFT] to gain access to the System Menu.

Options There are five menu options available to the end user. To navigate the system menu, see the following:

To change the menu option: Assert CONVEYOR ► or CONVEYOR◄ To engage or leave the menu option: Assert ON [SHIFT] To change the option value: Assert CONVEYOR UP or CONVEYOR DOWN

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Forced Potato Mining Electronics

1. Radio Channel

There are 8 selectable channels available to the end-user. This allows the mine to support multiple machines.

2. Radio Timeout

The RC supports a timeout that automatically powers the unit down if there is no switch activity after a defined period of time. A selectable range of between 2 and 60 minutes can be chosen.

TITO Remote Console – Operator’s Manual Issue: KN5602.C

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Forced Potato Mining Electronics

3. Tilt Switch

To support AS4240 requirements, dual tilt switches which detect the angle of inclination have been installed. If this option is enabled, the RC will automatically issue the Radio Stop command until the unit is righted upon detecting tilt motion beyond 45° relative to horizontal. (The LED display will show TILT as a diagnostic response.) After being righted, power is automatically removed.

Importantly, a 250ms timer acts to filter our mild impacts to compensate for the effects of inertia. This is an essential requirement when Tilt Monitoring is enabled.

4. ID Number

Each Remote Console is programmed with its respective serial number upon leaving the factory. This feature is not accessible to the end user and is password protected.

TITO Remote Console – Operator’s Manual Issue: KN5602.C

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Forced Potato Mining Electronics

5. Saving Changes

To save changes to the setup, you must select the EXIT & SAVE option and assert ON [SHIFT]. To abort changes to the setup, you can simply turn the RC OFF.

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Forced Potato Mining Electronics

Maintenance The maintenance required for Remote Consoles is basically limited to assembly, cleaning & inspection. Coal dust and other particulate deposits foul switch operation and can eventually lead to premature seal failure if not regularly expunged.

Inspection Frequency The following routines should be undertaken daily.

•

Determine if cleaning and disassembly is necessary. Onsite conditions should be used to determine the regularity of this procedure. If cleaning is required, see the following pages.

Typically, cleaning on a weekly basis is sufficient.

•

Perform a functional test on the Remote Control Battery Charger.

Factory Service Frequency Factory Service of this equipment is required 12-months from the date of dispatch with an allowance of 1-month for logistics.

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Forced Potato Mining Electronics

Tools Forced Potato Inc. recommends that the Maintenance Accessory Kit be acquired (or similar) to aid systematic maintenance. A maintenance kit is available which includes the following parts: Allen Hex Set

Allen ⅝″ Socket

Multi-Bit Precision Torque Driver

Field Part Replacements

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Forced Potato Mining Electronics

Disassembly • • • • •

Remove the M3 bolts.

Remove the switch guard.

Remove the switch caps.

Remove the comfort knobs by loosening the grub screw.

Remove the engraved plate.

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Forced Potato Mining Electronics

Cleaning • • •

•

Expunge heavy debris from the switch assembly with a Soft Bristle Cleaning Brush.

Wash the transmitter with warm soapy water.

Inspect the switch seals for signs of deterioration. Seals exhibiting wear require the equipment to be scheduled for factory service.

Note: these seals are the primary seal, a secondary seal within the switch itself and an internal neoprene seal operate as a barrier to moisture ingress.

Dry the transmitter with light compressed air or cloth.

Important Do not use caustic solvents or displacement solutions as this may cause premature seal failure.

Do not use metal implements to dig out coal, mud or soapstone that may be found in the charge receptacle.

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Forced Potato Mining Electronics

Reassembly • •

• • • •

Ensure all switch seals are tight. If a seal appears loose, tighten the seal to the recommended torque of 2.5Nm. Ensure all switch plate M2 bolts are tight. If an M2 bolt appears loose, tighten the bolt to the recommended torque of 1.5Nm. Do NOT over tighten these bolts as this may break the enclosure seal.

Install the engraved plate.

Install the comfort knobs as depicted. Tighten the grub screw to the recommended torque of 2.5Nm. Install the switch caps Install the switch guard. Tighten the switch guard M3 bolts to the recommended torque of 2.5Nm.

After reassembly, test the unit on the Remote Control Battery Charger to verify operation.

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Forced Potato Mining Electronics

B

O

Battery · 7

Options · 14

C

P

Cleaning · 21

Password Entry · 13 Power Up · 9 Preface · 3

D Diagnostics · 9 Disassembly · 20

E Ergonomics · 7

I Introduction · 4

R Radio Channel · 15 Radio Timeout · 15 Reassembly · 22 Remote Control Battery Charger · 8 Remote Control Diagnostics · 11

S Safety · 7 Safety Notice · 5 Size · 6

M Maintenance · 18

N

T Tilt Monitoring · 7 Tilt Switch · 16, 17 Tools · 19

Notes on “SERV” · 12 Notice · 4

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Forced Potato Mining Electronics

U

W

User Setup · 13

What’s New · 6

V Visual Diagnostics · 6

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