CLICK HERE TO DOWNLOAD THE COMPLETE MANUAL
• Thank you very much for reading the preview of the manual.
• You can download the complete manual from: www.heydownloads.com by clicking the link below
• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.
CLICK HERE TO DOWNLOAD THE
ThismanualisintendedtoprovideGENERALproductinformationfor theModel30M3LContinuousMiner.Theillustrations,descriptionsand procedurescontainedinthispublicationapplyonlytoTHISmachine. BucyrusAmerica,Inc.reservestherighttorevisemodelsanddesigns withoutpriornotice.
ThisContinuousMinerwasmanufacturedundertheguidelines,proceduresandrequirementsoftheU.S.FederalCoalMineHealthand SafetyAct,CodeofFederalRegulations,Title30,Chapter1,Subpart0, Part75forundergroundcoalmines,andotherapplicablenon-U.S. regulatoryagencystandards.
Atthecompletionofthemanufacturingprocess,thisunitwasissuedthe appropriateapprovalnumbersandnameplatesindicatingitmetthe technicalrequirementsoftheseregulatoryagencies.Anychangetothe designorstructureofthisunit,withouttheconsentofBucyrusAmerica, Inc.andtheseregulatoryagencies,oranyrepairorreplacementof partscontrarytoBucyrusAmerica,Inc.’sinstructions,mayinvalidate theseapprovalsandrenderthisunitunsafetooperate.
StrictcompliancewithallFederalandStateMininglaws,regulations andpracticesregardingthesafeoperationandmaintenanceofundergroundminingequipmentandstrictadherencetotheinstructionsinthis manualisnecessaryforthepersonalsafetyofthoseworkingonor aroundthisunit.
Whilethismanualattemptstoanticipatethemostimportantoperations andmaintenanceneedsforthisunit,unforeseencircumstancesmay arisethathavenotbeenaddressedinthismanual.Ifanyconcernsor questionsarise,pleasecontactyourBucyrusAmerica.Inc.Service Representative immediately
Thisworkcontainsinformationprotectedundertradesecretandother intellectualpropertylaws,andisprotectedundertheU.S.Copyright Actof1976,asamended.Thisworkisprovidedunderlicenseandthe licenseisnon-transferable.Distributionandaccessislimitedonlyto authorizedpersonnel.Disclosure,reproduction,distributionorunauthorizedusemaybeaviolationoffederalandstatelawsandmaysubjecttheunauthorizedusertocriminalliability.
2. Yoursafety 3. Aboutthismanual Aboutthismanual Thischapterprovidesimportantinformationmakingiteasierforyouto usethismanual.Itcontainsinformationonthestructureofthemanual andthesymbolsandcharactersused.
Beforestartingtowork applicableoperatingmanual
machinetype
newoperationmanual
Takecaretoensurethattheoperatingmanualavailabletoyouisapplicableforthetypeofequipmentormachineused.
Thisoperatingmanualisintendedfor: BucyrusModel30M3LContinuousMiner
andisonlypermittedtobeusedforequipmentofthistype.
Theoperatingmanualmustbeaccessibleatalltimestoallpersons workingonorwiththemachine.Itshould,ifpossible,alwaysbeavailableattheplaceofoperation.
Sendforanewoperationmanualimmediatelyifthepresentmanualis nolongercompleteorhasbecomeillegible.
Whoisthisoperatingmanualintendedfor? Thisoperatingmanualisintendedforthosepersonswhoworkwithor onthemachine.Everypersonworkingonthefaceorintheintersectionbetweenfaceandentryorintheentrymustreadthisoperating manual.
Thisincludespersonswho:
■ operatethemachine
■ areinchargeoftransport
■ performassembly/disassemblywork
■ find/fixfaults
■ performdailyroutineworkatthefaceorintheentry
■ performmaintenancework
■ performrepairwork
supervisorypersonnelwho:
■ initiateand/orsupervisetheactivitiesjustindicated.
Beforestartingtowork Whatisthepurposeofthisoperatingmanual? Thisoperatingmanualisintendedtohelpyouworkefficientlyand safelywithourproduct.Itcontainsimportantinformationonalltheactivitiesrelatedtothemachine.
Readthisoperatingmanualcompletelyandatease.Payspecialattentiontothesafetyinstructions.Trytomemorizetheappearanceandthe meaningofthesafetyandinstructionsymbols.
Ifanydetailsarenotclearlyunderstood,pleasecontactourservicedepartment.Ourserviceaddressisgiveninthechaptertitled“Foryour information”.
Readthechapter“Foryoursafety”withspecialattention.Thechapter containsimportantinformationindicatingpossiblehazards.Observe theinformationgivenandfollowtheproceduralinstructions.
Charactersandsymbolsused Thefollowingcharactersandsymbolsareusedforsafetyinstructions andimportantinformationintheoperatingmanual.
Trytomemorizethesymbolsandtheirmeanings.
DANGER! Pointsinthetextmarkedwiththissymboldrawyourattentionto immediatelyimpendingdanger.Possibleconsequencesare: veryseriousinjuryorevendeath.
WARNING! Thesepointscontaininformationondangeroussituations.Possibleconsequencesare:veryseriousinjuryorevendeath.
CAUTION! Thissymboldrawsattentiontodangeroussituations.Possible consequencesare:lighttomoderatelyseriousinjuriesandmachinedamage.
NOTICE! Pointsinthetextmarkedwiththissymboldrawattentiontoharmfulsituations.Possibleconsequencesare:damagetothemachineordamageintheimmediatevicinity.
IMPORTANT! Pointsinthetextmarkedwiththissymbolcontainusefultipsand informationintendedtofacilitateworkforyou.Theydonotwarn aboutharmfulordangeroussituations.
■ Itemsinlistsaremarkedwithbullets.
– Pointsinsub-listsaremarkedwithalongdashatthestartof theline.
Pointsintextmarkedinthiswaydescribeindividualoperations. Followtheseinstructionsstepbystep.Theywillhelpyoucarryout yourworkfasterandmoreimportantly,safer.
Yoursafety Thischapterprovidesvitalinformationforyoursafety.Payspecialattentiontothischapter.Thesafetyinstructionsandrulesofprocedure willhelpyoutoavoidhazardoussituationsandtoperformthenecessaryworkassafelyaspossible.
Thismachinehasbeenmanufacturedinaccordancewithstateofthe artandgenerallyrecognizedsafetystandardsandregulations. Youandotherscan,nevertheless,beexposedtodangeroussituations e.g.asaresultofenvironmentalinfluences,machinedamageoroperatorerrors.
Donotmakeanyalterationsormodificationswhichcouldimpairthe safeoperationandmaintainabilityofthemachine.Allmodifications andchangesmustbeapprovedbyBucyrusandallappropriateregulatoryagencies.
UseonlyoriginalsparepartsfromBucyrus.Notethattheuseofparts fromothermanufacturerswillvoidthewarranty.
Inadditiontothisoperatingmanualbesuretoalsoobservetherespectivelegalprovisionsandregulationsinyourcountry.
Observethesafetyandaccidentpreventionregulations
■ ofthemine,
■ ofthemine’sinspectors,and
■ oftheminingsupervisoryauthorities.
Readtheoperatingmanualsofthecomponentsrequiredforoperation, e.g.ofgearboxes,electricmotors,radioremotes,etc.,carefullyand thoroughly.Clarifyanyquestions before startingwork.
training
Personnel Operation Themachinemayonlybeoperatedbyqualified,trainedpersonnel. Themachineisonlyallowedtobeoperatedbyqualifiedpersonnelwho canprovideproofofhavingbeentrainedonthisunit.
Readingoftheoperationmanual,especiallythechapteronsafety,shall constituteapartofthistraining.
Youmusthaveadequateknowledgeofthe
■ mechanics,
■ hydraulics,and
■ controlengineering andmustbeabletoprovethisknowledge.
Installationandrepair Asafundamentalrule,installationandrepairworkmayonlybecarried outbypersonnelwhohavebeenadequatelytrainedfortheseparticular requirements.
Installationandrepairworkon:
■ safetycomponents(pressurereliefvalves,extinguishers,etc.)
■ theelectrics(motors,controllers,etc.)
■ thehydraulics(controls,cylinders,etc.) mayonlybecarriedoutbyserviceengineersfromBucyrusorbyspeciallyqualifiedpersonnelofthemine.
Operatingconditions Intendeduse
TheContinuousMinerhasbeendesignedandmanufacturedforspecificuses.Intendedusesinclude:
■ extractionofcoal,phosphate,potash,salt,trona,andothermediumhardnessminerals
■ loadingthematerialslistedaboveontoahaulagesystemorshuttle car,ordumpingitontothegroundforloadingatalatertime
■ operationongradesoflessthan10degrees
Unauthorizeduse
Applicationsnotexpresslylistedasintendedusesareunauthorized usesandarenotallowedtobeperformedwiththemachine.
■ thetransportofpersons
■ stonedevelopmentorextraction
BucyrusAmerica,Inc.acceptsnoliabilityforanydamageresulting fromanysuchunauthorizeduse.
Safetyinstructions Generalrules general noiseemissions
safetyequipment symbolplates emergencystop lock-outandtag
Alwaysworkwithfullconcentration.
Familiarizeyourselfwithyourworkingenvironment.
Alwayswearyourpersonalprotectiveequipment.Thisalsoincludes earprotectorsasthenoiseemittedbyotherequipmentintheareamay attimesexceed85db(A).
Informyourcolleaguesof
■ yourexactlocation,
■ theworkyouareperforming,and
■ thetimethatyouwillprobablyrequire.
Startthemachineonlywhenitisinagoodandsafeoperatingcondition andallprotectivedevices,e.g.emergencystopdevices,machinestop buttons,coverplates,etc.arecorrectlyinstalled.
Observetheacousticandopticalstart-upwarningsofthemachine.
Observethesymbolplatesonthemachine.
Presstheemergencystopbuttonimmediatelyintheeventoffaultor irregularitiesinoperation.Reportanyirregularitiestoyoursuperiorso thatnecessarymeasurescanbetakenimmediately.
Disconnect,lockout,andtagthepowersystemwhileperforming:
■ maintenance
■ inspection
■ repairwork
Followallapplicableregulationsregardinglockout/tagoutprocedures.
Cordonoffyourworkingareawidelyforthemachine.
cordonoffworkingarea movingparts
Neverallowpartsofyourbodytocomebetweenpartswhichcould move,suchas:
■ chains,flights,andchainsprockets
■ pivotpoints
■ crawlerassembliesandconveyors
■ cutterandgatheringheadassemblies
CLICK HERE TO DOWNLOAD THE COMPLETE MANUAL
• Thank you very much for reading the preview of the manual.
• You can download the complete manual from: www.heydownloads.com by clicking the link below
• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.
CLICK HERE TO DOWNLOAD THE
Safetyinstructions Storageandtransport Maintaintheprescribedstorageperiodsandobservetheinstructions forstorage.
Donotstorematerialsorpartsinthetravelwayorinyourworking area.
Informthepersonsinvolvedabouttheintendedtransportrouteandthe anticipateddurationofthetransport.
Ensurethatthetransportsafetydevicesarecorrectlyfitted. Fixallmovingpartswithtransportlocks.
Neverstandunderunsupportedpartsorsuspendedloads.
Connecttheliftingequipmentonlytothepointsofattachmentprovided forthatpurpose.Observethedifferentloadlimitsoftheattachment points.Alsoobservetheinstructionsonthetransportsheet.
Onlyusemeansofattachmentwhichareingoodconditionandhave beendesignedfortheloadstobehandled.
Forroundcomponentsusetransportstraps,only.Neverusechainsor steelcablesforthispurpose.
Donotdamagethetreatedorpolishedsurfacesofshafts,sealingsurfaces,etc.
Whenusingmobilehandlingsystemsfortransportmakesurethatthe centerofgravityisaslowaspossible.
Pre-startinspection Readthisentiremanualbeforeattemptingtooperatethismachine.
Inspectthemachineandhaveanymalfunctioning,brokenormissing partscorrectedorreplacedbeforeuse.
Verifythatallmaintenancehasbeenperformed.
Verifythatallinstructionandsafetytagsareinplaceandreadable. Theseareasimportantasanyotherequipmentonthemachine.
Installationandstart-up Oninclinedfacessecureallcomponentpartsbychains,e.g.tothe support.
Whenworkingwithoils,greasesandotherchemicalsubstances,observethesafetyregulationsapplicabletotheproduct.SafetyregulationscanbefoundonthecontainerorontheMaterialSafetyData Sheet(MSDS)fortheproduct.
Disposeofcleaningrags,etc.whichhavebeensoiledwithoil,grease orotherchemicalsubstancesinanenvironmentallysafemanner.
Whenstartingupmachine,donotoperateanycontrolslocatedinside theoperator’scompartment(optional)fromoutsidethecompartment.
Followthestartingprocedureinstructionsintheoperationsmanual.
Donotoperateanylevers,pedalsorcontrolsifanyoneisinthered zone.(SeeRedZoneinChapter5ofthismanual)
Operation Operatethemachineonlyifyouhaveaprofoundknowledgeofthe controlelementsandtheirfunctions.Itisnecessarythatyouhave beentasktrainedontherespectiveContinuousMiner.
Beforestart-up,ensurethattherearenopersonsorobstructionsin yourlineoftravelorinthearticulationareawhensteeringtheunit.
Checkthatallprotectivedevicesareinstalledonthemachineandfunctionproperly.
Useextremecautionwhentravelinginclosequartersorincongested orblind-travelareas.
Nevercarrypassengers.Passengersmaybethrownoffthemachine orcrushedbetweenthemachineandoutsideobjects.
Alwaysfollowallsafetyrulesofeachparticularminewhenoperating themachine.
Ifproblemsormalfunctionsareencounteredwhileoperatingtheunit, themachinemustbeproperlyshutdownandtheproblemcorrected immediately.
Safetyinstructions Stopping Alwaysparktheunitonsolid,levelground.Ifthisisnotpossible,park theunitatarightangletotheslopetopreventaccidentalmovementof themachine.
Useproperflags,warningsorbarrierswhenparkinginareasoftraffic.
Thereisauniquecodeswitchsetupwhichpermitseachoperatorto activateonlyhisdesignatedminer,allowingseveralremote-controlled minerstooperateinthesameareawithoutgettingtheirradiosignals crossed.Inaddition,animproperlydecodedradiosignalwillautomaticallyshut-offtheminer.Followthegeneralsafetynoticesandsafety recommendationslistedintheremotecontrolsystemguide.
Maintenanceandrepair Besuretoobservetheprescribedmaintenanceandinspectionintervals.
Informthesupervisorypersonnelandthefacecrewofanymaintenance andrepairoperations.Givetheminformationontheintendedoperationsandtheanticipatedduration.
trailingcableuncoupled andlockedandtaggedout
Beforeattemptinganyrepairs,a DANGER signmustbeattachedtothe appropriatecircuitatthepowerdistributionbox.Itismandatorythatthe trailingcablebeuncoupled,taggedandlocked-outfromthepower sourcetoprovidevisualevidencethattheminerisde-energized.Followallapplicableregulationsregardinglockout/tagout.
Secureyourworkingareaoverawiderange,inordertoavoidendangeringotherpersons.
Disconnectthepowerfromthemachinetopreventunauthorizedand unintentionalrestarting.
Protectyourworkareaagainstfallingrocks.
Passdefectivecomponentsremovedonforservicingwithoutdelayin ordertopreventthesepartsbeingreinstalledelsewhere.
Useonlysparepartswhichsatisfythespecifiedtechnicalrequirements. ThisisonlyensuredwithoriginalBucyrusspareparts.Pleasereferto thesparepartslistsorpartscatalogfortheordernumbers.
Beforeattemptinganyrepairsormaintenance,methaneairmonitoring mustbecompletedbeforeandduringtherepairandmaintenance.
handlingofhydraulicfluids lifting
maintenance/repair
Safetyinstructions ForraisingtheContinuousMineruseonly:
■ cribblockswithadequateload-holdingcapacity.
■ hoists,jacksorcraneswithadequateload-carryingcapacity.
Avoiddirectcontactbetweentheskinandhydraulicfluids.Hydraulic fluidcanpenetratetheskinandcauseseriousinfection.
Neverusehydraulicfluidforrinsingorcleaning.Hydraulicfluidrepresentsaveryseriousdangertohealth.
Onlypersonswhohaveandcandemonstrateaspecialknowledgeof hydraulicsareallowedtoworkonthehydraulicsystem.
Avoid,wheneverpossible,servicing,cleaningorexaminingthemachineincongestedareas.
Avoid,wheneverpossible,servicingorprovidingmaintenancetothe unitunlesstheappropriatesafetydevicesareplacedwhererecommendedtopreventaccidentalmovementoftheunit.
Donotaltertheelectricalorhydraulicsettingsfromthatindicatedinthis manualorassetatthefactory.
Alwaysreplacedamagedorlostdecalsandmetalinstructionplates.
Disconnectthepowerwhenworkingwiththeelectricalsystem,orwhen weldingontheunittopreventelectricalshock.
Alwaysfollowallsafetyproceduresofeachparticularminewhenperformingmaintenance.
Itisimportantthatanyprocedurenotspecificallyrecommendedinthis guidebethoroughlyevaluatedfromthestandpointofsafetybeforeitis implemented.
Safetyinstructions ____________________________________________ Someillustrationsinthismanualshowguardsorcoverpanelsremoved forpurposesofclarity.Neveroperateunitwithoutguardsorcoverpanelsinplace.
Carryoutavisualinspectionofallthehydrauliccomponentsatregular intervals.Inparticularcheckthat:
■ thehosesarenotpinchedortrapped.
■ thehoseshavenobubblesorblisters.
■ thehoseoroutersheathsofthehosearenotabnormallyrigidor hard.
■ theoutersheathofthehosesisnotdamaged.
■ theconnectorsaresecurelyinsertedintothesockets.
■ theconnectionsareleak-tight.
Ensurethatnodirtentersthehydraulicsystemduringrepairwork.Dirt inthehydraulicsystemcancauseseriousdamageinthewholesystem! Flushoutthehydrauliclinesthoroughlybeforeconnecting.
permissiblehoses
Ifhydraulichosecouplersaredifficulttodisconnectorcannotbedisconnected,thehydrauliclinemaystillbepressurized.Besuretodepressurizethelinebeforedisconnectingcouplers.
Securetheconnectorsofthehydraulicelementsonlywiththeproper couplingclamps.Alwaysfastentheclampscompletelyandwithboth sides.Neverusenails,wireorsimilarmaterialsforsecuring.
Afterfinishingrepairwork,checkallconnectorsandconnectionsfor leaksbeforepressurizingthesystemagain.
Useonlyhydraulichosesapprovedfortheprevailingpressures.
Donotuseanyhydraulichoseswithdamagedconnectorsorwornorings.
Replacehydraulichosesonlywithhosesofthesameorahigherquality.
Nevertrytoholdajumpinghydraulichose.Depressurizethelinein questionimmediately.
Nevertrytorepairdamagedhydraulichoses.
Replacehydraulichosesatthefirstsuspicionofdamage.
Safetyinstructions installinghydraulichoses
Installthehydraulichosesproperlybehindthebracketsandclamps providedforthem.
Alwaysinstallhydraulichosessothey:
■ alwayshavealittleslack.
Fig.1:Installinghydraulichoses,slack Right Wrong
■ arenottwisted.
Fig.2:Installinghydraulichoses,twisting Right Wrong
■ arenotbentdirectlybehindtheconnections. (distancemin.1.5xnominaldiameter).
Fig.3:Installinghydraulichoses,bending Right Wrong
Safetyinstructions ■ alwayshavealittleslack.
■ arenotkinked.
■ donothavetowithstandtensilestrains.
■ areprotectedagainstthermalradiation.
■ areaccessibleatalltimes.
Screwhydraulichosesintothesocketsonlybyhandandfingertighten. Nevertrytodrivethehydraulichosesinwithatoolasthiswilldamage theconnections.Usetheappropriateamountoftorquetoensurea properhosefit.
Wheninstallingthehydraulichoses,ensurethattheycannotbe:
■ tornout,
■ kinked,
■ crushed,
■ drivenoveror
■ twistedbymovementofthemachine.
Fig.4:Installinghydraulichoses,connectionsonmovingparts
Overviewofthesafetyinstructions Thisisasummaryofallthesafetyinstructionswhichhavetobeobservedinthefollowingchapters.Thissummaryisintendedonlytogive youanoverviewofalltheinstructions.Insomecases,thereisnologicalrelationshipbetweentheindividualinstructions.
Chapter3:Storageandtransport IMPORTANT!
Takecaretoinsurethatnewmaintenancesuppliesarestored separatelyfromexistingstockandthatremovaltakesplaceonthe “firstin,firstout”principle.
WARNING!
Useonlyloadhandlingdevicescomplyingwiththetechnicaland legalregulationsforthetransportofloads. Youcouldbeseriouslyinjuredorevenkilledbyfallingloads.
WARNING!
DonotusetheeyebolttoliftthecomponentANDitsrelatedassemblies.
Chapter4:Installation CAUTION!
SeriousdamagecanbecausedtotheContinuousMinerasaresultofincorrectinstallation.TheunitshouldthereforeonlybeinstalledundertheinstructionofspecialistsfromBucyrus.
IMPORTANT!
Thesequenceofoperationsduringinstallationmustbeadaptedto theindividualconditionsprevailingatthesite.Beforestartingthe workadetailedlistofstepstobetakenwithrespecttotransport andassemblyshouldbepreparedandacorrespondingplan established.
NOTICE!
Themachinewasinspectedpriortoshipmentfromthefactoryto ensureproperfunctioningandinstallationofallcomponents. However,toensurethatnotransitdamagehasoccurred,thefollowingpre-startupchecksshouldbeperformed:
NOTICE!
Theoperatormustbecomefamiliarwithallthesafetyfeaturesand theirlocationonthemachinepriortoinstallationoroperation.
WARNING!
Ifeitherofthefiresuppressionactuators(optional)isactuated, thesystemmustbecompletelyrechargedwithdrychemicalsand expellants.
Overviewofsafetyinstructions _________________________________ IMPORTANT!
Thefiresprayvalvemustbemanuallysettothenormalposition beforethedustsuppressionwaterspraysystemcanbeoperated.
CAUTION!
Theminesupplywaterpressureatthemachineshouldnotexceed 500psiandshouldsupply20gpmminimumforcooling.
DANGER!
Donotoperatethemachinewithanyoftheguardsorcoversremoved.Youorotherpersonnelcouldbeseriouslyinjuredfrom movingorrotatingparts.
Chapter5:Operation DANGER!
Incorrectoperationendangersyourselfandothers!Incorrectoperationofthemachineisoftenthecauseofveryseriousaccidents!Operatetheunitonlywhenyouhavebeensufficientlytrainedonthe machineandhavereadandunderstoodthisoperatingmanual. Shouldanythingbeunclear,pleasecontactyourimmediatesupervisor.
NOTICE!
Beforebeginningcuttingoperations,carefullyunloadthetrailing cableprovidingenoughslackandplacingitwhereitallowsadequateclearanceforsafemaneuverabilityoftheminer.
DANGER!
TheContinuousMinerisradioremotecontrolledduringproduction operations.Manualoperationviacontrolsattheoperator’sstation isnotpermittedforproductionoperation.Manualoperationisfor troubleshootingandmaintenanceundersupportedroofonly.TrammingviatheEmergencytrampendantisonlypermittedinsituations whentheradioremotesystemisinoperable.OperatingtheContinuousMinerwithmanualorpendantcontrolsunderunsupportedroof mayresultinsevereinjuryordeath.
NOTICE!
Onceahydrauliccontrolvalvehandleisreleasedbytheoperator, theleverwillautomaticallyreturntothecentered(“HOLD”)position.
DANGER!
Powertothemachinemustalwaysbeisolatedtothetrailingcableat thesectionpowercenterbeforeeithersocketisremovedorthe maincircuitbreakercaseisopened.Wheneveranyworkisperformedonthecontinuousminer,allmine,State,andFederalregulationsregardinglockout/tagoutofthemachine.
IMPORTANT!
Itistheresponsibilityofthecontinuousminerowner/operatorto knowandfollowallMine,State,andFederalregulationsregarding methanemonitoringrequirements,including,butnotlimitedto,daily operation,maintenanceandtesting.
WARNING! Overviewofsafetyinstructions Radioremotecontrolsystemsaredangerous.Thecontinuous mineroperatorcannotoperatearemotesystemuntilheisproperlytrainedintheoperationofthesystem.Remotecontrolsystemssometimeshaveautomaticfeaturesofwhichuntrainedoperatorsandworkersarenotaware.
IMPORTANT! Refertotheradioremotecontroloperationmanualsuppliedwith yourmachineforinformationregardingtheoperationofyour specificremotecontrol.
NOTICE!
Informationpriorityisgiventothegraphicsdisplayunlessthe graphicsdisplaybecomesunhealthy.Thetwomonitorswillnot necessarilydisplaythesameinformationatthesametime.
IMPORTANT! Allfunctionsandmotorsareshutdownanddisablewhenthesystemmenuisselected.
IMPORTANT! Itisnotrecommendedthatthefaultlogbeclearedunlessthereceiverhasbeenreplaced.Retainingthefaultsisveryhelpfulin troubleshootingaproblemwhenareceiverissentforservice. Faultscannotberetrievedoncetheyhavebeencleared.Usecautionandonlyclearthelogifitisabsolutelynecessary.
IMPORTANT! Thehoursmetersshouldonlybeclearedwhenamotorisreplacedorwhenthereceiverisinstalled.Tokeepanaccuratelog ofamotor’stotalhours,theinformationshouldberecordedanytimedataiscleared.
IMPORTANT! Thependantcontrolleranditsumbilicalcordshouldbestoredin aprotectedlocationontheworkingsection,awayfromtheminer, topreventdamage.
WARNING!
Failuretoreadandunderstandalloperatinginstructionsbefore startingtheContinuousMinercouldresultinseriousinjuryor deathtotheoperatororpersonsaroundthemachineorcause damagetothemachine.
WARNING!
Readallinstructionscarefullybeforeattemptingtostartoroperatethemachine.
WARNING!
UnderstandthefunctionsofallcontrolsbeforestartingtheContinuousMiner.Readandfollowtheinstructionsonallwarning tagsonthemachine,observeallregulationsandsafetyprecautions.
Overviewofsafetyinstructions _________________________________ WARNING!
NeveroperateaContinuousMinerwhichhasbeendamagedoris notoperatingproperly.AnypartoftheContinuousMinerwhich doesnotfunctionproperlycanbeahazard.Reportitimmediately toyoursupervisorortheirdesignee.
WARNING!
BeforestartingtheContinuousMiner,makesurethatnooneisin theredzone(Fig.26throughFig.30).
NOTICE!
Inextremelycoldweather,allowmotorsandgearcasestoidle. Thiswillwarmthehydraulicoilsandlubricants.Coldoilsand greasescouldimmobilizethemachine.
IMPORTANT!
Apump“growl”meansnotenoughoilisreachingthepumps throughthesuctionlines.Ensurethepumpgetsprimedbefore continuingoperation.Alwayschecktheoillevel.
DANGER!
Improperpositioncouldresultininjuryordeathtotheoperator bycrushinghimagainsttheriborroofsupports.Itmayalso causehimtorunoverthetrailingcableordislodgetheroofsupports.
WARNING!
Turningonthewatersprayspriortocuttingpreventstheaccumulationofdustandthegenerationofexcessiveheatwhichcould causeanignitionorexplosion.
WARNING!
TheContinuousMinerisoperatedbyradioremotecontrol.Manualoperationisnotallowedforproductionoperation.Manualoperationisfortroubleshootingandmaintenanceunderroofsupport.
IMPORTANT!
Beforestart-up,checkthatdailymaintenancehasbeenperformed onthemachine.
WARNING!
Visuallycheckforotherpersonnelandverballyshoutawarning beforestartingthismachine.Makesureallpersonnelarecompletelyclearofthemachineandit’scomponentsandcheckthat theareaisclearbeforestartingthemachine.
IMPORTANT!
The“PUMPON/OFF”keymustbereleasedbefore“SHIFT”.If “SHIFT”isreleasedfirst,thepumpmotorwillshutoff.
WARNING!
Afterturningoffthepowertothemachine,neverwalkawayand leavethetransmitterturnedon.Failuretoturnthetransmitteroff couldresultinanaccidentcausingseriousinjuryorlossoflife
NOTICE!
TheContinuousMinerhasskidtypesteering:itiscapableofturningwithinitsownlimits.
WARNING!
Trammingrequirescoolingwatertothetrammotors.Failureto coolthemotorswillresultinmotordamageandprematurefailure.
WARNING!
Adjustconveyorboomtoallowclearancefromroof,walls,and floor.Failuretodosowillresultindamagetotheconveyorboom.
WARNING!
Neverstartcutterheadmotorsunderaload.Startingmotorsunderloadmayresultinmotordamageorprematurefailure.
WARNING!
WarnALLCLEARbeforestartingthecutterhead.Failuretodoso mayresultinseriousinjuryordeath.
IMPORTANT!
Bothcuttermotorsdonotstartatthesametime.Thereisapreset timeddelaybetweentheleftcuttermotorstartingandtheright cuttermotorstarting.
IMPORTANT!
The“CUTTERON”buttonmustbereleasedbefore“SHIFT”.If “SHIFT”isreleasedfirst,thecuttermotorswillshutoff.
WARNING!
WarnALLCLEARbeforestartingtheconveyor.Failuretodoso mayresultinseriousinjuryordeath.
IMPORTANT!
The“CONVON”buttonmustbereleasedbefore“SHIFT”.If “SHIFT”isreleasedfirst,theconveyormotorswillshutoff.
IMPORTANT!
The“FAN/OFF”buttonmustbereleasedbefore“SHIFT”.If “SHIFT”isreleasedfirst,thefanmotorwillshutoff.
IMPORTANT!
Thebackupaccumulatormustmaintainpressureof500psifor12 minutesafterthepumphasbeende-energized.
CAUTION!
Alwaysensureoperatorsafetywhileoperatingthemachine.Be alertforhazardousconditionsandtakecorrectiveactionasnecessary.Failuretobealertandcorrecthazardoussituationsmay resultinseriousinjury.
Overviewofsafetyinstructions _________________________________ IMPORTANT!
Careshouldbetakennottostallcuttersorconveyorduringcuttingoperations.Severedamagetomotorsandgearboxescould occurifcuttersorconveyorarerepeatedlystalled.
IMPORTANT!
Tramislimitedintheforwarddirectionwhilethecuttersarerunningwiththecutterheadfeedbackcircuit.Asthecutterheadbeginstocutthematerialfromtheface,thesumpspeedwillautomaticallyslowthetramdowntopreventoversumpingthemachine.
WARNING!
ThissectionisintendedtofamiliarizetheuserwiththemajormechanicalassembliesoftheContinuousMiner.Allmechanical maintenanceshouldbeperformedbyaqualifiedtechnicianwith theknowledgeofthefunctionoftheassembliesinvolved.
WARNING!
Failuretomaintainthehydraulicsystemwillresultindamageto itshydrauliccomponentswhichwillresultinincreasedwearand prematurefailure.
IMPORTANT!
Schematicsmayvaryfromoneunittothenext.ConsulttheBucyrusAmerica,Inc.partsmanualforthecorrectschematicfor yourmachine.
IMPORTANT!
Duringdisassemblyofcontrolvalves,giveparticularattentionto identificationofpartsforreassembly.Spoolsareselectivelyfitted tovalvebodiesandmustbereturnedtothesamebodiesfrom whichtheywereremoved.SpoolsareNOTinterchangeablebetweenvalvebodies.
WARNING!
Donotsalvagespoolsorvalvebodiesforlaterusein“new”combinations.Damagedorimpropercomponentsusedduringassemblymayresultininternalleakageorin"sticking"(hangingup)of thespoolinthevalvebody.Incorrectcomponentcombinations mayresultinimproperoperationofthevalvesection,possibly causingunexpectedmachineoperationthatcouldresultinmachinedamageorinjurytopersonnel.
WARNING!
Neverrunthemachinewithouttheproperfilterelementsinplace. Runningthemachinewithincorrectornofiltersmayresultinhydraulicsystemcontamination,machinefailure,erraticoperation, andinjury.
WARNING!
Donotrelyontheloadholdingvalvewhenworkingunderthecutterheadortheconveyor.Alwaysblocktheconveyororthecutter headifitmustbeelevated.Seriousinjuryordeathmayresult fromnotmechanicallyblockingtheload.
WARNING!
TheloadholdingvalvesonthecutterheadandconveyorcylindersarepresetandDONOTrequireadjustment.Adjustmentof thesevalvemayresultinveryseriousinjuryorevendeath.
IMPORTANT!
Thetwoinchlockingballvalvemustbelockedopeninnormal operation.
DANGER!
Theareaunderandaroundtheraisedcutterheadisdangerous. Securelyblocktheheadbeforeperformingmaintenanceonor belowit.Failuretoblocktheraisedcutterheadcouldresultin seriousinjuryorevendeath.
DANGER!
Donotadjust,modify,orremovetheloadholdingcartridgevalve mountedinthecutterheadcylinders.Itisasafetyfeaturetopreventaccidentalloweringofthecutterhead.
DANGER!
Thisloadholdingvalve,likethoseonthestabilizercylindersis preset. DONOTADJUSTIT.Ifitmalfunctions,replaceitimmediately.
WARNING!
Youcouldbeseriouslyinjuredorkilledbyfallingloads.Blockthe minerbeforeperformingmaintenanceandalwaysobservethe safeworkingloadlimitsofallliftingandblockingdevices.
NOTICE!
Tojack-knifetheminer,thestabilizershoeisfirstloweredwiththe bypassvalveopened.Thecutterheadisthenloweredwiththe bypassopened.Atthispoint,themachinecanbeinspected,adjustmentscanbemadetothecrawlertracks,andthetramvoltage canbeadjusted.
DANGER!
Neverruntheconveyorwithouttheneedlevalveclosed.Injuryor deathmayoccur.
WARNING!
Thissectionisintendedonlytofamiliarizetheuserwiththeelectricalcomponentsofthecontinuousminer.Allelectricalmaintenanceshouldonlybeperformedbyaqualifiedelectricianwith knowledgeofthefunctionsofthecomponentsinvolved.
WARNING!
Beforeremovingthecoverfromthecontrollercaseorattempting anymaintenanceortroubleshooting,themainpowermustbedisconnectedandlockedoutatthemainpowercenter.
IMPORTANT!
Hangtrailingcablestopreventdamagefrommovingequipment!
Overviewofsafetyinstructions _________________________________ WARNING!
Neverrunoveranunprotectedtrailingcable.Damagedcables shouldberepairedimmediately.
DANGER!
Neverhandleenergizedtrailingcablewithoutproperprotective equipment.Contactwithanenergizedtrailingcablewithcompromisedinsulationcouldresultindeathbyelectrocution.
WARNING!
Alwaysusecautionwhenstandingnearorcrossingtrailingcables.Thetrailingcablemaymoveasthemachinemoves.
IMPORTANT!
Thiscomponentlocationinformationistypical.Alwaysverify componentlayoutwiththeinformationintheBucyruspartsbook foryourmachine.
IMPORTANT!
Neveruseasparebreakerwithoutproperlylabelingits newfunction.
WARNING!
Beforeperformingmaintenanceonthemachinethecircuitbreaker mustbeinthe“OFF”positionandthetrailingcabledisconnected. FollowallMine,State,andFederalregulationsforlockout/tagout procedures.Accidentalmachinemovementorelectricalshock canresultinseriousinjuryordeathtoyouorotherpersonnel.
IMPORTANT!
“MAINTENANCE”modeofoperationisnotforuseduringnormal maintenanceorreplacementofwearpartsprocedures. “MAINTENANCE”modeisforuseduringmotorvibrationanalysis only.
WARNING!
Donotmoveanyhydrauliccontrolleverunlessyouarecertain thateveryoneiscompletelyclearofanymachinemovement.Accidentalmachinemovementcancauseseriousinjuriesoreven deathtoyouorthemaintenanceperson.
WARNING!
Neverdisconnectahydraulichoseifthecircuitispressurizedorif thereisaloadonthecircuit.Ifahoseisdisconnectedwhilethe circuitispressurizedoraloadisonthecircuit,theloadwillfall causingdamagetothemachineorseriousinjuryordeathtoyou orotherworkers.
WARNING!
Youcouldbeseriouslyinjuredorevenkilledbyfallingloads.Observethesafeworkingloadlimitsofliftingorblockingdevices andkeepasafedistancefromsuspendedloads.
WARNING!
Observethesafeworkingloadlimitsofallblockingdevices.You couldbeseriouslyinjuredorkilledbyfallingloads.
Overviewofsafetyinstructions WARNING!
Useextremecautionwheninspectingforleakswiththemachine running.Unexpectedmachinemovement,orcontactwithmoving parts,couldresultininjury.
Escapingfluidsunderpressurecanpenetrateskinandcauseseriousinjury.Donotattempttolocatehydraulicleaksbefeeling hosesandfittingswithbarehands.Pinholeleakscanpenetrate theskin.
WARNING!
FollowallFederalandmineregulationsregardinglockout/tagout procedures.Failuretodosomayresultinseriousinjuryordeath.
NOTICE!
Switchassemblysealsbeneaththeengravedplatearetheprimary seal;asecondarysealwithintheswitchitselfandanintegralneoprenesealoperateasabarriertomoistureingress.
IMPORTANT!
Donotusecausticsolventsordisplacementsolutions,asthis maycauseprematuresealfailure.
IMPORTANT!
Donotusemetalimplementstodigoutcoal,mudorsoapstone thatmaybefoundinthechargereceptacle.
NOTICE!
Ifthegearcaseisscheduledforoildrainandrefill,obtaintheoil samplepriortotheoilchange.
IMPORTANT!
Alwayscollectoilsamplesusingasiphonpump.Donotremove thedrainplugandcollectoilbyallowingittorunoutintothebottle.
IMPORTANT!
Alwaysusethecollectionhoseprovidedwitheachbottle.Always discardhoseimmediatelyfollowingcollectionoftheoilanddonot useitforthenextsample.Todosowillcontaminatethenext samplewithoilfromtheprevioussample.
IMPORTANT!
Formotorbearingsthatrequirehightemperaturelithiumcomplex grease(Spec.100-15),Bucyrusprovidesaspecial“button”style lubricationfitting(Fig.122)topreventtheaccidentaluseofmultipurposelithiumcomplexgreaseattheselocations.
NOTICE!
Incorrectgreaseorovergreasingoftheelectricmotormaycause seriousdamagetothemotor.Followthegreasingprocedureoutlinedabove.
Overviewofsafetyinstructions _________________________________ IMPORTANT!
Formotorbearingsthatrequirehightemperaturelithiumcomplex grease(Spec.100-15),Bucyrusprovidesaspecial“button”style lubricationfittingtopreventtheaccidentaluseofmultipurpose lithiumcomplexgreaseattheselocations.
WARNING!
Useextremecautionwhenperformingtestproceduresandmaking adjustments.Unlessnotedintheprocedures,allcontrolsaretobe intheneutralposition.
IMPORTANT!
Alwaysusethepropertoolswhenadjustingvalvecartridges.
IMPORTANT!
Donotstartanymotors - CLA,cutterhead,pump,ortractionmotors - untilallpressuresareset.Startthepumpmotorasdirected.
WARNING!
Neverrelyontheloadholdingvalveasameansofsupportingthe cutterorconveyorboomwhilemakingrepairs.Severeinjuryor deathcouldresult.
IMPORTANT!
ReferencetheHydraulicsectioninthischapterforindividualcircuitinformation.Alwaysrefertothehydraulicschematicinyour BucyrusAmerica,Inc.partsmanualforyourminer.
WARNING!
Twopeoplearerequiredtoadjustpressuresettings.Oneperson willmaketheadjustmentswhilethesecondpersonmustremain atthemachinestopatalltimesduringtheadjustmentprocedure. Failuretodosomayresultinseriousinjuryordeath.
IMPORTANT!
Beforemakinganyfurtheradjustments,verifythatthehydraulic oilisatoperatingtemperature.
WARNING!
Alwaysallowcylinderfunctionstobottomout(stopmoving)beforeadjustinganypressure.Pressureadjustmentswillonlybe accuratewhenthecylinderisinthiscondition.
IMPORTANT!
Themainreliefissethigherthantheportreliefsandwillonlyrelieveifaspikeoccursinthesystemoriftheportreliefdoesnot functionproperly.Thisprovidesprotectionofthemainpumpsection,A1.
CAUTION!
Donotadjustthemainreliefover3,000psi.Destructionofthe valvebankandthemainpumpcouldresult.
CAUTION!
Alwaysbealertforanyunintendedmachinemovement.
IMPORTANT!
ReferencetheHydraulicsectioninthischapterforindividualcircuitinformation.Alwaysrefertothehydraulicschematicinyour Bucyruspartsmanualforyourminer.
WARNING!
Twopeoplearerequiredtoadjustpressuresettings.Oneperson willmaketheadjustmentswhilethesecondpersonmustremain atthemachinestopatalltimesduringtheadjustmentprocedure. Failuretodosomayresultinseriousinjuryordeath.
WARNING!
Keepbodypartsclearofmachinewhileinraisedpositionorseriousinjurycouldresult.
WARNING!
Alwaysallowfunctiontobottomoutandstopmovingbeforeadjustinganypressure.
CAUTION!
Shimsmustbeinsertedcompletelyintotheidlerslidechannel.A shimthatisnotcorrectlyseatedontheidlerslidechannel’sinside surfaceprovidesunevensupportthatcancauseidlerslant.A slantedidlercancauseunevenwearandstressonthetramtrack andcancauseimproperoperationofordamagetothetramsystem.
IMPORTANT!
Checkthattheshimsarecorrectlyseatedontheidlerslidechannel’sinsidesurfacebylookingatthechannel’sinsidesurface fromtheoppositesideoftheminerthroughthespacebetweenthe gatheringheadandtheidlerassembly.
WARNING!
Thefollowingstepsreleasestheshims,whichwillfallfree.Watch outforfallingshimswhenlooseningthecapscrews.
IMPORTANT!
Machinepowermustbedisconnectedduringinstallationofthe currentgenerator.Cuttermotorfeedbackadjustmentisnormally setwiththecrawlertracksofftheminefloor,stabilizerandcutter headdown(machinejack-knifed).Tojackknifethemachineyou shouldbefamiliarwiththehydrauliccircuitsontheminer,andin particular,thecutterheadcylindercircuitandthesheardown/ maintenancevalve(anti-chatter)operationasdescribedintheHydraulicsectionofthischapter.
NOTICE!
Thereferencevoltagewillbeapproximately0.55VDC.Adjustthe sumpvoltageusingtheadjustmentscrewsmarked“S”onthe traminterface.Settheleftandrighttramvoltagesthesame.
CLICK HERE TO DOWNLOAD THE COMPLETE MANUAL
• Thank you very much for reading the preview of the manual.
• You can download the complete manual from: www.heydownloads.com by clicking the link below
• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.
CLICK HERE TO DOWNLOAD THE
Overviewofsafetyinstructions CAUTION!
DisassemblyandassemblyprocedureslistedintheReplacement ofwearpartssectionarespecializedand,assuch,shouldonlybe performedbyqualifiedpersonnel.
WARNING!
Theshearcylinderisextremelyheavy.Makesurethatit’sweight issupportedandthatthecylinderwillnotswingfreeormove. Failuretofollowthiswarningmayresultinmachinedamageorin severeinjuryordeathtopersonnel.
WARNING!
Neverdisconnectahydraulichoseifthecircuitispressurizedorif thereisaloadonthecircuit.Ifahoseisdisconnectedwhilethe circuitispressurizedorunderload,theloadwillfall.Machine damageorseriousinjuryordeathtopersonnelmayresult.
WARNING!
Donotuseyourfingerstocheckthealignmentoftherodbearing intheclevis.Shiftingofthepartscouldresultinseriousinjury.
IMPORTANT!
Inadditiontotheshearcylinders,thestabilizerandgathering headcanbeusedtoadjustthecutterboom’spositiontoallow easierinstallationofthecutterboompivotpins.
WARNING!
Thefollowingstepswilldisconnecttheshearcylinderfromthe frame.Theshearcylinderisextremelyheavy.Makesurethatit’s weightissupportedandthatthecylinderwillnotswingfreeor move.Failuretofollowthiswarningmayresultinmachinedamageorinsevereinjuryordeathtopersonnel.
IMPORTANT!
Thepinshouldbeinsertedsothatit’sretainingchannelremains outsidethebushing.
CAUTION!
Iftheassemblyisseized,itmaybenecessarytopryontheedges. Caremustbetakennottodamagetheo-ringoritssealland.
IMPORTANT!
Beforedetachingthesethree(3)lugs,tagthewirestomakereconnectioneasier.
WARNING!
Powershouldnotbereconnectedtotheminerwhilethemotor powercableisdisconnected.Damagetotheminerorpersonal injuryordeathcouldresult.
WARNING!
Federallawrequiresthatminingequipmentelectricalcomponents mustbeinspectedbyacertifiedelectricianbeforetheequipment canbeoperated.
WARNING!
Thisprocedureinvolvesattachinganelectricalpowercabletoa motor.Thetrailingcablemustbedisconnectedandlockedand taggedouttosafelyperformthisoperation.FollowallMine,State, andFederallockout/tagoutprocedures.Failuretodosomayresultinseriousinjuryordeath.
IMPORTANT!
AnMSHAcertifiedelectricianmustinspectallworkandcheckfor permissibility.
IMPORTANT!
Duringtheremovalofthecapscrewsthatsecurethegearcaseto theframe,itmaybenecessarytoadjusttheblockingunderthe gearcase.Ensurethatthegearcaseissecurelyblockedatall timesandthatitdoesnotshiftasitisunbolted.
WARNING!
Standclearoftheminerandthegearcasewhiletrammingthe miner.Youcouldbeseriouslyinjuredorkilledbyfallingloads.
WARNING!
Donotattempttostartthecutterheadmotors.Youcouldbeseriouslyinjuredorkilled.
CAUTION!
Usecarewhentrammingtheminerawayfromthegearcase. Whileeachcuttermotorissupportedbyabracketattherearof themotor,excessivebumpingcouldcausethemotortofall.
NOTICE!
Thegatheringheadcylindersdonothavetoberemovedfromthe frame.Rotatethemawayfromthegatheringheadandsecurely fastenthemtothemainframe.
WARNING!
Donotattempttostartthecutterheadorgatheringheadmotors.
IMPORTANT! Makesurethatthelowersectionoftheconveyorchainisfreeof thefootshaftsothatwhenthemineristrammedawayfromthe gatheringhead,thechainwillpullfreeofthereturndeck.
NOTICE!
Whenthegatheringheadwasremoved,thelowerlengthofthe conveyorchainwaspulledfreeofthegatheringhead.Thisendof theconveyorchainmustbebroughtforwardwhenthemineris trammedtothegatheringhead.
DANGER!
Allpersonnelmuststayclearoftheminerwhileitistrammingand beingalignedwiththegatheringheadassembly.Standingunder thecutterheadorinthepathoftheminerwhileitistrammingmay resultinsevereinjuryordeath.
Overviewofsafetyinstructions _________________________________ CAUTION!
Toavoidinjurywhilerelievingtensionoffoftheconveyorchain, wearproperpersonalprotectiveequipment,toinclude,ataminimum,safetyglassesandgloves.
IMPORTANT! Positionthefootshaftsothatit’ssprocketwillengagetheconveyorchainlinkswhenthechainisreconnected.
WARNING!
Stayclearoftheblockedminerwhilethemachineisenergized. Failuretofollowthiswarningmayresultinseverinjuryordeath.
WARNING!
Thisprocedureinvolvesthealignmentofcylindercleviseswith mountingclevisesinordertoinstallretainingpins.Donotcheck foralignmentwithyourfingers.Shiftingofthealignedpieces couldcauseseriousinjury.
WARNING!
Donotreconnectthetrailingcabletotheminerwhilethepower cableisdisconnectedfromthemotor.Seriousinjuryordeathmay occur.
IMPORTANT!
Iftheminerandthegearcaseassemblyarenotbothleveland alignedcorrectly,installingthegearcaseassemblyintothemachinewillbeverydifficult.
WARNING!
Theendofthechain,justforwardoftheseparationpoint,should beblocked.Personnelshouldstayclearofthechainduringseparationtoavoidinjurywhenthechainisdisconnected.
IMPORTANT!
Besurethattherousersareinthecorrectdirectionbeforeinstallingthechainintothemachine.Checkthepartsbookforyourmachinetoverifythecorrectdirection.
CAUTION!
Toavoidinjurywhilerelievingtensionoffoftheconveyorchain, wearproperpersonalprotectiveequipment,toinclude,ataminimum,safetyglassesandgloves.
NOTICE!
Theconveyorchaindoesnothavearightorwrongrunningdirections,onlyacorrectupanddownside.Theflatsideoftheflight chainsmustrunonthedeck.
WARNING!
Makesureallpersonnelareclearoftheminerbeforeperforming thefollowingchecks.Donotstandbehindtheconveyorwhenthe chainisrunning.
NOTICE!
Ifthepivotpinistight,besuretheliftingdeviceisnotbindingthe pivot.Ifthepivotisnotinabind,usethepullerholetoaidinpin removal.
WARNING!
Besureallconveyorcomponentsarecorrectlyinstalledandthat theconveyorchainisproperlyengagedbythefootshaftbefore startingtheminer.
WARNING!
Someproceduresmustbecarriedoutwiththecoveroftheelectricalcontrollerremovedandsomeproceduresrequirethecontroller tobeenergizedduringthetests.Itisextremelyimportantthatyou takeallnecessaryprecautionstopreventaccidentalelectrical shockwhileworkingwithinthecontroller.AnMSHA-certifiedelectricianmustsuperviseandinspectallworkperformed.
Overviewofsafetyinstructions Chapter6:Technicaldata IMPORTANT!
Thetechnicaldatalistedinthischapterisforstockmachines only.Customerspecialsmaynotbelisted.
IMPORTANT!
Duetotheapplicationoffastenersbeingsubjecttogreatstresses andheavyorextremevibration,itisimperativethatallboltsbe appliedwithanadequateamountoftorque.Forthisreasonthis listofrecommendedtorquesettingsfordifferenttypesandsizes offastenersusedhasbeencompiled.Thetighteningtorques statedinthesparepartslistshavetobeobserved,aswell,forinstallationandmaintenance.
IMPORTANT!
Useacalibratedtorquewrenchforaccuracy!
NOTICE!
UseonlylubricationfluidsandgreasesapprovedbyBucyrus America,Inc.!ThesefluidsandgreaseshavebeentestedatBucyrusAmerica,Inc.andguaranteereliableoperationofthemechanicalandhydraulicfunctionsofthemachine.
IMPORTANT!
Thelubricationfluidsandgreaseslistedinthesametablecanbe mixed.Otherproductsmayonlybeusedifthesuppliercanguaranteethattheyareequivalent.
Differentlycomposedfluidsandgreasesmustnotbemixedas thismaychangetheconsistency,i.e.themixturecanbecome thinnersothatthelubricationeffectisnotsufficient.Itmayalso bedangeroustouselubricatinggreasesandfluidshavingthe samespecificationbasebutdifferentorigins. Incaseofdoubt,themanufacturerofthelubricationtobeused shouldbecontactedastothecompatibilityofthelubricationin question.
IMPORTANT!
BucyrusAmerica,Inc.expresslypointoutthattheapprovalofthe listedproductsrelatesonlytothepuretechnicaluseinourmechanicalandhydraulicsystems.Theresponsibilityfortheconstituentsusedinthehydraulicconcentratesliessolelywiththe respectivemanufacturer.
IMPORTANT!
Besuretousethemanufacturer’sinstructionsforuse.
NOTICE!
Whenperformingmaintenanceonthemachine,allusedoiland lubricantsshouldbestoredanddisposedofperyourlocalEPA standards.
Storageandtransport Storageandtransport Thischaptercontainsimportantinformationonthecorrectstorageand transportoftheContinuousMiner.Storageproceduresaregeneral. Forspecificproceduresforyourenvironment,contactBucyrusAmerica,Inc.Engineering.
Observanceoftheinstructionsandtipswillincreasetheservicelifeand availabilityofthemachine.Youwillalsobeabletocarryoutthetransportworkquickerandmoresafely.Carefulattentiontothepointsin thischapterwillhelpyoutosimplifyyourday-to-daywork.
Storage Componentscoatedwithtemporarycorrosioninhibitorareprotectedfor approximatelysixmonths.
Beforedelivery,thehydraulicfunctionsaretestedandthehydraulic pressuresarepresettoOEMspecifications.
Storageofthemachineandspareparts Storetheequipmentindoorsorcoverwithatarpaulintoprotectagainst directexposuretosunlight.
Protecttheequipmentandallsparepartsstoredoutdoorsagainst moistureanddirt,e.g.usingtarpaulins.
Protectthehydraulicplugconnectorsandtheconnectorsoftheelectricalcableswiththecapsandplugssupplied.
Duringshort-termstorage(approximately4weeks)ofequipmentoutdoors,butattemperaturesabovefreezing,electricalcomponentsneed notberemoved.Suchcomponentsmustbeparticularlyprotected againstexcessivetemperatures,dirt,andmoisture.
Iftheequipmentistobestoredmorethansixmonths,thefollowing lubricationandcorrosioninhibitingproceduresmustbefollowed:
■ Ifthecylinderrodsareexposed,therodsmustbecoatedwitha corrosioninhibitingfluid.
■ Completelyfillthehydraulicoiltankwithoil.
■ Fillallgearcase(s)tothemaximumfilllevel.Thegearcase(s) mustberotatedmonthlytoensurethattheinteriorofthegearcase remainslubricated.
■ Lubricateallgreasepoints(seetheMaintenancesectioninChapter5ofthismanual).
■ Completelydrainthewatersystemandrefillwitha50/50antifreeze/watersolution.Pumptheantifreezemixthroughthesystem untiltheantifreezemixcomesoutthewatersprays.ENSURE THATTHESYSTEMISCOMPLETELYPURGEDANDNOWATERORAIRPOCKETSEXIST.
■ Theequipmentmustbestoredinawellventilated,dryroom.Do notstoreoutdoors.
Storageandtransport Electroniccomponentsmustbestoredattemperaturesbetween -10°C and55°C(14°Fand131°F).
Thetractiondrivesshouldbestoredat -10to50°C(14to122°F).
Majorproblemswithcondensationcanoccurifadriveisstoredina coldenvironmentandisthentakenintoadeepminewherethetemperatureismuchhigher.Eventhoughthehumiditymaybeatanacceptablelevel,condensationwilloccuronthecolddrive.Slightexposuretoacondensingenvironmentisnotharmfulprovidedthedriveis completelydrybeforeelectricalpowerisapplied.
Afterastorageperiodofapproximatelytwoyears,arandomsample inspectionmustbeperformedtodeterminewhetherthemeasures takenandthemethodofstoragehaspreventeddamage. Onrequest,theinspectioncanbecarriedoutbyBucyrusAmerica,Inc.
Evenwithproperstorage,sealsandhosesaresubjecttonaturalageing.Donotusethesepartsiftheyhavebeenstoredformorethantwo years.
Instructionsonthestorageofconcentratesforhydraulicfluidscanbe found,ifrequired,inchapter6inthisoperatingmanual.
IMPORTANT! Takecaretoinsurethatnewmaintenancesuppliesarestored separatelyfromexistingstockandthatremovaltakesplaceonthe “firstin,firstout”principle.
Long-termstorageofsparecomponents Ifacomponentistobestoredmorethansixmonths,thehydrauliccomponentmustbecompletelyfilledwithacorrosioninhibitingfluid.Fillthe hollowareasofhydrauliccomponents(e.g.thepistonchambers)in horizontalposition(portsfacingupwards)untiltheystarttooverflow thensealtheportswithplasticorsteelplugs.
Storetheelectricalequipment,electroniccomponents,sparepartsof rubberorplastic – suchassealsandhoses – andhydraulicfluidsonly inclosedroomsattemperaturesof15°Cto25°C(60°Fto77°F).
Refertothemotormanufacturer’sstorageprocedureguideinyourBucyrusAmerica,Inc.partsmanual.
Rotatetheimpeller1-1/4turnoncepermonthtopreventdimplingofthe motorbearingsrollers.
Inordertopreventplasticdeformationofthesealelements,cylinders mustbestoredinanuprightposition.Somecylindersmustberemoved sothattheycanbestoredupright.
Transport Loadunits:dimensionsandweights Observethetransportsheetsforthemachineandspareparts.They containinformationon:
■ dimensions,
■ weights,
■ liftingpoints,etc.
Additionalinformationonthedimensionsandweightscanbefoundin chapter6andintheliftingweightguide(Table1)inthisoperatingsection.Fig.5illustratesthepositionofliftingeyesontheminer.
WARNING!
Useonlyloadhandlingdevicescomplyingwiththetechnicaland legalregulationsforthetransportofloads.Youcouldbeseriouslyinjuredorevenkilledbyfallingloads.Useonlysuitable loadhandlingdevices.
Table1:LiftingweightsofContinuousMinerAssemblies
CompleteMachine 160,370lbs(72,742kg)
TractorFrameAssembly 75,000lbs(34,019kg)
CuttingHead Assembly 47,000lbs(21,319kg)
GatheringHeadAssembly 19,300lbs(8,754kg)
ConveyorAssembly 15,800lbs(7,167kg)
ConveyorChainAssembly 3,270lbs(1,483kg)
Wheneverpossible,allremovalsshouldbeaccomplishedusinganadjustableliftingbeam.Allsupportingmembers(chainsandcables)should beparalleltoeachotherandasnearlyperpendicularaspossibletothe topoftheobjectbeinglifted.
Whenitisnecessarytoremoveacomponentonanangle,rememberthat thecapacityofaneyeboltdiminishesastheanglebetweenthesupportingmembersandtheobjectincreases.Eyeboltsandbracketsshould neverbebent.
Whenaneyeboltisprovidedtoliftacomponent,useittoliftonlythat component.
WARNING!
Youcouldbeseriouslyinjuredorkilledasaresultoffallingloads. Donotusetheeyebolttoliftthecomponent and itsrelatedassemblies.
Storageandtransport Fig.5:Liftingpoints
Frameliftingpoints Bumperliftingpoints Liftingeye (30ton)
Liftingeye (30ton)
Liftingeye(2) (100ton)
Fig.5:Liftingpoints,continued
Conveyorliftingpoints
Gatheringheadliftingpoints
Liftingeye (4.5ton)
Liftingeye (4.5ton)
Liftingeye (4.5ton)
Liftingeye (4.5ton)
Liftingeye (10ton)
Liftingeye (10ton)
Liftingeye (10ton)
Liftingeye (10ton)
Storageandtransport Fig.5(continued):Liftingpoints
Cutterheadliftingpoints Beforetransport Beforetransportingtheequipmentattemperaturesbelowfreezing,all hydrauliccomponentsoperatedwithemulsion(HFAEorHFAS)must becompletelydrainedandthenfilledwithacorrosioninhibitor/frostproofingfluid.
Transportofequipmentattemperaturesbetween -21°Cand -40°C (-6°Fand40°F)isonlypermissiblewhencertainmeasuresweretaken tomeettheseconditionsatthedesignandmanufacturestages.Nevertheless,theindividualpartsanddevicesofthisequipmentmustnotbe subjectedtosuddenimpactloadsatsuchlowtemperaturesandmay onlybeloadedstaticallyorquasi-statically.
Duringtransportofthisequipmentwithfloor-mountedvehiclesatsuch lowtemperatures,measuresmustalsobetakentoensurethatthe partsanddevicesarenotsubjectedtosuddenimpactloads.Atvery lowtemperaturesandonpoorroads,thetransportvehiclespeedmust thereforebelimitedtoamaximumof25kph(15mph)fortrucktransport.
Electricalandelectroniccomponentsmustbeprotectedagainstharmful environmentalinfluencesbyasuitablepackaging.
Theelectricalcablesremainintheequipment.Theymustbecarefully protectedagainsttransportdamageandsoilingoftheconnections.
Liftingeye (16ton)
Liftingeye (16ton)
Installation Installation Pointstoobservepriortoinstallation
Whoisallowedtocarryoutinstallation?
Installationisonlyallowedtobecarriedoutbypersonnelhavingreceivedadequatetrainingtoperformthistask.
Workon:
■ thesafetycomponents(pressurereliefvalves,fireextinguishing equipmentetc.)
■ theelectricalequipment(controlunits,signalingdevices,etc.)
■ thehydraulicequipment(cylinders,directionalcontrolvalves, hosesetc.)
shouldonlybecarriedoutbyBucyrusAmerica,Inc.serviceengineers orbyspeciallytrainedpersonnel.
Whichtoolsarerequiredforinstallation?
GeneraltoolsarerequiredtoputtheContinuousMinerintoservice.
Variousitemsofauxiliaryequipmentandmachinesmayberequiredat thepointofinstallation.
Theseinclude:
■ hoistswithadequateliftingcapacity
■ meansofattachmentwithadequateliftingcapacity
■ unloadingdockandcribblocks
■ jackswithadequateliftingcapacity
toolbox
installationplan
Notesoninstallation CAUTION! SeriousdamagecanbecausedtotheContinuousMinerasaresultofincorrectinstallation.TheunitshouldthereforeonlybeinstalledundertheinstructionofspecialistsfromBucyrusAmerica, Inc.
BucyrusAmerica,Inc.ContinuousMinersareshippedtothecustomer sitepercustomerpreference.TheContinuousMinercanbeshippedto thecustomersiteasacompletemachineorincomponentsections. Thisdependsonmineconditions,transportationweightrestrictions/ requirements,orsize/weightrestrictionsatthemine.
reassemblyinstructions
IMPORTANT! Thesequenceofoperationsduringinstallationmustbeadaptedto theindividualconditionsprevailingatthesite.Beforestartingthe workadetailedlistofstepstobetakenwithrespecttotransport andassemblyshouldbepreparedandacorrespondingplanestablished.
Whenassemblyisrequiredaftershipmentofthemachine,theassistanceofspecialistsfromBucyrusAmerica,Inc.isrecommended.This willinsurethatthecorrectinstallation,safetyandmaintenanceproceduresarefollowed.
Pre-installationchecklist NOTICE! Themachinewasinspectedpriortoshipmentfromthefactoryto ensureproperfunctioningandinstallationofallcomponents. However,toensurethatnotransitdamagehasoccurred,thefollowingpre-startupchecksshouldbeperformed:
■ visuallyinspectallcylinders,gearboxes,tanks,andhydraulic componentsforleaksordamage.
■ visuallyinspectallelectricmotorsandelectricalcomponentsfor signsofdamage.
■ checkthefulllengthofthetrailingcablefordamage
■ ensurethatthetrailingcableisproperlysuspendedacrossintersectionsandthatthetrailingcableclampattheContinuousMiner issecure
■ cleananyforeignmaterialfromtheconveyorandgatheringpan
■ checkthatallcoversandguardsareinplaceandsecure
■ checkthatalltagsandinstructionlabelsareinplaceandsecure
■ checksafetyprovisionsforoperationalconditiononfiresuppressionsystem
■ performdailymaintenance
■ visuallyinspectallhydraulichosesandelectricalcablesfordamage
■ startupthemachineandcheckforcorrectoperationofallstop andemergencystopbuttons(bothonthemachineandonthe transmitter)
■ afterstartingthemachine,allowthehydraulicsystemtowarmup forfive(5)toten(10)minutesandthencheckhydraulicsystem pressures(refertothehydraulicschematicsuppliedforyourparticularmachineforpressuresettings)
■ checkandoperateallcontrolhandlesandremoteswitchestoensureallmachinefunctionsareoperatingproperlyandareinneutral position
■ checkthetensionoftheconveyorchainandcrawlerchain
machinestopbutton
Safetyfeatures NOTICE!
Theoperatormustbecomefamiliarwithallthesafetyfeaturesand theirlocationonthemachinepriortoinstallationoroperation.
Safetyfeaturesinclude:(ReferenceFig.6)
Themachineisequippedwithtwomachinestopbuttons,oneoneach sideofthemachine.Themachinestopbuttonsareusedtobreakthe controlcircuitonlyinemergencysituations,stoppingallmotors.Strikingwithasmallamountofforcewillactuatethemachinestop.
Thereisalsoanemergencystopbuttonlocatedonthetransmitter.See themanualforyourradiocontrolsforfurtherinformation.
firesuppression(optional)
firesprays(optional)
Themachinemaybeequippedwithfiresuppression(remote)actuators.Ifequipped,thelocationmayvary.Thisparticularsuppression systemispneumaticallyactuatedandextinguisheswithdrychemicals. Toactuatethesystemfromtheactuators,pullthesafetypinandstrike downwardontheplunger.Immediatelyaftertheplungerisstruck,dry chemicalwillbedispensedthroughoutthemachine.Thefiresuppressionsystemmustbecompletelyrechargedwithdrychemicalsandexpellantsafterithasbeenactuated.
WARNING!
Ifeitherofthefiresuppressionactuatorsisactuated,thesystem mustbecompletelyrechargedwithdrychemicalsandexpellants.
Watercanbedirectedtothefirespraynozzles(optional) manually fromafiresprayvalve.Ifequipped,seeChapter5foroperating instructionsandlocationsofthevalves.
Ifequippedwithfiresprays,anelectronicallyactuated solenoidis usedtoactuatethefirespraysystem fromtheremoteposition.
IMPORTANT!
Thefiresprayvalvemustbemanuallysettothenormalposition beforethedustsuppressionwaterspraysystemcanbeoperated.
CAUTION!
Theminesupplywaterpressureatthemachineshouldnotexceed500psiandshouldsupply20gpmminimumforcooling.
TheContinuousMinerisequippedwithanoptionalblowingsystemthat allowstheMineroperatortoapplyfaninducedairtothefaceduring operation.Thefandrawstheairfromeitherintakelocatedattheleft andrightrearoftheMiner.Airisthendrawnfromtherearintakes throughthefanandductwork,tothecrossoverhood,whichislocated onthecutterheadsupportframe.Theblowingsystemassemblyis locatedonthelefthandsideoftheMiner.
Themachineisequippedwithguardsandcoverstoreducethepossibilityofpersonnelcomingincontactwithrotatingormovingparts.All guardsandcoversmustbeinstalledandsecurelyfastenedduringoperation.
DANGER! Donotoperatethemachinewithanyoftheguardsorcoversremoved.Youorotherpersonnelcouldbeseriouslyinjuredfrom movingorrotatingparts.
Therearetwocutterboomsafetysupports,oneoneachsideofthe cutterboom.Thesupportsareusedtoblockupthecutterboomduring maintenanceoperations.
Therearetwoconveyorsafetysupports,oneoneachsideoftheconveyor.Thesupportsareusedtoblockuptheconveyorduringmaintenanceoperations.
Themachineisequippedwithamethanemonitorthatdetectsthepresenceofmethaneinthemineatmosphere.Whentheminerisbeing poweredup,themonitorlooksformethanebeforeanyotherfunctionis energized.Ifthemethanemonitordetectsalevelofmethanewithina presettolerance,themethanemonitorrelaywillcloseandpowerwillbe suppliedtotheotherfunctionsonthemachine.(Themachinecanhave optionaldualsnifferheadsordualreadouts.)
CLICK HERE TO DOWNLOAD THE COMPLETE MANUAL
• Thank you very much for reading the preview of the manual.
• You can download the complete manual from: www.heydownloads.com by clicking the link below
• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.
CLICK HERE TO DOWNLOAD THE
Fig.6:SafetyfeaturesontheContinuousMiner
“MAINCIRCUIT BREAKER”reset
Machinestop
“TRAMCIRCUIT BREAKER”reset
Dualmethane monitordisplays
Fig.6(continued):SafetyfeaturesontheContinuousMiner
Machinestop (locationtypical)
Hand-heldtrampendant
Machinestop (locationtypical)
Radiocontroltransmitter
Fig.6(continued):SafetyfeaturesontheContinuousMiner
Conveyorsafetysupport (storagelocation)
Conveyorsafetysupport (installedlocation)
Fig.6(continued):SafetyfeaturesontheContinuousMiner
Cutterboomsafety support(2)(installed location - typicalboth sides)
Cutterboomsafety support(2)(installed location - typicalboth sides)
Conveyorboom Operator’s station
Fig.7:OverviewoftheContinuousMiner
Crawler assembly
Gatheringhead assembly
Cutterboom
Operation Operation Thischaptercontainsimportantinformationontheoperationandmaintenanceofthemachine.Italsoincludesinstructionsonthereplacementofwearparts.
Readthischaptercarefullyandthoroughly.Inparticular,observethe safetyinstructionsinchapter2“Yoursafety”.
Howtooperatethecontinuousminer DANGER! Incorrectoperationendangersyourselfandothers!Incorrectoperationofthemachineisoftenthecauseofveryseriousaccidents!Operatetheunitonlywhenyouhavebeensufficiently trainedonthemachineandhavereadandunderstoodthisoperatingmanual.Shouldanythingbeunclear,pleasecontactyourimmediatesupervisor.
Whoisallowedtooperatethecontinuousminer? TheContinuousMinerisonlyallowedtobeoperatedbypersonswith adequateknowledgeofthecompletemachine.
Thisalsoincludes:
■ whatsafetydevicesareinstalledonthemachine.
■ wherethesesafetydevicesarelocated.
■ howthesesafetydevicesaretobeoperated.
Whencanoperationbestarted? Operationmustnotbestarteduntilthesafeconditionandproperfunctionofthecompletemachinehasbeencheckedandthedailymaintenanceoperationshavebeencarriedout.
NOTICE! Beforebeginningcuttingoperations,carefullyunloadthetrailing cableprovidingenoughslackandplacingitwhereitallowsadequateclearanceforsafemaneuverabilityoftheminer.
Fig.8:Operator’sstation
Controlsandindicators Operator’sstation
DANGER!
TheContinuousMinerisradioremotecontrolledduringproductionoperations.Manualoperationviacontrolsattheoperator’s stationisnotpermittedforproductionoperation.Manualoperationisfortroubleshootingandmaintenanceundersupportedroof only.Trammingviathetrampendantisonlypermittedinsituationswhentheradioremotesystemisinoperable.Operatingthe ContinuousMinerwithmanualorpendantcontrolsunderunsupportedroofmayresultinsevereinjuryordeath.
Theoperator’sstation(Fig.8)islocatedontherighthandsideofthe machine,neartherearbumper.
“MACHINE STOP” Control breakers
Graphics display
“MINER” selectorswitch
Textdisplay
“CUTTERMOTOR CIRCUIT BREAKER” “TRAMCIRCUIT BREAKER” Machine lighting
Gaugepanel
“CONVEYORHOUR METER”
“CUTTERHOURMETER”
Maincircuitbreaker
Valvebank “WASH DOWN HOSE” valve
“MACHINESTOP”
“MINER”operation selectorswitch
“MACHINELIGHTING”operation selectorswitch
The“MACHINESTOP”button(Fig.9)isalargeredpushbuttonlocatedontheleftoftheoperator’scase.Pushing“MACHINESTOP”will shutdownthepump,causingtheminertoshutdown.Torestartthe minerafterpushingthe“MACHINESTOP”button,followthenormal startupprocedureforthepump(seeStartupproceduresinthischapter).
The“MINER”operationselectorswitch(Fig.9)islocatedtotherightof the“MACHINESTOP”button.Theselectorswitchhasthreepositions:
■ “E-TRAM” - Turningtheswitchtothispositionallowstheminerto betrammedfromthependantcontrols.“E-TRAM”isusedinthe eventthattheoperatorloseshisradiolinkwiththeminer.
■ “REMOTE” - Duringnormalminingoperations,theswitchshould beinthe“REMOTE”position.Thisallowstheminertobecontrolledbytheradioremotesystem.
■ “GNDCHK” - Placingtheoperationswitchinthegroundcheck positionshouldcausetheminepowercentertotrip,therebyshuttingdownallpowertotheminer.
The“MACHINELIGHTING”operationselectorswitch(Fig.9)islocated totherightofthe“MINER”operationselectorswitch.Theselector switchhasfourpositions:
■ “ALLON” - Locatedat3o’clock,turningtheswitchtothisposition allowsallmachinelightingtobeturnedon,includingheadlightsand arealights.(Theheadlightscanbeturnedonorofffromthetransmitter.Thearealightsarehard-wiredandcannotbeturnedoffby thetransmitter.)
■ “ALLOFF” - Locatedat12o’clockand6o’clock,turningthe switchtothispositionallowsallmachinelightingtobeturnedoff.
■ “AREALIGHTSONLY” - Locatedat9o’clock,turningtheswitch tothispositionallowsonlyarealightstobeturnedon.
Fig.9:“MACHINESTOP,”“MINER”and“MACHINELIGHTING” selectorswitches
“MINER”selector switch “MACHINESTOP”
“MACHINE LIGHTING” selector switch
controlbreakerswitches
“CONVEYORHOURMETER”
“CUTTERHEADHOURMETER”
“CUTTERMOTORCIRCUIT BREAKER”
Therearesixteencontrolbreakerresetbuttonslocatedacrossthetop oftheoperator’scase(Fig.10).Thebuttonwillpopoutwhenthecircuit breakertrips.Toresetacircuitbreaker,pushthebuttonin.
SeetheElectricalsectioninthischapterfordetailedinformationonthe individualbreakers.
Fig.10:Controlbreakerresetswitches
“TRAMCIRCUIT BREAKER”
The“CONVEYORHOURMETER”(Fig.11)indicatesthehoursofrunningtimefortheconveyormotors.
The“CUTTINGHEADHOURMETER”(Fig.11)indicatesthehoursof runningrimeforthecutterheadmotors.
The“CUTTERMOTORCIRCUITBREAKER”lever(Fig.11)isusedto turnthecircuitbreakerforthecuttermotors.Thisbreakermustbeon beforethecuttermotorswillstart.Toturnthecircuitbreakeron,move thelevertotheright.Toturnthecircuitbreaker“OFF”,movethelever totheleft.
The“TRAMCIRCUITBREAKER”lever(Fig.11)isusedtoturnthecircuitbreakerforthetrammotors.Thisbreakermustbeonbeforethe trammotorswillstart.Toturnthecircuitbreakeron,movetheleverto theright.Toturnthecircuitbreaker“OFF”,movethelevertotheleft.
Fig.11:“CONVEYORHOURMETER,”“CUTTERHEADHOUR METER”,“CUTTERMOTORCIRCUITBREAKER”and“TRAMCIRCUITBREAKER”
“CONVEYORHOUR METER”
“CUTTER MOTOR CIRCUIT BREAKER”
“TRAM CIRCUIT BREAKER”
“CUTTERHEAD HOURMETER”
Valvebank Themanuallyoperatedvalvebank(Fig.12)islocatedontherighthand sideoftheoperator’sstationandisusedtooperatetheminerduring maintenanceandtroubleshootingfunctionswhileundersupportedroof.
NOTICE! Onceahydrauliccontrolvalvehandleisreleasedbytheoperator, theleverwillautomaticallyreturntothecentered(“HOLD”)position.
Thefirstleverfromtheoperator’sleft,“CUTTINGHD”,controlsthecylindersthatraiseandlowerthecuttinghead.Toraisethecuttinghead, pullthelevertowardtheoperator.Tolowerthecuttinghead,pushthe leverawayfromtheoperator.
Thesecondleverfromtheoperator’sleft,“CONVEYOR”-”LOWER/ RAISE”,controlsthecylindersthatraiseandlowertheconveyorboom. Toraisetheconveyor,pullthelevertowardtheoperator.Tolowerthe conveyor,pushtheleverawayfromtheoperator.
Thethirdleverfromtheoperator’sleft,“CONVEYOR”-”LEFT/RIGHT”, controlstheconveyorswingcylinders.Toswingtheconveyorboomto theleft,pushtheleverawayfromtheoperator.Toswingtheconveyor boomtotheright,pullthelevertowardtheoperator.
Thefourthleverfromtheoperator’sleft,“GATHHD”,controlsthecylindersthatpositionthegatheringhead.Toraisethegatheringhead, pushtheleverawayfromtheoperator.Tofloatthegatheringhead, pullthelevertowardtheoperator.
Thefifthleverformtheoperator’sleft,“STABILIZER”,controlsthecylinderthatraisesandlowersthestabilizershoe.Toraisethestabilizer shoeoffofthefloor,pullthelevertowardtheoperator.Tolowerthe stabilizershoetothefloor,pushtheleverawayfromtheoperator.
Fig.12:Valvebank
“CUTTINGHD”
“CONVEYOR” “RAISE/LOWER”
“CONVEYOR” “LEFT/RIGHT”
“GATHHD” “STABILIZER”
Gaugepanel
Thereisagaugepanel(Fig.13)consistingofnine(9)gaugeslocated abovetheoperator’sstationthatisusedtomonitorhydraulicandwater pressurethroughouttheminer.
Thefirstgaugefromtheoperator’sleftontherowofgaugesis“LH HEADSPRAYPRESSURE.”Thisgaugeisusedtomonitorthewater pressureatthelefthandcutterheadspraymanifoldinthedustsuppressionsystem.Thegaugesettingsaredependentontheindividual minerequirements.ConsulttheschematicintheBucyrusAmerica,Inc. PartsManualforyourmachine.
Thesecondgaugefromtheoperator’sleftonthetoprowofgaugesis “RHHEADSPRAYPRESSURE.”Thisgaugeisusedtomonitorthe waterpressureattherighthandcutterheadspraymanifoldinthedust suppressionsystem.Thegaugesettingsaredependentontheindividualminerequirements.ConsulttheschematicintheBucyrusAmerica, Inc.PartsManualforyourmachine.
Thethirdgaugefromtheoperator’sleftontherowofgaugesis “OUTBYWATERFILTERPRESSURE.”Thisgaugemonitorsthepressureofthesupplywatercomingintothewatersystemfromthemine. Thepressureshouldbeaminimumof250psiunderdynamicconditionsandshouldnotexceed500psi.Ifthepressureexceeds500psi, immediatelyadjustthesupplywaterpressureorshutdownthemachine (seeShutdownprocedureinthischapter).
Thefourthgaugefromtheoperator’sleftontherowofgaugesis“MAIN PRESSURE.”Thisgaugeisusedtomeasurethepressureinmainflow - primarypressurecircuit.SeetheMainflow - primarypressurecircuit intheHydraulicsectionofthischapterforfurtherinformation.
Thefifthgaugefromtheoperator’sleftontherowofgaugesis“PILOT CIRCUITPRESSURE.”Thisgaugeisusedtomonitorthesupplypressureforallpilotfunctions.SeethePilotpressurecircuitintheHydraulic sectionofthischapterforfurtherinformation.
Thesixthgaugefromtheoperator’sleftonthetoprowofgaugesis “ACCUMULATORPRESSURE.”Thisgaugeisusedtomonitortheaccumulatorpressure.Thepurposeoftheaccumulatoristostorethe necessarypilotpressuretoallowremoteoperationofthefiresuppressionandbreakeron/offcontrolvalves(optional)whenthepumpisnot operational.Theaccumulatorpressureshouldcloselytrackthepilot circuitpressure.Iftheaccumulatordoesnotholdpressurewhenthe pumpisshutdown,callmaintenance.Seetheaccumulatorcircuitin theHydraulicsectionofthischapterforfurtherinformation.
Theseventhgaugefromtheoperator’sleftontherowofgaugesis“GH FLOATPRESSURE.”Thisgaugeisusedtomonitorthepressurein thegatheringheadcircuitduringgatheringheadfloatoperations.See theGatheringheadraise/hold/float-lowercircuitintheHydraulicsection ofthischapterforfurtherinformation.
“CONVEYORCHAIN TAKE-UPPRESSURE”
“SHEARDOWN PRESSURE”
Theeighthgaugefromtheoperator’sleftontherowofgaugesis “CONVEYORTAKE-UPPRESSURE.”Thisgaugeisusedtomonitor thepressureoftheautomaticconveyorchaintensioner.SeetheConveyortake-upcircuitintheHydraulicsectionofthischapterforfurther information.
Theninthgaugefromtheoperator’sleftontherowofgaugesis “SHEARDOWNPRESSURE.”Thisgaugeisusedtomonitorthepressureofthecuttingheadcylindercircuitduringsheardownoperations. SeetheSheardown/maintenance(anti-chatter)valveintheCutter headcylindercircuitintheHydraulicsectionofthischapterforfurther information.
Fig.13:Gaugepanel
“LHHEAD SPRAY PRESSURE” “RHHEAD SPRAY PRESSURE”
“OUTBYWATER FILTER PRESSURE”
“MAIN PRESSURE” “PILOT CIRCUIT PRESSURE”
“ACCUMULATOR PRESSURE” “GHFLOAT PRESSURE”
“CONVEYOR CHAINTAKE-UP PRESSURE” “SHEAR DOWN PRESSURE”
Themaincircuitbreakercase(Fig.14)islocatedattherighthandof theoperator’sstation.Incomingcableisconnectedtothemachinevia thecablehandlerandorcablesocket.
Thecasecontainsacircuitbreakerproviding600Aoverloadand 1500Ashortcircuitprotectiontothemachine.Thecircuitbreakeralso functionsasanisolationdeviceforthemachine.
DANGER! Powertothemachinemustalwaysbeisolatedfromthetrailing cableatthesectionpowercenterbeforeeithersocketisremoved orthemaincircuitbreakercaseisopened.Wheneveranyworkis performedonthecontinuousminer,followregulationsregarding lockout/tagoutofthemachine.
Fig.14:Maincircuitbreaker
maincircuitbreaker
Maincircuit breaker
methanemonitordisplays (typical)
Themachineisequippedwithamethanemonitoringsystem(Fig.15) which,whenenergized,maintainsacontinuouscheckonmethanegas concentration.ThismachinehastwoLEDindicatordisplayswhich showthepercentageofmethanegasinlargernumerals.
Consultthemanufacturer’smanualandliteratureintheBucyrusparts bookforyourmachineforthesetup,operation,andmaintenanceofthe methanemonitoringsystem.
IMPORTANT! Itistheresponsibilityofthecontinuousminerowner/operatorto knowandfollowallregulationsregardingmethanemonitoringrequirements,including,butnotlimitedto,dailyoperation,maintenanceandtesting.
Fig.15:Methanemonitordisplays(typical)
Methanegas concentration percentage
receivercontrolunit
Machinecontrolsystem Amulti-componentsystemisusedtocontrolandmonitorthefunctions ofthemachine.Thissystemconsistsofthefollowingmaincomponents:
■ Receivercontrolunit
■ Powersupply
■ Input/Output(I/O)modules
■ Remotecontroltransmitter
■ Graphicsdisplay
Thefollowinginformationispresentedasageneralguidetothecapabilitiesandfunctionsofthecontrolsystem.Beforeattemptingtooperate,service,ortroubleshootthecontinuousminer,trainingmustbe completed.
Thereceivercontrolunitisthemaincontrolunitofthesystem.Itincludestheradiodatareceiverwhichisusedtoreceiveanddecode commandsfromtheremotecontroltransmitter.
powersupply
Input/Outputmodules
Thecontrolsystemhasitsownpowersupply,withtheoptionofhaving batterybackupforthepowersupply,whichprovidespowertothereceivercontrolandI/Omodules.
Input/Outputmodulesareusedtoreaddatafromand/orsendcommandstothefollowingmachinefunctions:
■ Cuttermotors(leftandright)
■ Gatheringheadmotors(leftandright)
■ Tractionmotors(leftandright)
■ Pumpmotor
■ Hydraulicoillevel
■ Methanemonitoring
Basedontheparametersettingsandtheinputreceivedfromdifferent components,thecontrolsystemshastheabilitytoissueerrormessages,faultmessages,and/orshutdownthemachine.
radiocontroltransmitter
Theradiocontroltransmitter(Fig.16)isabatterypoweredremoteused tocontrolthecontinuousminerduringnormaloperations.
WARNING!
Radioremotecontrolsystemsaredangerous.Thecontinuous mineroperatorcannotoperatearemotesystemuntilheisproperlytrainedintheoperationofthesystem.Remotecontrolsystemssometimeshaveautomaticfeaturesofwhichuntrainedoperatorsandworkersmaynotbeaware.
Fig.16Radiocontroltransmitter(typical)
Theremotecontroltransmittershownmayvaryfromthetransmitter thatshippedwithyourmachine.
IMPORTANT! Refertotheradioremotecontroloperationmanualsuppliedwith yourmachineforinformationregardingtheoperationofyourspecificremotecontrol.
Therearetwodisplayslocatedonthemachine:agraphicsdisplaylocatedattheoperator’scaseandatextdisplaylocatedneartheback righthandsideofthemachine(Fig.17).Bothscreensareusedtodisplaydiagnosticinformationontheminer.
Fig.17:Controlsystemdisplaylocations(typical)
displays Thegraphicsdisplay,locatedontheoperator’scase,isusedtomonitor machineoperatingparameters,fordiagnosingerrorandfaultcodes, andforinputofoperatingparameters.
Thetextdisplay,locatedonthenearthebackrighthandsideofthe machine,hasthesamefunctionsasthegraphicsdisplay.Ifthecontrol systemlosespower,thetextdisplaywillremainpoweredthroughthe batterybackup.
NOTICE! Informationpriorityisgiventothegraphicsdisplayunlessthe graphicsdisplaybecomesunhealthy.Thetwomonitorswillnot necessarilydisplaythesameinformationatthesametime.
Therearedifferentscreensthatcanbedisplayed:productionmonitoring,functionmonitoring,diagnostic,motorhours,andfaultpages.A systemhaltmessagecanappearasapop-updialogboxinthemiddle ofanyscreen.Amessagewillappearwhenacriticalconditionshas occurredthatpreventscontinuedoperationofthemachineinasafe manner.Themessageboxcannotbeclearedanditisnecessaryto recyclepowertothecontrolsystemtorestoremachineoperation.
Normaldisplaypages Themaindiagnosticscreen(Fig.18)isdisplayedduringnormalremote controloperationofthemachine.Thescreenpresentsrealtimediagnosticandperformanceinformation.
Fig.18:Mainpage,example
Graphicsdisplay
Textdisplay
SystemMenu Thecontrolsystemprovidesinformation,diagnostic,andsetupscreens thataregroupedtogetherinthesystemmenu(Fig.19).Thesystem menuisaccessedbyusingeitherdisplaymoduleandaremotecontrol handset.
Toaccessandnavigatethesystemmenuusingtheradioremote:
PresstheSHIFTandMENUkeytoaccessthesystemmenu screen.
IMPORTANT! Allfunctionsandmotorsareshutdownanddisablewhenthesystemmenuisselected.
PressCONVUPorCONVDOWNtomovethecursorupanddown thelist.
PressSHIFTandMENUtoselectthehighlighteditem
Toleavethemenuandreturntoremotemode,pressSHIFTand REMOTE.
Fig.19:Systemmenu,example
Fig.19:Systemmenu,example,continued
Textdisplay
DiagnosticMode Diagnosticmodeallowsalargenumberofmonitoringscreenstobe selectedanddisplayedwhilethemachineisoperating.Eachscreen provideshelpfultroubleshootinginformationsuchasmachineinformation,softwarerevision,andmachineconfiguration.Italsoprovidesthe statusofthemotors,digitalandanaloginputs,etc.Diagnosticmodeis forinformationalpurposesonly.Noconfigurationchangescanbe madewithinthismode.
Tonavigatethroughthescreens,holdtheSHIFTswitchwhilepressing aconveyorswitch.Toreturntothemainmenu,pressSHIFTand MENU
Graphicsdiagnosticsincludesthefollowingpages:
■ Mainmonitor
■ Productionmonitor
■ Pumpmonitor
■ Cuttermonitor
■ Conveyormonitor
■ I/Omonitor - relayoutputs
■ I/Omonitor - digitalinputs
■ I/Omonitor - analogoutputs
■ Solenoid6 - breakerresetmonitor
■ Solenoid5 - dustsprayandfiresuppression
■ Solenoid4 - stabliftmonitor
■ Solenoid3 - gatheringheadmonitor
■ Solenoid2 - conveyorliftmonitor
■ Solenoid1 - conveyorswingmonitor
■ Solenoid0 - cutterliftmonitor
■ Inverterrightmonitor
■ Inverterleftmonitor
■ Rectifiermonitor
■ Smartslicemonitor
■ Thermistormonitor
■ Motormatenetworkmonitor
■ CANnetworkmonitor
SeeFig.20forexamplescreenshotsofvariousdiagnosticpages.
Fig.20:Graphicsdisplaydiagnosticpages,examples
Fig.20:Graphicsdisplaydiagnosticpages,examples,continued
Textdiagnosticsincludesthefollowingpages:
■ Mainmonitor
■ Machineinformation
■ Pumpdiagnostics
■ Cutterdiagnostics
■ Conveyordiagnostics
■ Fandiagnostics
■ Tramdiagnostics
■ 24VDCdigitalinput
■ I/Omonitor - relayboard
■ I/Omonitor - solenoidboard
■ I/Omonitor - analogoutputs
■ Solenoidboarddiagnostics
■ Relayboardstatus
■ Powersupplystatus
■ Thermistormodulestatus
Fig.21:Textdisplaydiagnosticpages,examples
Faultlog
Thefaultlog(Fig.22)allowstheusertoviewthelast100faultsthat haveoccurredsincethelogwaslastcleared.
Tonavigatethefaultlogpage:
PresstheCONVUPorCONVDOWNkeytomovethecursorupor downthepage.
PressSHIFTandCONVUPorCONVDOWNmoveupordown onepage.
ItispossibletoclearthefaultlogundertheEngineeringSetupMenu, whichispasswordprotected.
IMPORTANT! Itisnotrecommendedthatthefaultlogbeclearedunlessthereceiverhasbeenreplaced.Retainingthefaultsisveryhelpfulin troubleshootingaproblemwhenareceiverissentforservice. Faultscannotberetrievedoncetheyhavebeencleared.Usecautionandonlyclearthelogifitisabsolutelynecessary.
Onceafaulthasbeenselected,theSHIFTandMENUkeyscanbe usedtoaccessmoreinformationonthefault(Fig.23).
Fig22:Faultlog,example
Graphicsdisplay
Fig.22:Faultlog,examples,continued
Textdisplay
Onceafaulthasbeenselected,theSHIFTandMENUkeyscanbe usedtoaccessmoreinformationonthefault(Fig.20).
Fig.23:Faultdetailedinformation,example
Foracompletelistoffaults,seethetroubleshootingsectionofthis chapter.
Hourmeters Selectinghourmeters(Fig.24)fromtheMainMenuwilldisplayruntime forthefollowingmotors:pump,fan,leftcutter,rightcutter,andconveyor.Timeisdisplayedinhours:minutes:secondsformat.Thisruntimeonlyreflectsaccumulatedtimesincethereceiverhasbeeninstalledorsincethecounterwaslastreset.Thehourmeterscanbe clearedundertheEngineeringSetupMenu,whichispasswordprotected.
IMPORTANT! Thehoursmetersshouldonlybeclearedwhenamotorisreplaced orwhenthereceiverisinstalled.Tokeepanaccuratelogofamotor’stotalhours,theinformationshouldberecordedanytimedata iscleared.
SetupMenus
Therearethreepasswordprotectedsetupmenusavailable:Tradesman,Engineering,andOEM.Informationregardingtheadjustableparametersaccessedoneachscreenisgiveninthemachinespecific training.
Fig.24:Hourmeters,examples
Trampendant
Themachinecanbeoperatedusingapendantcontrol(Fig.25)connectedtotheminerbyanumbilicalcable.Thiscontrolisusedinthe eventthattheoperatorlosesradiolinkwiththeminetosafelyrecover theminerfromthefacetoanareaundersupportedrooffortroubleshootingandmaintenance.
Thependantcontrollerallowslimitedoperationofthemachine:trammingandpumpmotoractivationtoprovidehydraulicpowertoraiseor lowerthecuttinghead.
Inordertousethependant,itmustbeconnectedtothemachineviaa pigtail.Afterpluggingintheumbilicalcord,the“MACHINE”modeof operationswitchmustberotatedtothe“E-TRAM”.
IMPORTANT! Thependantcontrolleranditsumbilicalcordshouldbestoredina protectedlocationontheworkingsection,awayfromtheminer,to preventdamage.
Fig.25:Trampendant
Redzone Remotecontrolledcontinuousminers
Theremotecontrolofminersintroducescertainpotentialsafetyhazards whichthemineroperatormustwatchforandbeawareof.Whilethe operatorisnowfreetopositionhimselfforconvenientvisibilityofmining operationsattheface,hecaneasilyexposehimselftothedangerof beingnearmobileheavyequipment.
Mostsignificantly,theoperator’sgreatestdangerisfromhisContinuous Miner,especiallywhenheismaneuveringitduringminingoperations. Themineriscapableofslewingwhenturning,especiallywhenthe crawlersaresplit.Thedischargeconveyorcanalsoswing.Ineachof thesecases,themineroperatorisindangerofbeinghit,orworseyet, runoverbyhisownmachine.Equallydangerousisthepossibilityof theoperatorbeingpinnedagainsttheribbyhisownminer.
Mineroperatordangerareas,orRedzones Sometypicalsituationsdangeroustothemineroperatorareillustrated onthefollowingpages.Thedangerarea,orredzone(Fig.26)isindicatedbyalternatingredandwhitediagonalstripes.
Fig.26:Redzone
Trammingtheminer (Fig.27)fromoneplacetoanother,especially maneuveringaroundintersections.Thisillustratesthattheoperator shouldnotplacehimselfbetweenhisminerandtherib.
Beginningthefirstsump (Fig.27)inanewcut.Theminerisagainst theleftribandthedischargeconveyorisswungtowardthecenterof theentryreadyforthehaulagecar.Theoperatormuststayclearofthe dischargeconveyorandtherearoftheminer.
Fig.27:Redzones
Trammingtheminerredzone Beginning1stsumpredzone
Sumpinginthelefthandside ofthecut(Fig.28).Astheminerpenetratestheface,newunsupportedroofisbeingexposed,andtheoperatornowhasanadditionalconstrainttohismovements.Hemustalso stayclearofthehaulagevehicleattherearoftheminerasitapproachestheminerandwhileitisloading.
Repositioningtheminerfortherighthandcut (Fig.28).Because theminerisbackingoutandturninginclosequarters,theoperator muststaybehindtheminertobesafe.
Sumpingintherighthandcut (Fig.28).Again,theoperatormust stayawayfromthefacewherethenewly-exposedroofisunsupported, aswellasstayingclearofthehaulagevehiclewhileitapproachesand loads.
Sumpingonthelefthand sideredzone
Sumpingintherighthand cutredzone
Repositioningminerforright handcutredzone
Fig.28:Redzones
Crosscutredzones (Fig.29). Beginningandcompletingcrosscuts requiresalotofmaneuveringoftheminerandloadingthehaulagevehiclewhileatawkwardpositions.Crosscutsalsoresultinnewlyexposedunsupportedroof.Respectingareddangerzoneisimportant tooperatorsafetyintheseconditions.
Whentheminerbeginningarighthandcrosscutitisnearlyagainstthe opposite(lefthand)rib,whilethedischargeconveyorisswungtoits maximum45o rightpositionforloadingthehaulagevehicle.Hence,the entirerearofthemineristreatedasaredzone.Therearetwoother dangerareas.Ontherighthandside,theminerformsapinchpointat theribwhichmustbeavoided.Also,onthelefthandsideoftheminer, astheminerprogressesintotherib,asharp-angledfenderwillbe formedwhichwillbesusceptibletosloughingandfallingoff.Hence, thatribmustbeconsideredaredzone.
Theredzonesurroundstheminerasthedischargeconveyorisfreeto swingeitherwayandmoreunsupportedroofisexposedduringthefurtherdevelopmentoftherighthandcrosscut.
Beginningarighthand crosscutredzone
Righthandcrosscut development
Fig.29:Crosscutredzones
Pillaringredzones (Fig.30) Remotecontroloffersasignificantsafety advantageinpartialorcompleteremovalofthepillarsinretreatmining becauseitplacestheoperatorfurtherawayfrompotentialcollapsing roof.
Muchoftheareaaroundtheminermustbeconsideredaredzone, mostlybecauseofextensiveunsupportedroofandtheneedfortemporarysupportsunderweakenedroof.Withremotecontrol,theoperator canpositionhimselfsafelyawayfromtheminerwhilestillretaininga goodviewoftheminingcycle.
Aredzonearoundtheminerisnolongerapplicablewhenworkingin theoppositerighthandpillar,astheoperatorisnowexcludedfromthe entireworkingareabecauseoffailingroofconsiderations, evenwiththe existenceoftemporaryroofsupports
Whenmakinganadditionalendcutintothepillar,creatingafenderof coalbetweenthetwocuts,additionaltemporaryroofsupportsareinstalled.
Becauseofroofpressures,thefenderwilltendtosloughitsribsinthe processofeventuallycrushing.Hence,theoperatormuststayaway fromthisfenderaswellasavoidingtheentryandcrosscutareasas shown.
Fig.30:Pillaringredzones
Safetyprecautionsforundergroundoperation
InadditiontotheprecedinginstructionsforoperatingtheContinuous Miner,observethefollowingspecialprecautionsaftertheContinuous Mineristakenunderground.
■ Communicationisakeyelementinmaintainingsafety.Exactinstructionsandwarningsshouldbegivento,andthoroughlyunderstoodbyeachworkman.Goodcommunicationsbetweentheentire crewmustbemaintainedthroughouttheshift.
■ Checktheconditionofthetrailingcablebeforeturningpoweronat thepowersource.
■ Thismachinemustbemaintainedinapermissiblecondition,followingallstateandfederallaws.
■ MakeavisualcheckoftheContinuousMinerbeforeenergizing. Lookforloosebolts,covers,lockingdevices,damagedparts,and crackedorbrokenlenses.Anypartofthemachinewhichdoesnot functionproperlyisahazard.Reportitimmediatelytoyourimmediatesupervisorortheirdesignee.
■ Whenoperatingtheblowingsystem,theoperatorshouldstandto thelefthandrearoftheminertoavoidairflowanddebrismoving acrosscuttingheadandrighthandsideoftheMiner.
■ Priortooperation,makesuretheworkingareaissafe.Makea visualinspectionofroofandribsandtakeallstepsnecessaryto insuresafety.
Trammingsafetyrules ■ Communicateyourintentionstotheworkmenaffectedbythe movementoftheContinuousMiner.
■ Checkthepositionofthewaterhoseandtrailingcabletobe sure thereissufficientslacktofinishtheoperation.
■ Notetheconditionoftheroadwaysandphysicalsurroundingsof theroute.
■ Positionthecutterandgatheringheadfortramming.
■ Positionthestabilizershoeandboomsfortramming.
■ Positionyourbodycompletelyinsidetheoperator'scompartment (optional),facingtheintendeddirectionoftravel.
■ PositiontheContinuousMinerinthecenteroftheroadwaytoallowmaximumsafeclearance.Consistentlymaintainclearance, whichiscriticaltothesafemovementoftheContinuousMiner.
Startingprocedure WARNING!
Failuretoreadandunderstandalloperatinginstructionsbefore startingtheContinuousMinercouldresultinseriousinjuryor deathtotheoperatororpersonsaroundthemachineorcause damagetothemachine.
WARNING!
Readallinstructionscarefullybeforeattemptingtostartoroperatemachine.
WARNING!
UnderstandthefunctionsofallcontrolsbeforestartingtheContinuousMiner.Readandfollowtheinstructionsonallwarning tagsonthemachine,observeallregulationsandsafetyprecautions.
WARNING!
NeveroperateaContinuousMinerwhichhasbeendamagedoris notoperatingproperly.AnypartoftheContinuousMinerwhich doesnotfunctionproperlycanbeahazard.Reportitimmediately toyoursupervisorortheirdesignee.
WARNING!
BeforestartingtheContinuousMiner,makesurethatnooneisin theredzone(Fig.26throughFig.30).
NOTICE!
Inextremelycoldweather,allowmotorsandgearcasestoidle. Thiswillwarmthehydraulicoilsandlubricants.Stilloilsand greasescouldimmobilizethemachine.
IMPORTANT!
Apump“growl”meansnotenoughoilisreachingthepumps throughthesuctionlines.Ensurethepumpgetsprimedbefore continuingoperation.Alwayschecktheoillevel.
DANGER! Improperpositioncouldresultininjuryordeathtotheoperator bycrushinghimagainsttheriborroofsupports.Itmayalso causehimtorunoverthetrailingcableordislodgetheroofsupports.
WARNING!
Turningonthewatersprayspriortocuttingpreventstheaccumulationofdustandthegenerationofexcessiveheatwhichcould causeanignitionorexplosion.
WARNING!
Whenoperatingtheblowingsystem,theoperatorshouldstandto thelefthandrearoftheminertoavoidairflowanddebrismoving acrosscuttingheadandrighthandsideoftheMiner.
Afterreadingthepreviousdescriptionsandlocatingeachcontrol,the operatorisreadytooperatetheContinuousMiner.Anexperienced operatorshouldmonitoranewoperator’sindoctrinationtothestarting procedure.
TheContinuousMineristypicallyoperatedbyradioremotecontrol. Manualoperationisnotallowedforproductionoperationunlessthe minerhasanoperator’spitandcanopy.Manualoperationgenerallyis fortroubleshootingandmaintenanceunderroofsupport.
WARNING! TheContinuousMineristypicallyoperatedbyradioremotecontrol.Manualoperationisnotallowedforproductionoperation unlesstheminerhasanoperator’spitandcanopy.Manualoperationgenerallyisfortroubleshootingandmaintenanceunderroof support.
Theoperatingprocedureslistedinthefollowingsectionsareforradio operation.
IMPORTANT! Beforestart-up,checkthatdailymaintenancehasbeenperformed onthemachine.
WARNING! Visuallycheckforotherpersonnelandverballyshoutawarning beforestartingthismachine.Makesureallpersonnelarecompletelyclearofthemachineandit’scomponentsandcheckthat anyloosematerial,tools,oilcansorotherobjectsareclearfrom theareabeforestartingthemachine.
Turnthemaincircuitbreakertothe“ON”position.
Select“RADIO”onthe“RADIO/MANUALSW.
Turnthepowerswitchonradiotransmittertotheonposition.
Press“SHIFT”andwait1/4second.
Whilepressing“SHIFT”,press“PUMPON”.Holdbothkeysinuntil thepumpstarts.
Releasethe“PUMPON”key.
IMPORTANT!
The“PUMPON/OFF”keymustbereleasedbefore“SHIFT”.If “SHIFT”isreleasedfirst,thepumpmotorwillshutoff.
Releasethe“SHIFT”key.
Shutdownprocedure TheContinuousMinermustbeproperlyshutdownbeforeleavingthe areaorbeforeperforminganymaintenanceorservice.Somemaintenanceorserviceproceduresmayrequireadditionalstepstoinsurethe safetyofthemaintenancepersonnelworkingonoraroundthemachine andwillbelistedinthemaintenancesectionofthisguide.
Backthemineraboutonefootfromthefaceprovidingsufficient clearanceandshutoffthecutterheadmotors(seeCutteroperation inthissection).
Tramtheminertoanareaofwellsupportedroof.Parkthemachine initsdesignatedparkingareaoutoftraffic,onflat,solidground.Ifit isnotpossibletoparkthemachineonflatground,parkthemachine atarightangletotheslope.
WARNING! Afterturningoffthepowertothemachine,neverwalkawayand leavethetransmitterturnedon.Failuretoturnthetransmitteroff couldresultinanaccidentcausingseriousinjuryorlossoflife.
Emptytheconveyorandshutitoff(seeConveyoroperationinthis chapter).
Lowerthecutterheadtothefloor.
Lowertheconveyorandgatheringhead.
Pressandholdthe“PUMPOFF”key.Thepumpmotorshould shutdownimmediately.
Releasethe“PUMPOFF”key.
Turnoffthewatersprays.
PositionallleversandcontrolstoNeutralorOff.
Shutoffthemainpowersupply.
Shutofftheminewatersupply.
Trammingtheminer Trammingrequirescoolingwatertopreventdamage.
NOTICE!
TheContinuousMinerhasskidtypesteering:itiscapableofturningwithinitsownlimits.
WARNING!
Trammingrequirescoolingwatertothetrammotors.Failureto coolthemotorswillresultinmotordamageandprematurefailure.
Ensurethatthestabilizershoeisawayfromtheminefloor.
Raisecutterboomtobestpossiblepositiontoallowclearancefrom roof,ribs,andfloor.
Raisegatheringheadawayfromtheminefloor.
Adjustconveyorboomtobestpossiblepositiontoallowclearance fromroof,walls,andfloor.
WARNING!
Adjustconveyorboomtoallowclearancefromroof,walls,and floor.Failuretodosowillresultindamagetotheconveyorboom.
Ensureadequateclearanceatalltimeswhiletrammingmachine. Beawardofpeople,equipment,andcables.
Remotecontrol - tramenable
Toenablemachinetramming,pressandreleasethe“TRAM2-3” key.
Onceenabled,thetramleverscanbeusedtodriveleftandright trammingtracksforwardsandbackwards.Ifthetramleversare releasedforacontinuousperiodoffive(5)seconds,thetrambecomesdisabled.
Tore-enablethetramfunction,pressandreleasethe“TRAM2-3” key.
Remotecontrol - tramtrackconsole
Pressthe“LEFTFWD”tramkeytoturnthelefttrammingtrackforward.
Pressthe“LEFTREV”tramkeytoturnthelefttrammingtrack backwards.
Pressthe“RIGHTFWD”tramkeytoturntherighttrammingtrack forward.
Pressthe“RIGHTREV”tramkeytoturntherighttrammingtrack backwards.
CLICK HERE TO DOWNLOAD THE COMPLETE MANUAL
• Thank you very much for reading the preview of the manual.
• You can download the complete manual from: www.heydownloads.com by clicking the link below
• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.
CLICK HERE TO DOWNLOAD THE
Remoteconsole - tramspeedcontrol
Thesystemallowsthetrammingtobedriveninthreediscretespeeds (SPEED1,SPEED2,andSPEED3).SPEED1isthedefaulttrammingspeed.
Toadvanceaspeed:
Pressthetramleversand“TRAM2-3”keystogethertomovefrom SPEED1toSPEED2.
OnceinSPEED2,pressthetramleversand“TRAM2-3”together tomovefromSPEED2toSPEED3.
Thefollowingtrammingconfigurationsareenforcedbythecontrolsystemforsafetyreasons:
■ SpilttracktrammingislimitedtoSPEED1whencuttermotorsare notrunning.
■ SingletracktrammingisnormallylimitedtoSPEED1.
■ ItispossibletospeedupasingletrackfromSPEED1toSPEED2 providingthattrammingisstartedinSPEED1.
■ Trammingislimitedtosumpspeedwhilethecuttersareon.
■ Whilethecuttersarerunning,reversespeedcanbeincremented whilethereversekeysarebeingpressed.Notethatthisoptionis usedwhentheminerisretreatingorpillarmining.
Cutterheadoperation Tostartthecuttermotors
Ensurethatthecutterheadisnotincontactwithanything.Cutter headmotorsmustneverbestartedunderaload.
WARNING!
Neverstartcutterheadmotorsunderaload.Startingmotorsunderloadmayresultinmotordamageorprematurefailure.
Warn“ALLCLEAR” beforestartingthecutterhead.
WARNING!
Warn“ALLCLEAR”beforestartingthecutterhead.Failuretodo somayresultinseriousinjuryordeath.
Ensurethatthepumpmotorisrunning.Thecuttermotorswillnot runifthepumpmotorisnotrunning.
Press“SHIFT”andwait1/4second.
Whileholdingin“SHIFT”,press“CUTTERON”.Continuetohold bothkeysinuntilthecuttermotorsturnon.
IMPORTANT!
Bothcuttermotorsdonotstartatthesametime.Thereisapreset timeddelaybetweentheleftcuttermotorstartingandtheright cuttermotorstarting.
Releasethe“CUTTERON”key.
IMPORTANT!
The“CUTTERON”keymustbereleasedbefore“SHIFT”.If “SHIFT”isreleasedfirst,thecuttermotorswillshutoff.
Releasethe“SHIFT”key.
Tostopthecuttermotors
Pressandholdthe“CUTTEROFF”key.Thecuttermotorsshould shutdownimmediately.
Releasethe“CUTTEROFF”key.
Blowingsystemoperation Tooperatetheblowingsystem
Placedamperleverandbi-directionalintakeleverontheplenum boxindesiredposition.
Ensurethatthepumpmotorisrunningastheblowingsystemfan motorwillnotstartifthepumpmotorisnotrunning.
Press“SHIFT”andwait1/4second.
IMPORTANT! Holdingthe“SHIFT”buttonfortwo(2)secondsorlongerwillresultinaradioswitchfault.Ifthisoccurs,allbuttonsmustbereleasedandthestartre-attempted.
Whileholdingshift,press“FAN/OFF”.Thepre-startwarninghorn willsound.Continuetoholduntiltheblowingsystemfanmotor turnson.
Releasethe“FAN/OFF”button.Thepre-startwarninghornwill stop.
IMPORTANT! The“FAN/OFF”buttonmustbereleasedbefore“SHIFT”.If “SHIFT”isreleasedfirst,thefanmotorwillshutoff.
Releasethe“SHIFT”button.
Tostoptheblowingsystemfanmotor
Pressandholdthe“FAN/OFF”button.Thefanmotorwillshutdownimmediately.
Releasethe“FAN/OFF”button.
Conveyoroperation Tostarttheconveyormotorsinforward
Placeconveyorboomindesiredposition.
Warn“ALLCLEAR” beforestartingtheconveyor.
WARNING!
Warn“ALLCLEAR”beforestartingtheconveyor.Failuretodoso mayresultinseriousinjuryordeath.
Ensurethatthepumpmotorisrunning.Theconveyormotorswill notstartifthepumpmotorisnotrunning.
Press“SHIFT”andwait1/4second.
Whileholdingin“SHIFT”,press“CONVON”.Continuetoholduntil theconveyormotorturnsonandtheconveyorstartstorunforward.
Releasethe“CONVON”key.
IMPORTANT!
The“CONVON”keymustbereleasedbefore“SHIFT”.If“SHIFT” isreleasedfirst,theconveyormotorswillshutoff.
Releasethe“SHIFT”key.
Tostoptheconveyormotors - conveyorforward
Pressandholdthe“CONVOFF”key.Theconveyormotorsshould shutdownimmediately.
Tostarttheconveyormotorsinreverse(momentaryonly)
Placeconveyorboomindesiredposition.
Warn“ALLCLEAR” beforestartingtheconveyor.
WARNING!
Warn“ALLCLEAR”beforestartingtheconveyor.Failuretodoso mayresultinseriousinjuryordeath.
Ensurethatthepumpmotorisrunning.Theconveyormotorswill notstartifthepumpmotorisnotrunning.
Press“SHIFT”andwait1/4second.
Whileholdingin“SHIFT”,press“CONVREV”.Continuetohold untiltheconveyormotorturnsonandtheconveyorstartstorunin reverse.
Theconveyorwillcontinuetoruninreverseuntilthe“CONVREV” orthe“SHIFT”keyisreleased.
Controlheadlightsandarealights Thelightswitchhasthreepositions:arealightsonly,allonandalloff. Whenthepoweristurnedontothecontinuousminer,themethane monitorrelayisclosedandthelightswitchisoff.Whenthelightswitch isturnedtotheallonposition,theheadlightsandthearealightswill comeon.Whenthelightswitchisturnedtothearealightsonlyposition,theheadlightsonly(notthearealights)canbeturnedonandoff withtheradio.
Theheadlightscanbeturnedoffandonfromtheremoteconsoleat anytimethatthelightswitchisinallonpositionandtheremoteconsoleisonby:
Pressthe“SHIFT”and“LIGHTS”keystogethertoturnthelights on.
Pressthe“SHIFT”and“LIGHTS”keystogethertoturnthelights off.
Seetheoperationmanualfortheradioremotethatshippedwithyour machineforoptions.
Firesuppressioninradioremote Thecontrolsystemusesasolenoidoutputtodrivethefiresuppression systemonthecontinuousminer.Thefiresuppressioncanbeactivated atanytimefromtheremotecontrolconsole.Ifthemachineisfitted withthebatterybackupversionofthepowersupply,thefiresuppressioncanalsobeactivatedinbatterystandbymode.Thesystemwill remaininbatterystandbymodeforatleasttenminutesafterlossof mainpowertothemachine.
Wheninradiomode,thefiresuppressioncanbeactivatedfromtheradioasfollows:
Pressthe“SHIFT”and“FIRE”keysatthesametimeandholdfor two(2)fullseconds.
Aftertwoseconds,thefiresuppressionsystemwillactivate.Atthis time,the“SHIFT”and“FIRE”keyscanbereleased.
Seetheoperationmanualfortheradioremotethatshippedwithyour machineforoptions.
Shearup/downinradioremote
Thepumpmotormustberunninginordertoraiseorlowerthecutter head.
Press“SHEARUP”tomovethecutterheadup.Theshearupsolenoidremainsenergizeduntilthekeyisreleased(unlessheight limitingisinforce).
Press“SHEARDOWN”tomovethecutterheaddown.Theshear downsolenoidremainsenergizeduntilthekeyisreleased.
Seetheoperationmanualfortheradioremotethatshippedwithyour machineforoptions.
Gatheringheadraise/floatinradioremote
Thepumpmotormustberunninginordertoraiseorlowerthegatheringhead.
Press“PANUP”toliftthegatheringhead.Thepanupsolenoid remainsenergizeduntilthekeyisreleased.
Press“PANFLOAT”to“float”theheaddown.
Seetheoperationmanualfortheradioremotethatshippedwithyour machineforoptions.
Stabilizer(stab)cylinderraise/lowerinradioremote Thepumpmotormustberunninginordertoraiseorlowerthestabilizercylinder.
Press“STABUP”toraisethestabilizercylinder.Thestabilizercylindersolenoidremainsenergizeduntilthekeyisreleased.
Press“STABDOWN”tolowerthestabilizercylinder.Thestabilizer cylinderdownsolenoidremainsonuntilthekeyisreleased.
Seetheoperationmanualfortheradioremotethatshippedwithyour machineforoptions.
Conveyorraise/lowerandleft/rightinradioremote
Thepumpmotormustberunninginordertocontroltheconveyorraise, lower,andswingleft/right.
Tocontroltheconveyorfromtheradioremote:
Pressthe“CONVEYORLEFT”keytothelefttoswingtheconveyor tailtotheleft.Thesolenoidcontrollingtheleftconveyorswingwill remainenergizeduntilthekeyisreleased.
Pressthe“CONVEYORRIGHT”keytotherighttoswingtheconveyortailtotheleft.Thesolenoidcontrollingtherightconveyor swingwillremainenergizeduntilthekeyisreleased.
Pressthe“CONVEYORDWN”keytolowertheconveyorboom. Thesolenoidcontrollingtheconveyorlowerfunctionwillremain energizeduntilthekeyisreleased.
Pressthe“CONVEYORUP”keytoraisetheconveyorboom.The solenoidcontrollingtheconveyorraisefunctionwillremainenergizeduntilthekeyisreleased.
Seetheoperationmanualfortheradioremotethatshippedwithyour machineforoptions.
Note:Conveyorleftandrightaredescribedasviewedbytheoperator fromtherearofthemachinefacingtowardstheconveyordischarge.
Typicalcuttingsequence CAUTION! Alwaysensureoperatorsafetywhileoperatingthemachine.Be alertforhazardousconditionsandtakecorrectiveactionasnecessary.Failuretobealertandcorrecthazardoussituationsmay resultinseriousinjury.
IMPORTANT! Careshouldbetakennottostallcuttersorconveyorduringcuttingoperations.Severedamagetomotorsandgearboxescould occurifcuttersorconveyorarerepeatedlystalled.
Ensurethatthepumpmotorisrunning(seeStartupprocedurein thischapter).
Placegatheringheadinthefloatposition.
Positionconveyorsoitdoesn'thittheroof,walls,otherequipment oranyotherobstacle.Neveroperatetheconveyorinitsfullylimited position,rightleft,up,ordown.Ifinthefullylimitedpositionand contactinganyobstacle,damagecouldoccur.
Startthegatheringheadandconveyor.Donotstartmachinein faceorwithexcessivematerialinthegatheringhead.
Engagetramandadjustforspeedanddirection.
Startcutterheadpriortocontactingareatocut.
Raisecutterheadtodesiredminingheight.
Lowertherearstabilizertothefloortoprovidestabilityifnecessary. Donotlowertheshoeenoughtoraisetherearofthemachine.If theshoeisloweredtoofarthemachinewillnotsumpintotheface properly.
Engagetramintheforwardposition.
IMPORTANT! Tramislimitedintheforwarddirectionwhilethecuttersarerunningwiththecutterheadfeedbackcircuit.Asthecutterheadbeginstocutthematerialfromtheface,thesumpspeedwillautomaticallyslowthetramdowntopreventoversumpingthemachine.
Continuetosumpuntilthedesireddepthofcutisachieved.The depthofthesumpwilldependonthetypeofmaterialbeingcut,the diameterofthecutterdrum,andbitlacing.
Releasetramlevers.
CLICK HERE TO DOWNLOAD THE COMPLETE MANUAL
• Thank you very much for reading the preview of the manual.
• You can download the complete manual from: www.heydownloads.com by clicking the link below
• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.
CLICK HERE TO DOWNLOAD THE
