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ThismanualisintendedtoprovideGENERALproductinformationfor theModel35M3ContinuousMiner.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

Aboutthismanual

Aboutthismanual

Thischapterprovidesimportantinformationmakingiteasierforyouto usethismanual.Itcontainesinformationonthestructureofthemanualandthesymbolsandcharactersused.

Beforestartingtowork

applicableoperatingmanual

machinetype

newoperationmanual

Takecaretoensurethattheoperatingmanualavailabletoyouisapplicableforthetypeofequipmentormachineused.

Thisoperatingmanualisintendedfor:

BucyrusModel35M3ContinuousMiner

SerialNo.:N/A

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.

Beforestartingtowork

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

FollowallMine,State,andFederalregulationsregardinglockout/tag outprocedures.

cordonoffworkingarea movingparts

Cordonoffyourworkingareawidelyforthemachine.

Neverallowpartsofyourbodytocomebetweenpartswhichcould move,suchase.g.:

■ chains,flights,andchainsprockets

■ pivotpoints

■ crawlerassembliesandconveyors

■ cutterandgatheringheadassemblies

Safetyinstructions

Storageandtransport

Maintaintheprescribedstorageperiodsandobservetheinstructions forstorage.

Donotstorematerialsorpartsinthetravelwayorinyourworking area.

Informthepersonsinvolvedabouttheintendedtransportrouteandthe anticipateddurationofthetransport.

Ensurethatthetransportsafetydevicesarecorrectlyfitted. Fixallmovingpartswithtransportlocks.

Neverstandunderunsupportedpartsorsuspendedloads.

Connecttheliftingequipmentonlytothepointsofattachmentprovided forthatpurpose.Observethedifferentloadlimitsoftheattachment points.Alsoobservetheinstructionsonthetransportsheet.

Onlyusemeansofattachmentwhichareingoodconditionandhave beendesignedfortheloadstobehandled.

Forroundcomponentsusetransportstraps,only.Neverusechainsor steelcablesforthispurpose.

Donotdamagethetreatedorpolishedsurfacesofshafts,sealingsurfaces,etc.

Whenusingmobilehandlingsystemsfortransportmakesurethatthe centerofgravityisaslowaspossible.

Pre-startinspection

Readthisentiremanualbeforeattemptingtooperatethismachine.

Inspectthemachineandhaveanymalfunctioning,brokenormissing partscorrectedorreplacedbeforeuse.

Verifythatallmaintenancehasbeenperformed.

Verifythatallinstructionandsafetytagsareinplaceandreadable. Theseareasimportantasanyotherequipmentonthemachine.

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.

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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.Itismandatoryunder theUnitedStatesFederalLawthatthetrailingcablebeuncoupled, taggedandlocked-outfromthepowersourcetoprovidevisualevidencethattheminerisde-energized.

Secureyourworkingareaoverawiderange,inordertoavoidendangeringotherpersons.

Disconnectthepowerfromthemachinetopreventunauthorizedand unintentionalrestarting.

Protectyourworkareaagainstfallingrocks.

Passdefectivecomponentsremovedonforservicingwithoutdelayin ordertopreventthesepartsbeingreinstalledelsewhere.

Useonlysparepartswhichsatisfythespecifiedtechnicalrequirements. ThisisonlyensuredwithoriginalBucyrusspareparts.Pleasereferto thesparepartslistsorpartscatalogfortheordernumbers.

Beforeattemptinganyrepairsormaintenance,methaneairmonitoring mustbecompletedbeforeandduringtherepairandmaintenance.

Safetyinstructions

lifting

ForraisingtheContinuousMineruseonly:

■ cribblockswithadequateload-holdingcapacity.

■ hoists,jacksorcraneswithadequateload-carryingcapacity.

handlingofhydraulicfluids

maintenance/repair

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.

DANGER!

Donotoperatethemachinewithanyoftheguardsorcoversremoved.Youorotherpersonnelcouldbeseriouslyinjuredfrom movingorrotatingparts.

Overviewofsafetyinstructions

Chapter5:Operation

DANGER!

Incorrectoperationendangersyourselfandothers!Incorrectoperationofthemachineisoftenthecauseofveryseriousaccidents!Operatetheunitonlywhenyouhavebeensufficiently trainedonthemachineandhavereadandunderstoodthisoperatingmanual.Shouldanythingbeunclear,pleasecontactyourimmediatesupervisor.

NOTICE!

Beforebeginningcuttingoperations,carefullyunloadthetrailing cableprovidingenoughslackandplacingitwhereitallowsadequateclearanceforsafemaneuverabilityoftheminer.

DANGER!

TheContinuousMinerisradioremotecontrolledduringproductionoperations.Manualoperationviacontrolsattheoperator’s stationisnotpermittedforproductionoperation.Manualoperationisfortroubleshootingandmaintenanceundersupportedroof only.TrammingviatheEmergencytrampendantisonlypermitted insituationswhentheradioremotesystemisinoperable.OperatingtheContinuousMinerwithmanualorpendantcontrolsunder unsupportedroofmayresultinsevereinjuryordeath.

NOTICE!

Onceahydrauliccontrolvalvehandleisreleasedbytheoperator, theleverwillautomaticallyreturntothecentered(“HOLD”)position.

DANGER!

Powertothemachinemustalwaysbeisolatedtothetrailingcable atthesectionpowercenterbeforeeitherthevictorsocketisremovedorthemaincircuitbreakercaseisopened.Wheneverany workisperformedonthecontinuousminer,allmine,State,and Federalregulationsregardinglockout/tagoutofthemachine.

WARNING!

Radioremotecontrolsystemsaredangerous.Thecontinuous mineroperatorcannotoperatearemotesystemuntilheisproperlytrainedintheoperationofthesystem.Remotecontrolsystemssometimeshaveautomaticfeaturesofwhichuntrainedoperatorsandworkersarenotaware.

IMPORTANT!

Foroperatinginstructions,includingstarting,shuttingdown, tramming,andmining,usingtheremotecontrol,seetheOperating proceduressectionofthischapter.

IMPORTANT!

Thependantcontrolleranditsumbilicalcordshouldbestoredina protectedlocationontheworkingsection,awayfromtheminer,to preventdamage.

WARNING!

Readallinstructionscarefullybeforeattemptingtostartoroperatethemachine.Failuretoreadandunderstandalloperating instructionsbeforestartingtheContinuousMinercouldresultin seriousinjuryordeathtotheoperatororpersonsaroundthemachineorcausedamagetothemachine.

WARNING!

UnderstandthefunctionsofallcontrolsbeforestartingtheContinuousMiner.Readandfollowtheinstructionsonallwarning tagsonthemachine,observeallregulationsandsafetyprecautions.

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!

Turningonthewatersprayspriortocuttingpreventstheaccumulationofdustandthegenerationofexcessiveheatwhich couldcauseanignitionorexplosion.

WARNING!

TheContinuousMinerisoperatedbyradioremotecontrol.Manualoperationisnotallowedforproductionoperation.Manualoperationisfortroubleshootingandmaintenanceunderroofsupport.

IMPORTANT!

Beforestart-up,checkthatdailymaintenancehasbeenperformed onthemachine.

Overviewofsafetyinstructions

WARNING!

Visuallycheckforotherpersonnelandverballyshoutawarning beforestartingthismachine.Makesureallpersonnelarecompletelyclearofthemachineandit’scomponentsandcheckthat theareaisclearbeforestartingthemachine.

IMPORTANT!

The“PUMP/OFF”keymustbereleasedbefore“SHIFT”.If“SHIFT” isreleasedfirst,thepumpmotorwillshutoff.

NOTICE!

TheContinuousMinerhasskidtypesteering:itiscapableofturningwithinitsownlimits.

WARNING!

Trammingrequirescoolingwatertothetrammotors.Failureto coolthemotorswillresultinmotordamageandprematurefailure.

WARNING!

Adjustconveyorboomtoallowclearancefromroof,walls,and floor.Failuretodosowillresultindamagetotheconveyorboom.

WARNING!

Neverstartcutterheadmotorsunderaload.Startingmotorsunderloadmayresultinmotordamageorprematurefailure.

WARNING!

WarnALLCLEARbeforestartingthecutterhead.Failuretodoso mayresultinseriousinjuryordeath.

IMPORTANT!

Holdingthe“SHIFT”buttonfortwo(2)secondsorlongerwillresultinaradioswitchfault.Ifthisoccurs,allbuttonsmustbereleasedandthestartre-attempted.

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.

Overviewofsafetyinstructions

NOTICE!

TheContinuousMinerhasskidtypesteering.Itiscapableofturningwithinitsownlimits.

WARNING!

Trammingrequirescoolingwatertothetrammotors.Failureto coolthemotorswillresultinmotordamageandprematurefailure.

DANGER!

Iftheminerisunderunsupportedroofandtrammingwiththe emergencypendantcontrolsisrequired,cribouttotheminer. Nevergooutunderunsupportedroof.Failuretofollowthiswarningmayresultinveryseriousinjuryordeath.

IMPORTANT!

Theminercanbeshutdownatanytimein“ETRAM”modeby pressingthe“MACHINESTOP”buttonontheemergencytram pendant.

WARNING!

Assoonasatrammingfunctionisperformed,thestabilizershoe willraiseautomatically.Iftheshoeisbeingusedtolifttheminer offofthefloor,therearofthemachinewilldropassoonasthe tramfunctionisperformed.Seriousinjuryordeathcanoccurto personnel.

CAUTION!

Alwaysensureoperatorsafetywhileoperatingthemachine.Be alertforhazardousconditionsandtakecorrectiveactionasnecessary.Failuretobealertandcorrecthazardoussituationsmay resultinseriousinjury.

IMPORTANT!

Careshouldbetakennottostallcuttersorconveyorduringcuttingoperations.Severedamagetomotorsandgearboxescould occurifcuttersorconveyorarerepeatedlystalled.

IMPORTANT!

Tramislimitedintheforwarddirectionwhilethecuttersarerunningwiththecutterheadfeedbackcircuit.Asthecutterheadbeginstocutthematerialfromtheface,thesumpspeedwillautomaticallyslowthetramdowntopreventoversumpingthemachine.

WARNING!

ThissectionisintendedtofamiliarizetheuserwiththemajormechanicalassembliesoftheContinuousMiner.Allmechanical maintenanceshouldbeperformedbyaqualifiedtechnicianwith theknowledgeofthefunctionoftheassembliesinvolved.

WARNING!

Failuretomaintainthehydraulicsystemwillresultindamageto itshydrauliccomponentswhichwillresultinincreasedwearand prematurefailure.

Overviewofsafetyinstructions _________________________________

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!

Theloadholdingvalvesonthecutterheadandconveyorcylinders arepresetandDONOTrequireadjustment.Adjustmentofthese valvemayresultinveryseriousinjuryorevendeath.

IMPORTANT!

Thetwoinchlockingballvalvemustbelockedopeninnormaloperation.

DANGER!

Theareaunderandaroundtheraisedcutterheadisdangerous. Securelyblocktheheadbeforeperformingmaintenanceonor belowit.Failuretoblocktheraisedcutterheadcouldresultin seriousinjuryorevendeath.

DANGER!

Donotadjust,modify,orremovetheloadholdingcartridgevalve mountedinthecutterheadcylinders.Itisasafetyfeaturetopreventaccidentalloweringofthecutterhead.

DANGER!

Thisloadholdingvalve,likethoseonthestabilizercylindersis preset. DONOTADJUSTIT.Ifitmalfunctions,replaceitimmediately.

WARNING!

Youcouldbeseriouslyinjuredorkilledbyfallingloads.Blockthe minerbeforeperformingmaintenanceandalwaysobservethe safeworkingloadlimitsofallliftingandblockingdevices.

DANGER!

Neverruntheconveyorwithouttheneedlevalveclosed.Injuryor deathmayoccur.

WARNING!

Thissectionisintendedonlytofamiliarizetheuserwiththeelectricalcomponentsofthecontinuousminer.Allelectricalmaintenanceshouldonlybeperformedbyaqualifiedelectricianwith knowledgeofthefunctionsofthecomponentsinvolved.

WARNING!

Beforeremovingthecoverfromthecontrollercaseorattempting anymaintenanceortroubleshooting,themainpowermustbedisconnectedandlockedoutatthemainpowercenter.

IMPORTANT!

Hangtrailingcablestopreventdamagefrommovingequipment!

WARNING!

Neverrunoveranunprotectedtrailingcable.Damagedcables shouldberepairedimmediately.

DANGER!

Neverhandleenergizedtrailingcablewithoutproperprotective equipment.Contactwithanenergizedtrailingcablewithcompromisedinsulationcouldresultindeathbyelectrocution.

WARNING!

Alwaysusecautionwhenstandingnearorcrossingtrailingcables.Thetrailingcablemaymoveasthemachinemoves.

IMPORTANT!

Thiscomponentlocationinformationistypical.Alwaysverify componentlayoutwiththeinformationintheBucyruspartsbook foryourmachine.

WARNING!

Beforeperformingmaintenanceonthemachinethecircuitbreaker mustbeinthe“OFF”positionandthetrailingcabledisconnected. FollowallMine,State,andFederalregulationsforlockout/tagout procedures.Accidentalmachinemovementorelectricalshock canresultinseriousinjuryordeathtoyouorotherpersonnel.

IMPORTANT!

“MAINTENANCE”modeofoperationisnotforuseduringnormal maintenanceorreplacementofwearpartsprocedures.

“MAINTENANCE”modeisforuseduringmotorvibrationanalysis only.

Overviewofsafetyinstructions _________________________________

WARNING!

Donotmoveanyhydrauliccontrolleverunlessyouarecertain thateveryoneiscompletelyclearofanymachinemovement.Accidentalmachinemovementcancauseseriousinjuriesoreven deathtoyouorthemaintenanceperson.

WARNING!

Neverdisconnectahydraulichoseifthecircuitispressurizedorif thereisaloadonthecircuit.Ifahoseisdisconnectedwhilethe circuitispressurizedoraloadisonthecircuit,theloadwillfall causingdamagetothemachineorseriousinjuryordeathtoyou orotherworkers.

WARNING!

Youcouldbeseriouslyinjuredorevenkilledbyfallingloads.Observethesafeworkingloadlimitsofliftingorblockingdevices andkeepasafedistancefromsuspendedloads.

WARNING!

Useextremecautionwheninspectingforleakswiththemachine running.Unexpectedmachinemovement,orcontactwithmoving parts,couldresultininjury.

WARNING!

FollowallFederalandmineregulationsregardinglockout/tagout procedures.Failuretodosomayresultinseriousinjuryordeath.

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!

Useextremecautionwhenperformingtestproceduresandmakingadjustments.Unlessnotedintheprocedures,allcontrolsare tobeintheneutralposition.

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.

Overviewofsafetyinstructions _________________________________

CAUTION!

Alwaysbealertforanyunintendedmachinemovement.

IMPORTANT!

ReferencetheHydraulicsectioninthischapterforindividualcircuitinformation.Alwaysrefertothehydraulicschematicinyour Bucyruspartsmanualforyourminer.

WARNING!

Twopeoplearerequiredtoadjustpressuresettings.Oneperson willmaketheadjustmentswhilethesecondpersonmustremain atthemachinestopatalltimesduringtheadjustmentprocedure. Failuretodosomayresultinseriousinjuryordeath.

WARNING!

Keepbodypartsclearofmachinewhileinraisedpositionorseriousinjurycouldresult.

CAUTION!

Shimsmustbeinsertedcompletelyintotheidlerslidechannel.A shimthatisnotcorrectlyseatedontheidlerslidechannel’sinside surfaceprovidesunevensupportthatcancauseidlerslant.A slantedidlercancauseunevenwearandstressonthetramtrack andcancauseimproperoperationofordamagetothetramsystem.

IMPORTANT!

Checkthattheshimsarecorrectlyseatedontheidlerslidechannel’sinsidesurfacebylookingatthechannel’sinsidesurface fromtheoppositesideoftheminerthroughthespacebetweenthe gatheringheadandtheidlerassembly.

CAUTION!

DisassemblyandassemblyprocedureslistedintheReplacement ofwearpartssectionarespecializedand,assuch,shouldonlybe performedbyqualifiedpersonnel.

WARNING!

Theshearcylinderisextremelyheavy.Makesurethatit’sweight issupportedandthatthecylinderwillnotswingfreeormove. Failuretofollowthiswarningmayresultinmachinedamageorin severeinjuryordeathtopersonnel.

WARNING!

Powershouldnotbereconnectedtotheminerwhilethemotor powercableisdisconnected.Damagetotheminerorpersonal injuryordeathcouldresult.

WARNING!

Thisprocedureinvolvesattachinganelectricalpowercabletoa motor.Thetrailingcablemustbedisconnectedandlockedand taggedouttosafelyperformthisoperation.FollowallMine,State, andFederallockout/tagoutprocedures.Failuretodosomayresultinseriousinjuryordeath.

Overviewofsafetyinstructions _________________________________

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.

CAUTION!

Toavoidinjurywhilerelievingtensionoffoftheconveyorchain, wearproperpersonalprotectiveequipment,toinclude,ataminimum,safetyglassesandgloves.

Overviewofsafetyinstructions _________________________________

WARNING!

Stayclearoftheblockedminerwhilethemachineisenergized. Failuretofollowthiswarningmayresultinseverinjuryordeath.

WARNING!

Donotreconnectthetrailingcabletotheminerwhilethepower cableisdisconnectedfromthemotor.Seriousinjuryordeathmay occur.

NOTICE!

Ifthepivotpinistight,besuretheliftingdeviceisnotbindingthe pivot.Ifthepivotisnotinabind,usethepullerholetoaidinpin removal.

WARNING!

Besureallconveyorcomponentsarecorrectlyinstalledandthat theconveyorchainisproperlyengagedbythefootshaftbefore startingtheminer.

WARNING!

Someproceduresmustbecarriedoutwiththecoveroftheelectricalcontrollerremovedandsomeproceduresrequirethecontroller tobeenergizedduringthetests.Itisextremelyimportantthatyou takeallnecessaryprecautionstopreventaccidentalelectrical shockwhileworkingwithinthecontroller.AnMSHA-certifiedelectricianmustsuperviseandinspectallworkperformed.

Chapter6:Technicaldata

IMPORTANT!

Thetechnicaldatalistedinthischapterisforstockmachines only.Customerspecialsmaynotbelisted.

IMPORTANT!

Duetotheapplicationoffastenersbeingsubjecttogreatstresses andheavyorextremevibration,itisimperativethatallboltsbe appliedwithanadequateamountoftorque.Forthisreasonthis listofrecommendedtorquesettingsfordifferenttypesandsizes offastenersusedhasbeencompiled.Thetighteningtorques statedinthesparepartslistshavetobeobserved,aswell,forinstallationandmaintenance.

IMPORTANT!

Useacalibratedtorquewrenchforaccuracy!

NOTICE!

UseonlylubricationfluidsandgreasesapprovedbyBucyrus America,Inc.!ThesefluidsandgreaseshavebeentestedatBucyrusAmerica,Inc.andguaranteereliableoperationofthemechanicalandhydraulicfunctionsofthemachine.

IMPORTANT!

Thelubricationfluidsandgreaseslistedinthesametablecanbe mixed.Otherproductsmayonlybeusedifthesuppliercanguaranteethattheyareequivalent. Differentlycomposedfluidsandgreasesmustnotbemixedas thismaychangetheconsistency,i.e.themixturecanbecome thinnersothatthelubricationeffectisnotsufficient.Itmayalso bedangeroustouselubricatinggreasesandfluidshavingthe samespecificationbasebutdifferentorigins. Incaseofdoubt,themanufacturerofthelubricationtobeused shouldbecontactedastothecompatibilityofthelubricationin question.

IMPORTANT!

BucyrusAmerica,Inc.expresslypointoutthattheapprovalofthe listedproductsrelatesonlytothepuretechnicaluseinourmechanicalandhydraulicsystems.Theresponsibilityfortheconstituentsusedinthehydraulicconcentratesliessolelywiththe respectivemanufacturer.

IMPORTANT!

Besuretousethemanufacturer’sinstructionsforuse.

NOTICE!

Whenperformingmaintenanceonthemachine,allusedoiland lubricantsshouldbestoredanddisposedofperyourlocalEPA standards.

Overviewofsafetyinstructions _________________________________

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.

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Transport

Loadunits:dimensionsandweights

Observethetransportsheetsforthemachineandspareparts.They containinformationon:

■ dimensions,

■ weights,

■ liftingpoints,etc.

Additionalinformationonthedimensionsandweightscanbefoundin chapter6andintheliftingweightguide(Table1)inthisoperatingsection.Fig.5illustratesthepositionofliftingeyesontheminer.

removalandinstallationof heavycomponents

WARNING!

Useonlyloadhandlingdevicescomplyingwiththetechnicaland legalregulationsforthetransportofloads.Youcouldbeseriouslyinjuredorevenkilledbyfallingloads.Useonlysuitable loadhandlingdevices.

Table1:LiftingweightsofContinuousMinerAssemblies

Description

CompleteMachine

187,000lbs(85,000kg)

TractorFrameAssembly 93,000lbs(42,185kg)

CutterHeadAssembly

GatheringHeadAssembly

53,500lbs(24,267kg)

23,500lbs(10,659kg)

ConveyorAssembly 17,000lbs(7,711kg)

Wheneverpossible,allremovalsshouldbeaccomplishedusinganadjustableliftingbeam.Allsupportingmembers(chainsandcables) shouldbeparalleltoeachotherandasnearlyperpendicularaspossibletothetopoftheobjectbeinglifted.

Whenitisnecessarytoremoveacomponentonanangle,remember thatthecapacityofaneyeboltdiminishesastheanglebetweenthe supportingmembersandtheobjectincreases.Eyeboltsandbrackets shouldneverbebent.

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?

NospecialtoolsarerequiredtoputtheContinuousMinerintoservice. Variousitemsofauxiliaryequipmentandmachinesmayberequiredat thepointofinstallation.

Theseinclude:

■ hoistswithadequateliftingcapacity

■ meansofattachmentwithadequateliftingcapacity

■ unloadingdockandcribblocks

■ jackswithadequateliftingcapacity

■ impactwrenches,includingaccessories

toolbox

installationplan

Notesoninstallation

CAUTION!

SeriousdamagecanbecausedtotheContinuousMinerasaresultofincorrectinstallation.TheunitshouldthereforeonlybeinstalledundertheinstructionofspecialistsfromBucyrusAmerica, Inc.

BucyrusAmerica,Inc.ContinuousMinersareshippedtothecustomer sitepercustomerpreference.TheContinuousMiner canbeshippedto thecustomersiteasacompletemachineorincomponentsections. Thisdependsonmineconditions,transportationweightrestrictions/ requirements,orsize/weightrestrictionsatthemine.

reassemblyinstructions

IMPORTANT!

Thesequenceofoperationsduringinstallationmustbeadaptedto theindividualconditionsprevailingatthesite.Beforestartingthe workadetailedlistofstepstobetakenwithrespecttotransport andassemblyshouldbepreparedandacorrespondingplanestablished.

Whenassemblyisrequiredaftershipmentofthemachine,theassistanceofspecialistsfromBucyrusAmerica,Inc.isrecommended.This willinsurethatthecorrectinstallation,safetyandmaintenanceproceduresarefollowed.

Pre-installationchecklist

NOTICE!

Themachinewasinspectedpriortoshipmentfromthefactoryto ensureproperfunctioningandinstallationofallcomponents. However,toensurethatnotransitdamagehasoccurred,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.

scrubber/dustsuppression (optional)

guardsandcovers

TheContinuousMinermaybeequippedwithanoptionaldustsuppressionpackage(scrubber).ThedustsuppressorallowstheMineroperatortousefaninducedventilationattheface.Thefansuctiondrawsin thedustandliberatedmethanefromtheintakeduct(s).Thedustladen airisthendrawnthroughthescrubberscreen,whichisconstantly floodedwithwaterspray.Thedirtywateristhenremovedfromtheair streambyade-misterwhichislocateddirectlybehindthescrubber screen.Thedirtywaterflowsdowntoasumptankwhereawaterpoweredjetpumpemptiesthesumpanddumpsthedirtywaterontothe conveyor.Theclean,dryairexitsthede-misterandisdischargedinto themineatmosphereattherearoftheminer,diffuseddownwardand towardstheribtopreventcoalfinesfrombeingblownontheoffside shuttlecaroperator.

Themachineisequippedwithguardsandcoverstoreducethepossibilityofpersonnelcomingincontactwithrotatingormovingparts.All guardsandcoversmustbeinstalledandsecurelyfastenedduringoperation.

cutterboomsafetysupports

conveyorsafetysupports methanemonitor

DANGER!

Donotoperatethemachinewithanyoftheguardsorcoversremoved.Youorotherpersonnelcouldbeseriouslyinjuredfrom movingorrotatingparts.

Therearetwocutterboomsafetysupports,oneoneachsideofthe cutterboom.Thesupportsareusedtoblockupthecutterboomduring maintenanceoperations.

Therearetwoconveyorsafetysupports,oneoneachsideoftheconveyor.Thesupportsareusedtoblockuptheconveyorduringmaintenanceoperations.

Themachineisequippedwithamethanemonitorthatdetectsthepresenceofmethaneinthemineatmosphere.Whentheminerisbeing poweredup,themonitorlooksformethanebeforeanyotherfunctionis energized.Ifthemethanemonitordetectsalevelofmethanewithina presettolerance,themethanemonitorrelaywillcloseandpowerwillbe suppliedtotheotherfunctionsonthemachine.

Maincircuit breakerreset

Machinestop

“TRAMCIRCUIT BREAKER”reset

Fig.6(continued):SafetyfeaturesontheContinuousMiner

Scrubber/dustsuppression

Machinestop (locationtypical)

Transmitteremergency “STOP”button

Fig.6(continued):SafetyfeaturesontheContinuousMiner

Conveyorsafetysupport (installedlocation)

Conveyorsafetysupport (storagelocation)

Fig.6(continued):SafetyfeaturesontheContinuousMiner

Cutterboomsafetysupport (storagelocation)

Cutterboomsafetysupport (installedlocation)

Cutterboomsafetysupport (installedlocation)

Cutterboomsafetysupport(2) (installedlocation - typicalbothsides)

Operator’s station

Fig.7:OverviewoftheContinuousMiner

Cutterboom

Conveyorboom

Crawler assembly

Gatheringhead assembly

Scrubberintake

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.

TheBucyrus35M3ContinuousMinerisanelectricallypowered,drum type,radioremotecontrolledminer.

TheMinerismountedoncrawlertracksthatprovidefullmobilityanda sharpturningradiusinbothroomandpillarandlongwalldevelopment miningplans.Therangingcutterheadminesmaterialfromthesolid faceusingachainlessrotatingdrum,andaCLA-typegatheringhead withhighspeedconveyorefficientlymovesminedmaterialtoahaulage systembehindtheMiner.

Fig.8:Operator’sstation

“MACHINE STOP”

Controlsandindicators

Operator’sstation

DANGER!

TheContinuousMinerisradioremotecontrolledduringproductionoperations.Manualoperationviacontrolsattheoperator’s stationisnotpermittedforproductionoperation.Manualoperationisfortroubleshootingandmaintenanceundersupportedroof only.TrammingviatheEmergencytrampendantisonlypermitted insituationswhentheradioremotesystemisinoperable.OperatingtheContinuousMinerwithmanualorpendantcontrolsunder unsupportedroofmayresultinsevereinjuryordeath.

Theoperator’sstation(Fig.8)islocatedontherighthandsideofthe machine,neartherearbumper.

Maincircuit breakerreset lever

Control breakers

Pressure reducingvalve gauge

“HSCHRAISE SHUTOFF VALVE”

“MINER”operation selectorswitch Valvebank

“CONVEYOR HOURMETER”

“CUTTINGHEAD HOURMETER”

“TRAMCIRCUIT BREAKER” Keyswitch

Gaugepanel

“MACHINESTOP”

“MINER”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.Theselectorswitchhasfourpositions:

■ “MAINTENANCE” - Thismodeofoperationlimitstheminertoone motorfunctionatatime.Thismodeisforuseduringmotorvibrationanalysis.Assoonas“MAINTENANCE”modeisselected,a thirty(30)minutetimerisactivated.Attheendofthethirty(30) minutes,thepumpmotorwillshutdown.Torestartthetimer,the “MINER”switchmustbecycledto“REMOTE”andbackto “MAINTENANCE”.

■ “E-TRAM” - Turningtheswitchtothispositionallowstheminerto betrammedfromthependantcontrols.“E-TRAM”isusedinthe eventthattheoperatorloseshisradiolinkwiththeminer.

■ “REMOTE” - Duringnormalminingoperations,theswitchshould beinthe“REMOTE”position.Thisallowstheminertobecontrolledbytheradioremotesystem.

■ “GRNDCHK” - Placingtheoperationswitchinthegroundcheck positionshouldcausetheminepowercentertotrip,therebyshuttingdownallpowertotheminer.

Fig.9:“MACHINESTOP”and“MINER”selectorswitch

“MACHINESTOP”

“MINER”selector switch

controlbreakerswitches

Therearesixteencontrolbreakerresetbuttonslocatedacrossthetop oftheoperator’scase(Fig.10).Thebuttonwillpopoutwhenthecircuit breakertrips.Toresetacircuitbreaker,pushthebuttonin.

SeetheElectricalsectioninthischapterfordetailedinformationonthe individualbreakers.

Fig.10:Controlbreakerresetswitches

Controlbreaker resetswitches

“CONVEYORHOURMETER”

“TRAMCIRCUITBREAKER”

The“CONVEYORHOURMETER”(Fig.11)indicatesthehoursofrunningtimefortheconveyormotor.

The“CUTTINGHEADHOURMETER”(Fig.11)indicatesthehoursof runningrimeforthecutterheadmotors.

Thekeyswitch(Fig.11)isasafetydevicebuiltintothecontrolcircuit. Tocompleteandenergizethecontrolcircuit,turnthekeycounterclockwise.

The“TRAMCIRCUITBREAKER”lever(Fig.11)isusedtoturnthecircuitbreakerforthetrammotors.Thisbreakermustbeonbeforethe trammotorswillstart.Toturnthecircuitbreakeron,movetheleverto theright.Toturnthecircuitbreaker“OFF”,movethelevertotheleft.

Fig.11:“TRAM/FANCIRCUITBREAKER”

“CONVEYORHOUR

METER”

“CUTTERHEAD HOURMETER”

“TRAMCIRCUIT BREAKER” Keyswitch

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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

Gaugepanel

Thereisagaugepanel(Fig.13)consistingoften(10)gaugeslocated ontherightsideoftheoperator’sstationthatisusedtomonitorhydraulicandwaterpressurethroughouttheminer.

Thefirstgaugefromtheoperator’sleftonthetoprowofgaugesis “CONVEYORTAKE-UPPRESSURE”.Thisgaugeisusedtomonitor thepressureoftheautomaticconveyorchaintensioner.SeetheConveyortake-upcircuitintheHydraulicsectionofthischapterforfurther information.

Thesecondgaugefromtheoperator’sleftonthetoprowofgaugesis “SHEARDOWNPRESSURE”.Thisgaugeisusedtomonitorthepressureofthecuttingheadcylindercircuitduringsheardownoperations. SeetheSheardown/maintenance(anti-chatter)valveintheCutter headcylindercircuitintheHydraulicsectionofthischapterforfurther information.

Thethirdgaugefromtheoperator’sleftonthetoprowofgaugesis “MAINPRESSURE”.Thisgaugeisusedtomeasurethepressurein mainflow - primarypressurecircuit.SeetheMainflow - primarypressurecircuitintheHydraulicsectionofthischapterforfurtherinformation.

Thefourthgaugefromtheoperator’sleftonthetoprowofgaugesis “PILOTCIRCUITPRESSURE”.Thisgaugeisusedtomonitorthesupplypressureforallpilotfunctions.SeethePilotpressurecircuitinthe Hydraulicsectionofthischapterforfurtherinformation.

Thefifthgaugefromtheoperator’sleftonthetoprowofgaugesis “BOOSTERPUMPPRESSURE”.Thisgaugeisusedtomonitorthe boosterpumppressure.SeetheBoosterpumpcircuitintheWatersectionofthischapterforfurtherinformation.

Thefirstgaugefromtheoperator’sleftonthebottomrowofgaugesis “STABSHOEDOWNPRESSURE”.Thisgaugeisusedtomonitorthe pressureofthestabilizershoecircuitwhenthestabilizershoeisbeing loweredtothefloor.SeetheStabilizershoecylinderscircuitintheHydraulicsectionofthischapterforfurtherinformation.

Thesecondgaugefromtheoperator’sleftonthebottomrowofgauges is“GHFLOATPRESSURE”.Thisgaugeisusedtomonitorthepressureinthegatheringheadcircuitduringgatheringheadfloatoperations.SeetheGatheringheadraise/hold/float-lowercircuitintheHydraulicsectionofthischapterforfurtherinformation.

Thethirdgaugefromtheoperator’sleftonthebottomrowofgaugesis “MINEWATERPRESSURE”.Thisgaugemonitorsthepressureofthe supplywatercomingintothewatersystemfromthemine.Thepressureshouldbeaminimumof250psiunderdynamicconditionsand shouldnotexceed500psi.Ifthepressureexceeds500psi,immediatelyadjustthesupplywaterpressureorshutdownthemachine(see Shutdownprocedureinthischapter).

“BPINTAKEWATER PRESSURE”

“BPOUTPUTWATER PRESSURE”

Thefourthgaugefromtheoperator’sleftonthebottomrowofgauges is“BPINTAKEWATERPRESSURE”.Thisgaugemonitorsthepressureofthewatergoingintotheboosterpump.SeetheBoosterpump circuitintheWatersectionofthischapterforfurtherinformation.

Thefifthgaugefromtheoperator’sleftonthebottomrowofgaugesis “BPOUTPUTWATERPRESSURE”.Thisgaugemonitorsthepressureofthewatercomingoutoftheboosterpump.SeetheBooster pumpcircuitintheWatersectionofthischapterforfurtherinformation.

Fig.13:Gaugepanel

“CONVEYOR CHAINTAKE-UP PRESSURE” “SHEAR DOWN PRESSURE”

“MAIN PRESSURE” “PILOT CIRCUIT PRESSURE” “BOOSTER PUMP PRESSURE”

“STABSHOE DOWN PRESSURE” “GHFLOAT PRESSURE”

“MINE WATER PRESSURE”

“BPINTAKE WATER PRESSURE”

“BPOUTPUT WATER PRESSURE”

Themaincircuitbreakercase(Fig.14)islocatedattherighthandrear ofthemachineabovethemaincase.Incomingcableisconnectedto themachineviathecablehandlerandthevictorcablesocket.

Thecasecontainsacircuitbreakerproviding600Aoverloadand 1500Ashortcircuitprotectiontothemachine.Thecircuitbreakeralso functionsasanisolationdeviceforthemachine.

DANGER!

Powertothemachinemustalwaysbeisolatedtothetrailingcable atthesectionpowercenterbeforeeitherthevictorsocketisremovedorthemaincircuitbreakercaseisopened.Wheneverany workisperformedonthecontinuousminer,allmine,State,and Federalregulationsregardinglockout/tagoutofthemachine.

Fig.14:Maincircuitbreaker

maincircuitbreaker

Maincircuit breakercase Maincircuit breaker

“HSCHRAISE SHUTOFFVALVE”

pressurereducingvalvegauge

The“HSCHRAISESHUTOFFVALVE”(Fig.15)isaballvalveused tomanuallyshutoffflowtothehighspeedcutterheadraisecircuit. Whenthehandleisin-linewiththevalve,thevalveisopen.Toshut thevalve,turnthehandle90°.

Locateddirectlyabovethecut-offvalve,thereisagaugethatisusedto monitorthepilotpressureontheboosterpumpsupplydivertervalve (Fig.15).Thispressurepilots(opensandcloses)theboosterpump supplydivertervalve.Theboosterpumpsupplydivertervalvediverts flowfrompumpsectionA2toeithertheboosterpumpcontrolvalveor backtothemaincontrolvalveforthehighspeedcutterheadraise function.

Pressurereducing valvegauge

“HSCHRAISE SHUTOFFVALVE”

Fig.15:Shut-offvalveandgauge

pressureregulatingvalve

Thereisapressureregulatingvalveandgauge(Fig.16)locatedonthe lefthandsideofthemachine.Thevalveandgaugeareusedtoadjust thepressureofthescrubberscreensprays.

Fig.16:Pressureregulatingvalveandgauge

methane/dustwater monitordisplay(typical)

Themachineisequippedwithamethaneanddustwatermonitoring system(Fig.17)which,whenenergized,maintainsacontinuouscheck onmethanegasconcentrationandthedustsystemwaterpressureand flow.

AtypicalreadoutunithasLEDindicatorsthatdisplaythepercentageof methanegasinlargernumerals.Therearestatuslightsthatindicate “METHANEHEALTHY”,“METHANETRIP”,and“METHANEALARM”.

Thewaterdisplayisapartofthemethanemonitordisplayandconsists ofindicatorlightsfor“WATERPRESSHEALTHY”,“WATERFLOW HEALTHY”,“WATERSYSTEMTRIP”,and“BYPASS”.

Consultthemanufacturer’smanualandliteratureintheBucyrusparts bookforyourmachine,forthesetup,operation,andmaintenanceofthe methanemonitoringsystem.

IMPORTANT!

Itistheresponsibilityofthecontinuousminerowner/operatorto knowandfollowallMine,State,andFederalregulationsregarding methanemonitoringrequirements,including,butnotlimitedto, dailyoperation,maintenance,andtesting.

Fig.17:Methane/dustwatermonitordisplay(typical)

“METHANE HEALTHY”

“WATER PRESSHEALTHY”

“WATERFLOW HEALTHY”

MethaneLED (%methane)

“METHANE TRIP”

“METHANE ALARM”

“WATER SYSTEMTRIP” “BYPASS”

Machinecontrolsystem

Anmulti-componentsystemisusedtocontrolvariousaspectsofthe machineandconsistsofthefollowingmaincomponents:

■ Powersupply

■ Controlmodule(hub)

■ Input/Outputmodules

■ Radiosremotetransmitter

■ Graphicsdisplay

Thefollowinginformationispresentedasageneralguidetothecapabilitiesandfunctionsofthecontrolsystem.Beforeattemptingtooperate,service,ortroubleshoottheContinuousMiner,trainingmustbe completed.Foradetaileddescriptionofcomponentlocations,please seetheBucyruspartsbookforyourmachine.

powersupply

controlmodule(hub)

Input/Output(I/O)modules

Thereisa24VDCpowersupplylocatedinsidethecontrollerthatprovidespowertothecontrolandinput/outputmodulesinthecontrolsystem.

Thecontrolmodule,alsoknownasthehub,isthe“brain”ofthecontrol systemandislocatedinsidethecontroller.Theapplicationsoftware forthemachineisstoredonthecontrolmodule.Whenthesystemis poweredup,thesoftwareisusedtocontrolthemachine.Itmonitors inputsandcontrolsoutputstoothermodules.

Input/Outputmodules,locatedinthecontroller,areusedtoreaddata fromandsendcommandstothefollowingmachinefunctions:

■ Cuttermotors(leftandright)

■ DCelectrictractionmotors(leftandright)

■ Gatheringheadmotors(leftandright)

■ Scrubbermotor

■ Pumpmotor

■ Hydraulicoillevel

■ Methanemonitoring

Basedontheparameterssetandtheinputreceived,thecontrolsystem hastheabilitytoissueerrormessages,faultmessages,and/orshutdownthemachine

radiotransmitter (remotecontrol)

Theradiotransmitter(Fig.18)isusedtocontrolthecontinuousminer duringnormalminingoperations.

WARNING!

Radioremotecontrolsystemsaredangerous.Thecontinuous mineroperatorcannotoperatearemotesystemuntilheisproperlytrainedintheoperationofthesystem.Remotecontrolsystemssometimeshaveautomaticfeaturesofwhichuntrainedoperatorsandworkersarenotaware.

Fig.18:Radiotransmitter

Theradiotransmitterhasthefollowingcontrolbuttons: IMPORTANT!

Foroperatinginstructions,includingstarting,shuttingdown, tramming,andmining,usingtheremotecontrol,seetheOperatingproceduressectionofthischapter.

Table1:Radiotransmitterbuttons

Button Primaryfunction Secondaryfunction

TramForward

- Tramsbothtracks forward.

TramReverse

- Tramsbothtracksin reverse.

EmergencyStop

- Shutsdownalltransmitterfunctions.

FireExtinguisher (optional)

- Pushandholdtoincrease speedwhentraveling forward.

- Pushandholdtodecrease speedwhentravelingin reverse.

- Pushandholdtoincrease speedwhentravelingin reverse,

- Pushandholdtodecrease speedwhentraveling forward.

- Whenpressedwith “SHIFT”,tripsthepilot relay.

None

Lights

- Whenpressedwith “SHIFT”,turnsthe headlightson.

Menu

- Usedtoaccessthe menuscreen

Lights

- Turnstheheadlightsoff.

Remote

- Whenpressedwith “SHIFT”,returnsfromthe menuscreen

Tobespecified. Tobespecified.

Stab

- Operatesthestab raisesolenoid.

ATRSUp(optional)

- Whenpressedwith “SHIFT”,operatesthe ATRSraisesolenoid.

Table1:Radiotransmitterbuttons,continued

Button Primaryfunction Secondaryfunction

Pan

- Operatesthegathering headraise.

Shear

- Operatesshearup solenoid.

TramLeftForward

- Tramslefttrackforward.

TramLeftReverse

- Tramslefttrackin reverse.

PanExtend(optional)

- Whenheldwith“SHIFT”, operatesplowextend solenoid.

ShearExtend

- Whenheldwith“SHIFT”, operatesthecutterextend solenoid.

- Pushandholdtoincrease speedwhiletravelling forward.

- Pushandholdtodecrease speedwhentravelingin reverse.

- Pushandholdtoincrease speedwhiletravelling reverse.

- Pushandholdtodecrease speedwhentraveling forward.

Tobespecified. Tobespecified.

Stab

- Operatesstablower solenoid.

Pan

- Operatesgathering headfloat.

ShearDown

- Operatessheardown solenoid.

TramRightReverse

- Tramsrighttrackin reverse

ATRSDown(optional)

- Whenpressedwith “SHIFT”,operatesthe ATRSdownsolenoid.

PanRetract(optional)

- Whenpressedwith “SHIFT”,operatesplow retractsolenoid.

Retract

- Whenpressedwith ‘SHIFT”,operatesplow retractsolenoid.

- Pushandholdtoincrease speedwhiletravelling reverse.

- Pushandholdtodecrease speedwhentraveling forward.

Table1:Radiotransmitterbuttons,continued

Button

Primaryfunction Secondaryfunction

TramRightForward

- Tramsrighttrack forward.

FanOff

- Pushtoturnfanmotor off.

- Pushandholdtoincrease speedwhiletravelling forward.

- Pushandholdtodecrease speedwhentravelingin reverse.

FanOn

- Whenpushedwith “SHIFT”,turnsthefan motoron.

PumpOff

- Pushtoturnpump motoroff.

ConveyorOff

- Pushtoturnconveyormotoroff

ConveyorRaise

- Raisestheconveyor boom.

TransmitterOn

- Turnstheremote controlon.

Auto

PumpOn

- Whenusedwith“SHIFT”, turnsthepumpmotoron.

ConveyorOn

- Whenpushedwith “SHIFT”,turnstheconveyormotoron

None

WaterOff

- Pushtoturnthewater spraysoff.

TransmitterOff

- Turnstheremotecontrol off.

None

CutterOff

- Turnsthecuttermotorsoff.

WaterOn

- Whenpushedwith “SHIFT”,turnsthewater sprayson.

CutterOn

- Whenpressedwith “SHIFT”,turnsthecutter motorson.

Table1:Radiotransmitterbuttons,continued

Button Primaryfunction Secondaryfunction

LeftBoom

- Swingstheconveyor boomtotheleft.

RightBoom

- Swingstheconveyor boomtotheright.

Shift

- Usedinconjunction withanygreenbutton.

Boom

- Lowerstheconveyor boom.

None

None

None

Reverse

- Whenpressedwith “SHIFT”,runstheconveyorinreverse

Therearesixparametersthatcanbesetfromtheradioremote:

■ Channel: 15channelsavailable

■ Timeout: Lengthoftimewithnoactivitybeforeremotepowersoff. Canvaryfromtwo(2)tosixty(60)minutes.

■ Tilt: Whenenabled,thisoptionallowstheradioremotetoautomaticallyissuetheRadioStopcommandwhenatiltanglegreaterthan 45°relativetothehorizonisdetected.

■ FreeFall: Whenenabled,theradioremotecanautomaticallyissue theRadioStopcommandfortwosecondsifafreefalldropfault eventisdetected.Aftertwoseconds,powerisautomaticallyremoved.

■ Wifi: TheradioremoteincorporatesaWificommunicationmodule. Atthisstage,theoptionshouldbedisabled.

■ LowBattery: Thresholdbatteryvoltage,variablein0.1Vincrementsbetween3.1Vand4.2V.Itisrecommendedtoselectbetween3.2Vand3.4Vand3.4Visthedefaultvalue.Whenthebatteryvoltagedropstothisthreshold,alowbatterywarningwillbe displayedontheremoteLCD.

■ SerialNumber: Eachremotehasauniqueserialnumberthatis programmedatthefactory.Thisfeatureispasswordprotectedand isnotavailabletotheoperator.

graphicsdisplay

Thegraphicsdisplay(Fig.19)islocatedabovethemethanemonitoron therightrearbumperofthemachine.Thegraphicsdisplayisusedto monitormachineoperatingparameters,fordiagnosingerrorandfault codes,andforinputofoperatingparameters

Asystemhaltmessagecanappearasapop-updialogboxinthemiddleofanyscreen.Thismessageappearswhenacriticalconditionhas occurredthatpreventscontinuedoperationofthemachineinasafe manner.Themessageboxcannotbeclearedanditisnecessaryto recyclepowertothecontrolsystemtorestoremachineoperation.

Graphicsdisplay

Fig.19:Graphicsdisplay

Normaldisplaypages

Whenthesystemisturnedon,themainpage(Fig.20)isdisplayed. Theoperatorcantogglebetweenthree(3)differenttypesofscreensin normaloperationmode:themainpage,theproductionmonitor(Fig. 21),andtheindividualmonitorpages(boom,pump,scrubber,cutters, andgatheringhead)(Fig.22).Topageleft,press“SHIFT”and“CONV LEFT”ontheradioremote.Topageright,press“SHIFT”and“CONV RIGHT”ontheradioremote.

Themainpageconsistsofanalarmbanner,methanestatus,oillevel status,andinputcurrentandtemperaturereadingsfromthepump,left andrightcuttermotors,scrubbermotor,leftandrightgatheringhead motors,andleftandrighttractionmotors.Italsodisplayvoltageonthe machineandmodeofoperation(remote,etram,ormaintenance).

Astatusmessageistypicallyonlydisplayedonthemainpage.Itisa brieftextdescriptionofaeventorfunctionthatiscurrentlyactive.A statusmessageistypicallynotusedtoindicateanyfaultorwarning conditionandarenotnumbered.

Transmitter information

Oillevelstatus

Methanestatus

Modeofoperation

Fig.20:Mainpage

Alarmbanner

Fig.21:Productionmonitor

Fig.22:Functionmonitor,example

SystemMenu

Thesystemmenu(Fig.23)allowsaccesstodifferentfunctionsofthe controlsystem.

Fig.23:Systemmenu

Usingtheradioremote:

 Toenterthesystemmenuscreen,presstheMENUkey.

 Tomovethecursor,presstheCONVLEFTorCONVRIGHTkey.

 Toselectanoption,presstheMENUkey.

 Toexitorgoback,presstheTRAMFORWARDkey.

Diagnosticmode

Diagnosticmodeallowsalargenumberofmonitoringscreenstobe displayedandselectedwhilethemachineisoperatingandincludesthe followingpages:

■ Mainmonitorpage

■ Productionmonitorpage

■ Boommonitorpage

■ PumpMonitorpage

■ Scrubbermonitorpage

■ Cuttersmonitorpage

■ Gatheringheadmonitorpage

■ Tractionmotormonitorpage

■ I/Omonitorpages - three(3)inputspages

■ I/Omonitorpages - two(2)outputspages

■ Networkmonitorpage

■ RMSdrivemonitorpage

SeeFig.24forexamplesofvariousdiagnosticpages.

Fig.24:Diagnosticpages,examples

Faultlog

Thefaultlog(Fig.25)storesthelastonehundred(100)faultsthathave occurredonthemachine.ThefaultsarestoredinaFirstInFirstOut basis(asanewfaultisadded,theoldestfaultisdeleted).Eachpossiblefaulteventisidentifiedbyauniquenumber.Individualfaultscanbe selectedtoviewmoredetail.

Toselectafaultfromthefaultlog,fromtheradioremote:

 Tomovethecursorup,presstheCONVUPkey.

 Tomovethecursordown,presstheCONVDOWNkey.

 Tomoveuponepage,presstheSHIFTandCONVUPkeys.

 Tomovedownonepage,presstheSHIFTandCONVDOWNkeys.

 Toselectafault,presstheMENUkey.

Fig.25:Faultlog

Anerrormessageisusedbythecontrolsystemtoindicatedwarning conditionsthatarecurrentlyactivebutdonotnecessarilyshutdown machineoperation.Errormessagesaresetandclearedbythecontrol systemautomaticallyinresponsetoreal-timesystembackground monitoring.Errormessagesaretypicallyonlyvisibleduringnormal machineoperationonthemainpageofthecontrolsystemgraphicdisplayscreen.Errormessagesarenumberedandusenumberlessthan 200.

Afaultmessageisaconditionthatshutsdownamotororfunctionor thatpreventsafunctionfrombeingstarted.Whenafaultisdetected,a faultscreen(Fig.26)willdisplayovertopofthecurrentmonitoring screen.Thefaultmessage,explainingwhatiskeepingthemachine fromrunning,willbedisplayed.Theoperatormustclearthefaultby pressingSHIFTandRESUMEontheradiotransmitterunlessthesystemissettoAutoFaultClear.IfthesystemissettoAutoFaultClear, thefaultisautomaticallyclearedbythenextkeypress.

Faultmessagesareloggedinthecontrolsystemfaultlogandarenumberusingnumbersgreaterthan200.

Foracompletelistoferrorandfaultcodes,pleaseseetheTroubleshootingsectionofthischapter.

Fig.26:Individualfaultdetail

Motorhours

Themotorhoursscreen(Fig.27)allowstherunningtimeforallhour meterstobeviewed.Hourmetersarestoredintheprocessor’snonvolatilememory(NVRAM).Iftheprocessorischanged,thecorrectmotorhoursmustbeconfiguredintothesystem.

Fig.27:Motorhoursdisplay

Thecontrolsystemprovidesthreelevelsofaccesstomachineconfigurationparameters:Tradesman,Engineer,andOEM.Eachlevelhas itsownpasswordthatmustbeenteredinordertovieworchangeparameters.

TradesmanSetup

ThefollowingparametersareavailablefromtheTradesmanSetup screenwiththeTradesmenpassword:

1. TestMenu

a. Solenoidtestpage

b. Consoletestpage

2. InclinometerMenu

a. Boominclinometerenable/disable

b. Bodyinclinometerenable/disable

c. Inclinometerrooflimits

1. Cutterincoal

2. Rooflimit

3. Topairovershoot

4. Topcuttingovershoot

5. Floorlimit

6. Bottomairovershoot

7. Bottomcuttingovershoot

EngineerSetup

ThefollowingparametersareavailablefromtheEngineerSetupscreen withtheEngineerpassword:

1. TestMenu - SameasTradesman

2. InclinometerMenu

a. Zeroboomheight

b. Boominclinometerenable/disable

c. Bodyinclinometerenable/disable

d. Boomrawmilliampspercentage

e. GeometrySettings

1. Boomlength

2. Boompivotheight

3. Cutterdrumradius

f. Inclinometerrooflimits

1. Cutterincoal

2. Rooflimit

3. Topairovershoot

4. Topcuttingovershoot

5. Floorlimit

6. Bottomairovershoot

7. Bottomcuttingovershoot

3. ClearMotorHoursPage

4. DataLogging

a. Dataloggingenabled

b. Dataloggingbaudrate

c. Dataloggingrefreshrate

5. MachineConfigMenu

a. Fan/cuttermenu

1. Fan/cuttermode - fanfirst/cutterfirst/either

2. Fan/cutterstaggerdelay

3. Fanautooffdelay

4. Cutterratchetstarttimer

5. Cutterwaterflowdelay

6. Blockedscrubberdetectionenabled

7. Blockedscrubberfilter

8. Backflushspray

9. Backflushspraytime

10. Backflushcycletime

b. InterlockMenu

1. Oillevelshutdown

2. Oillevelwarning

3. Waterflow

c. VerboseFaultAlert

d. ModuleDiagnosticMode

e. EStoptrip

f. Machinevoltagemax

g. Machinevoltagemin

h. Machinevoltagebrownout

i. Brakereleasedelay

j. Autofaultclear

6. RTDSettings

a. EnableRTDmonitoring

b. EnablepumpRTD

c. EnableleftcutterRTD

d. EnablerightcutterRTD

e. EnablescrubberRTD

f. EnableleftconveyorRTD

g. EnablerightconveyorRTD

h. EnabletramtransformerRTD

i. EnablelefttramRTD

j. EnablerighttramRTD

7. OfflineChecks

a. Methanewarning

b. Operatorkeyswitch

c. Oilshutdown

d. Oilwarning

e. Controlearthleakage

f. Supplyearthleakage

g. Tractionearthleakage

h. Waterflow

8. Pre-StartTimers

a. Pump

b. Scrubber

c. Cutters

d. Conveyors

e. Modechange

9. MotorConfig

a. Motorfullloadcurrentsettings(viewingonly)

1. Pump

2.Scrubber

3. Cutter

4. Conveyor

5. Traction

b. Shearmaxcuttercurrent

c. Shearmincuttercurrent

d. Motortriptimers

1. Cutterimbalancerun-time

2. Cutterimbalancestartup

3. Tractionundercurrenttime

4. Tractionillegalcurrenttime

10. TractionConfig

a. Lefthandtrim

b. Righthandtrim

c. Sumpsettings

1. Maxcuttercurrent

2. Mincuttercurrent

3. Sumpspeeddelta

4. Lefthandmaxsumpspeed

5. Righthandmaxsumpspeed

6. Lefthandminsumpspeed

7. Righthandminsumpspeed

d. Lefttramspeeds

1. Speed1

2. Speed2

3. Speed3

e. Righttramspeeds

1. Speed1

2. Speed2

3. Speed3

f. Tramstartdelay

11. AutoStabConfig

a. Autostabenable

b. Autostabincoalseamcurrent

c. Autostabdowntimer

12. PasswordSetup

a. TradesmanPassword

13. Date/TimeConfig

14. ClearFaultLogPage

15. ResetDefaultsPage

LEDdisplay

TheLEDdisplay(Fig.28),locatedontherearbumper,givespictorial representationofthefollowingsituations:

■ E-Stop

■ MethaneTrip

■ WaterTrip

■ KeySwitchOff

■ MotorOverloadTrip

■ LowOilTrip

■ RadioSignalLoss

■ EarthLeakage

■ LowOilWarning

■ ScrubberFilterBlocked

■ BoomLowerLimit

■ BoomUpperLimit

■ NoFault

Fig.28:LEDdisplay

LEDdisplay

Fig.29showssomeexamplesofthetypicaldisplays.

Fig.29:TypicalLEDdisplays

Boomlower limit

Watertrip

Operatorkey switchoff Emergency stop

pendantcontrols

Themachinecanbeoperatedusingapendantcontrol(Fig.30)connectedtotheminerbyanumbilicalcable.Thiscontrolisusedinthe eventthattheoperatorlosesradiolinkwiththeminetosafelyrecover theminerfromthefacetoanareaundersupportedrooffortroubleshootingandmaintenance.

Thependantcontrollerallowslimitedoperationofthemachine:trammingandpumpmotoractivationtoprovidehydraulicpowertoraiseor lowerthecuttinghead.

Inordertousethependant,itmustbeconnectedtothemachineviaa pigtail.Afterpluggingintheumbilicalcord,the“MACHINE”modeof operationswitchmustberotatedtothe“E-TRAM”.

IMPORTANT!

Thependantcontrolleranditsumbilicalcordshouldbestoredina protectedlocationontheworkingsection,awayfromtheminer,to preventdamage.

Fig.30:Pendantcontrols

“MACHINESTOP” “PUMPSTART/ENABLE”

Pendantfunctions

Depressingthe“MACHINESTOP”buttonwillstopallfunctionoutputs createdbythetrampendantinterfacemodule(pump,auger(shear) raise/lower,andleft/righttram).

The“PUMPSTART/ENABLE”buttonisusedwiththe“PUMPON”buttontostartthepumpmotor.

The“PUMPON”buttonisusedtoturnonandoffthepumpmotor. Whenpressedbyitself,“PUMPON”willturnoffthepumpmotor.

Whenusedinconjunctionwith“PUMPSTARTENABLE”,“PUMPON” willstartthepumpmotor:

 Pressandholdthe“PUMPSTART/ENABLE”button.

 Pressthe“PUMPON”button.Holdbothbuttonsinuntilthepump starts(approximatelyonesecond).

 Releasethebuttons.

Press“TRAMENABLE”toactivatethetrammingfunction.Once “TRAMENABLE”ispressed,itremainsactiveunlessnotrammingbuttonispressedforfive(5)seconds.Afterthefive(5)secondtimeout, the“TRAMENABLE”buttonmustbepressedtoreactivatetramming.

Afterpressing“TRAMENABLE”,presstheright“TRAMFWD”buttonto tramtherighttrackforward,presstheleft“TRAMFWD”buttontotram thelefttrackforward,orpressboth“TRAMFWD”buttonstogetherto trambothtracksforward.

Afterpressing“TRAMENABLE”,presstheright“TRAMREV”buttonto tramtherighttrackinreverse,presstheleft“TRAMREV”buttonto tramthelefttrackinreverse,orpressboth“TRAMREV”buttonstogethertotrambothtracksinreverse.

The“AUGERRAISE”buttonisusedtoextendtheshearcylindersand raisethecutterhead.Pushtoactivate,releasetodeactivate.

The“AUGERLOWER”buttonisusedtoretracttheshearcylindersand lowerthecutterhead.Pushtoactivate,releasetodeactivate.

Therearefour(4)LEDlightsacrossthetopofthependant:

“WDG”:1/2secondon,1/2secondoffindicatesunitpoweredandprocessorisrunning.

“TRME”:Tramactionenabled.

“TRML”:Tramleftcommandbeingsent.

“TRMR”:Tramrightcommandbeingsent.

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.31)isindicatedbyalternatingredandwhitediagonalstripes.

Fig.31:Redzone

Trammingtheminer (Fig.32)fromoneplacetoanother,especially maneuveringaroundintersections.Thisillustratesthattheoperator shouldnotplacehimselfbetweenhisminerandtherib.

Beginningthefirstsump (Fig.32)inanewcut.Theminerisagainst theleftribandthedischargeconveyorisswungtowardthecenterof theentryreadyforthehaulagecar.Theoperatormuststayclearofthe dischargeconveyorandtherearoftheminer.

Fig.32:Redzones

Trammingtheminerredzone Beginning1stsumpredzone

Sumpinginthelefthandside ofthecut(Fig.33).Astheminerpenetratestheface,newunsupportedroofisbeingexposed,andtheoperatornowhasanadditionalconstrainttohismovements.Hemustalso stayclearofthehaulagevehicleattherearoftheminerasitapproachestheminerandwhileitisloading.

Repositioningtheminerfortherighthandcut (Fig.33).Because theminerisbackingoutandturninginclosequarters,theoperator muststaybehindtheminertobesafe.

Sumpingintherighthandcut (Fig.33).Again,theoperatormust stayawayfromthefacewherethenewly-exposedroofisunsupported, aswellasstayingclearofthehaulagevehiclewhileitapproachesand loads.

Sumpingonthelefthand sideredzone

Sumpingintherighthand cutredzone

Repositioningminerforright handcutredzone

Fig.33:Redzones

Crosscutredzones (Fig.34). 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.34:Crosscutredzones

Pillaringredzones (Fig.35) 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.35:Pillaringredzones

Safetyprecautionsforundergroundoperation

InadditiontotheprecedinginstructionsforoperatingtheContinuous Miner,observethefollowingspecialprecautionsaftertheContinuous Mineristakenunderground.

■ Communicationisakeyelementinmaintainingsafety.Exactinstructionsandwarningsshouldbegivento,andthoroughlyunderstoodbyeachworkman.Goodcommunicationsbetweentheentire crewmustbemaintainedthroughouttheshift.

■ Checktheconditionofthetrailingcablebeforeturningpoweronat thepowersource.

■ Thismachinemustbemaintainedinapermissiblecondition,followingallstateandfederallaws.

■ MakeavisualcheckoftheContinuousMinerbeforeenergizing. Lookforloosebolts,covers,lockingdevices,damagedparts,and crackedorbrokenlenses.Anypartofthemachinewhichdoesnot functionproperlyisahazard.Reportitimmediatelytoyourimmediatesupervisorortheirdesignee.

■ Priortooperation,makesuretheworkingareaissafe.Makea visualinspectionofroofandribsandtakeallstepsnecessaryto insuresafety.

Trammingsafetyrules

■ Communicateyourintentionstotheworkmenaffectedbythe movementoftheContinuousMiner.

■ Checkthepositionofthewaterhoseandtrailingcabletobe sure thereissufficientslacktofinishtheoperation.

■ Notetheconditionoftheroadwaysandphysicalsurroundingsof theroute.

■ Positionthecutterandgatheringheadfortramming.

■ Positionthestabilizershoeandboomsfortramming.

■ Positionyourbodycompletelyinsidetheoperator'scompartment (optional),facingtheintendeddirectionoftravel.

■ PositiontheContinuousMinerinthecenteroftheroadwaytoallowmaximumsafeclearance.Consistentlymaintainclearance, whichiscriticaltothesafemovementoftheContinuousMiner.

Emergencystopfromthetransmitter(remotecontrol)

IMPORTANT!

Useofthered“STOP”buttononthetransmitterisrecommended whenthemachinemustbeshutdownURGENTLY.Thisisthe fastestwastoshutdownthemachinefromthetransmitter.

ToshutthemachinedownURGENTLY:

 Pressandholdthered“STOP”buttonlocatedatthetopofthe transmitter.

Thecontrolsystemwillshutdownallfunctionsandmotors.IftheESTOPMODEparameterissettoPOWERCENTERTRIPinthesystem setup,thecontrolsystemwillopenthepilotrelayandpowerwillberemovedfromthemachine.

EmergencystopfromaMachineStopbutton

Therearetwomachinemountedstopbuttonsthatcanbepressedat anytimetoshutdownallmotorsandfunctions.Onebuttonismounted ontheleftsideofthemachineandoneismountedontherightsideon thefrontoftheoperator’scase.

Toshutdownthemachineusingeithermachinestop:

 Pressandholdthemachinestopbutton.

Thecontrolsystemwillshutdownallfunctionsandmotors.IftheESTOPMODEparameterissettoPOWERCENTERTRIPinthesystem setup,thecontrolsystemwillopenthepilotrelayandpowerwillberemovedfromthemachine.

Startingprocedure

WARNING!

Readallinstructionscarefullybeforeattemptingtostartoroperatethemachine.Failuretoreadandunderstandalloperating instructionsbeforestartingtheContinuousMinercouldresultin seriousinjuryordeathtotheoperatororpersonsaroundthemachineorcausedamagetothemachine.

WARNING!

UnderstandthefunctionsofallcontrolsbeforestartingtheContinuousMiner.Readandfollowtheinstructionsonallwarning tagsonthemachine,observeallregulationsandsafetyprecautions.

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!

Turningonthewatersprayspriortocuttingpreventstheaccumulationofdustandthegenerationofexcessiveheatwhich couldcauseanignitionorexplosion.

Aftertraining,whichincludesreadingandunderstandingtheControls andIndicatorssectionofthischapter,andbecomingfamiliarwiththe locationsandfunctionsofallmachinecontrols,theoperatorisreadyto operatetheContinuousMiner.Anexperiencedoperatorshouldmonitor anewoperator’sindoctrinationtothestartingprocedure.

WARNING!

TheContinuousMinerisoperatedbyradioremotecontrol.Manualoperationisnotallowedforproductionoperation.Manualoperationisfortroubleshootingandmaintenanceunderroofsupport.

IMPORTANT!

Beforestart-up,checkthatdailymaintenancehasbeenperformed onthemachine.

WARNING!

Visuallycheckforotherpersonnelandverballyshoutawarning beforestartingthismachine.Makesureallpersonnelarecompletelyclearofthemachineandit’scomponentsandcheckthat theareaisclearbeforestartingthemachine.

 Turnthemaincircuitbreakertothe“ON”position.

 Turnthekeyswitchtothe“ON”position.

 Turnthe“TRAMCIRCUITBREAKER”tothe“ON”position.

 Turnthe“MINER”modeofoperationselectorswitchto“REMOTE”.

 Pressthe“ON/OFF”buttononthetransmittertoturnonthetransmitter.

 Pressandholdthe“SHIFT”buttononthetransmitter.

 Whileholdingthe“SHIFT”button,pressthe“PUMP/OFF”button.A pre-startwarninghornwillsound.Holdbothbuttonsinuntilthe pumpstarts.

 Releasethe“PUMP/OFF”key.Thepre-startwarninghornwillstop.

IMPORTANT!

The“PUMP/OFF”keymustbereleasedbefore“SHIFT”.If“SHIFT” isreleasedfirst,thepumpmotorwillshutoff.

 Releasethe“SHIFT”key.

Shutdownprocedure

Thecontinuousminermustbeproperlyshutdownbeforeleavingthe areaorbeforeperforminganymaintenanceorservice.Somemaintenanceorserviceproceduresmayrequireadditionalstepstoinsurethe safetyofthemaintenancepersonnelworkingonoraroundthemachine andwillbelistedinthemaintenancesectionofthisguide.

 Backthemineraboutonefootfromthefaceprovidingsufficient clearanceandshutoffthecutterheadmotors(seeCutteroperation inthissection).

 Turnoffthewaterspraysbypressingthe“WATER/OFF”buttonon thetransmitter.

 Makesurethattheconveyorisemptyandthenshutdowntheconveyormotors.

 Pressandholdthe“CONV/OFF”buttononthetransmitter. Theconveyormotorsshouldshutdownimmediately.

 Tramtheminertoanareaofwellsupportedroof.Parkthemachine initsdesignatedparkingareaoutoftrafficandonflat,solidground. Ifitisnotpossibletoparkthemachineonflatground,parkthemachineatarightangletotheslope.

 Lowerthecutterheadtothefloor.

 Lowertheconveyorandgatheringhead.

 Pressandholdthe“PUMP/OFF”buttononthetransmitter.The pumpmotorshouldshutdownimmediately.

 Releasethe“PUMP/OFF”button.

 Turnthemachinecircuitbreakertothe“OFF”position.

 Turnthekeyswitchtothe“OFF”position.

 Turnoffthemainpowersupply.

 Turnofftheminewatersupply.

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