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Operation and Maintenance Manual Bucyrus - Continuous Miner Model - 30M4-NP Doc. No.: A6474X337

Bucyrus ____________________________________________________ 4041 Wurno Road Pulaski, VA 24301

Telephone: 540-980-4530 Fax: 540-994-3763

Internet: www.bucyrus.com

__________________________________________________________

This manual is intended to provide GENERAL product information for the Model 30M4-NP Continuous Miner. The illustrations, descriptions and procedures contained in this publication apply only to THIS machine. Bucyrus reserves the right to revise models and designs without prior notice.

This Continuous Miner was manufactured under the guidelines, procedures and requirements of the appropriate government regulatory agencies.

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

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

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

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

BUCYRUS© ALL RIGHTS RESERVED

________________________________________________ Table of contents

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

2. Your safety

© BUCYRUS

Your safety .............................................................................. 2.3 Personnel............................................................................. 2.4 Operation ........................................................................ 2.4 Installation and repair...................................................... 2.4 Operating conditions ............................................................ 2.5 Intended use ................................................................... 2.5 Unauthorized use............................................................ 2.5 Safety instructions................................................................ 2.7 General rules: ................................................................. 2.7 Storage and transport ..................................................... 2.8 Pre-start inspection ......................................................... 2.8 Installation and start-up................................................... 2.9 Operation ........................................................................ 2.9 Stopping .........................................................................2.10 Maintenance and repair .................................................2.10

3. Storage and transport Storage and transport ............................................................ 3.3 Storage ................................................................................ 3.3 Storage of the machine and spare parts......................... 3.3 Long-term storage of spare components........................ 3.4 Transport.............................................................................. 3.5 Hoisting of heavy components........................................ 3.6

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

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Table of contents _________________________________________________

Operation ................................................................................. 5.3 How to operate the Continuous Miner ................................. 5.3 Who is allowed to operate the Continuous Miner ........... 5.3 When can operation be started?..................................... 5.3 Controls and indicators ........................................................ 5.4 Machine control system ......................................................5.18 Red zone.............................................................................5.34 Safety precautions for underground operation ...................5.37 Tramming safety rules ........................................................5.37 Starting procedure in radio remote .....................................5.38 Shutdown procedure in radio remote..................................5.40 Tramming the miner in radio remote...................................5.42 Cutter head operation in radio remote ................................5.44 Conveyor operation in radio remote ...................................5.45 Scrubber motor in radio remote ..........................................5.47 Control headlights in radio remote......................................5.48 Fire suppression in radio remote ........................................5.49 Shear up/down in radio remote...........................................5.49 Gathering head raise/float in radio remote .........................5.49 Stabilizer shoe in radio remote ...........................................5.49 Conveyor raise/lower in radio remote .................................5.50 Tramming with pendant controls.........................................5.51 Starting procedure from operator’s pit ................................5.52 Shutdown procedure form operator’s pit.............................5.54 Tramming the miner from operator’s pit..............................5.55 Cutter head operation from operator’s pit ...........................5.56 Conveyor operation from operator’s pit ..............................5.57 Mechanical assemblies.......................................................5.58 Hydraulic system.................................................................5.64 Electrical system .................................................................5.110 Instructions on the maintenance....................................... 5.138 Important notes ............................................................ 5.138 Before maintenance..................................................... 5.138 Torque values .............................................................. 5.140 Lubricants, fluids and capacities .................................. 5.140 Specific lubrication and maintenance instructions ............ 5.146 Every shift .................................................................... 5.146 Every third shift (daily) ................................................. 5.149 Weekly ......................................................................... 5.156 Monthly......................................................................... 5.161 Every three months ...................................................... 5.167 Every six months.......................................................... 5.173 Instructions on the adjustment procedures....................... 5.176 Pilot pressure circuit relief/reducing valve ................... 5.178 Direction control valve (main control and cutter head) 5.180 Cutter head port reliefs ................................................ 5.185 Multi-purpose valve...................................................... 5.185 Conveyor chain tension pressure ................................ 5.186 Tram track .................................................................... 5.187 Tail shim....................................................................... 5.192 Conveyor chain tension ............................................... 5.195

_________________________________________________________________ Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS

5. Operation

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© BUCYRUS

Replacement of wear parts ............................................... 5.197 Cutter head (boom) assembly ..................................... 5.197 Cutter head assembly removal/installation ............. 5.197 Shear cylinder ......................................................... 5.201 Center cutter drum .................................................. 5.206 End cutter drum....................................................... 5.209 Drum drive motor .................................................... 5.212 Drum drive gear case.............................................. 5.217 Gathering head assembly ............................................ 5.220 Gathering head assembly removal/installation ....... 5.221 Gathering head drive motor .................................... 5.226 Gathering head gear case ...................................... 5.229 Gathering head foot shaft ....................................... 5.232 CLA ......................................................................... 5.235 CLA tip replacement................................................ 5.237 Gathering head lift cylinder ..................................... 5.238 Crawler assembly ........................................................ 5.242 AC drive encoder removal/installation .................... 5.246 Tram motor.............................................................. 5.248 Tram case ............................................................... 5.250 Crawler chain .......................................................... 5.255 Tram track front idler ............................................... 5.259 Tram brake.............................................................. 5.262 Conveyor assembly ..................................................... 5.267 Conveyor chain ....................................................... 5.268 Conveyor assembly removal/installation ................ 5.272 Discharge conveyor ................................................ 5.275 Tail roller ................................................................. 5.280 Troubleshooting procedures ............................................. 5.283 Typical hydraulic problems .......................................... 5.284 Contaminants in hydraulic systems ............................. 5.285 Specific hydraulic circuits............................................. 5.286 General safety procedures for shutdown..................... 5.290 Excessive noise ........................................................... 5.291 Excessive heat............................................................. 5.292 Incorrect flow................................................................ 5.293 Incorrect pressure ........................................................ 5.294 Faulty operation ........................................................... 5.295 Restarting checklist...................................................... 5.296 Bearings ....................................................................... 5.297 E-tram pendant LEDs .................................................. 5.298

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Table of contents _________________________________________________ 6. Technical data Technical data ......................................................................... 6.3 Tightening torques................................................................ 6.4 Permissible data................................................................... 6.6 Lubrication fluids and greases......................................... 6.6

7. For your information

© BUCYRUS

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

_________________________________________________________________ Bucyrus – Model 30M4-NP Continuous Miner

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1

About this manual

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_______________________________________ Before starting to work

About this manual This chapter provides important information making it easier for you to use this manual. It contains information on the structure of the manual and the symbols and characters used.

Before starting to work applicable operating manual machine type

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

This operating manual is intended for: Bucyrus Model 30M4-NP Continuous Miner Serial No.: N/A and is only permitted to be used for equipment of this type.

new operation manual

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

© BUCYRUS

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

Who is this operating manual intended for?

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

This includes persons who: ■

operate the machine

■

are in charge of transport

■

perform assembly/disassembly work

■

find/fix faults

■

perform daily routine work at the face or in the entry

■

perform maintenance work

■

perform repair work

supervisory personnel who: ■

initiate and/or supervise the activities just indicated.

______________________________________________________________ A6474X337 VLSS/0 1.3

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

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

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

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

safety

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

© BUCYRUS

service

_________________________________________________________________ 1.4 Bucyrus – Model 30M4-NP Continuous Miner

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

Try to memorize the symbols and their meanings.

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

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

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

© BUCYRUS

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

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

■

Items in lists are marked with bullets.

–

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

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

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

______________________________________________________________ A6474X337 VLSS/0 1.5

© BUCYRUS

Before starting to work ________________________________________

_________________________________________________________________ 1.6 Bucyrus – Model 30M4-NP Continuous Miner

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2

Your safety

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__________________________________________________ Personnel

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

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

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

alterations

Do not make any alterations or modifications which could impair the safe operation and maintainability of the machine. All modifications and changes must be approved by Bucyrus and all appropriate regulatory agencies.

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

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

© BUCYRUS

Observe the safety and accident prevention regulations

further operating manuals

■

of the mine,

■

of the mine’s inspectors, and

■

of the mining supervisory authorities.

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

______________________________________________________________ A6474X337 VLSS/0 2.3

Personnel ___________________________________________________ Personnel Operation training

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

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

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

You must have adequate knowledge of the ■

mechanics,

■

hydraulics, and

■

control engineering

and must be able to prove this knowledge.

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

Installation and repair work on: ■

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

■

the electrics (motors, controllers, etc.)

■

the hydraulics (controls, cylinders, etc.)

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

_________________________________________________________________ 2.4 Bucyrus – Model 30M4-NP Continuous Miner

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Installation and repair

_________________________________________ Operating conditions Operating conditions Intended use The Continuous Miner has been designed and manufactured for specific uses. Intended uses include: ■

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

■

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

■

operation on grades of less than 10 degrees

Unauthorized use

© BUCYRUS

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

■

the transport of persons

■

stone development or extraction

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

______________________________________________________________ A6474X337 VLSS/0 2.5

© BUCYRUS

Operating conditions __________________________________________

_________________________________________________________________ 2.6 Bucyrus – Model 30M4-NP Continuous Miner

___________________________________________ Safety instructions Safety instructions General rules general

noise emissions

Always work with full concentration and familiarize yourself with your working environment.

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

Inform your colleagues of

safety equipment

© BUCYRUS

symbol plates

■

your exact location,

■

the work you are performing, and

■

the time that you will probably require.

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

Observe the symbol plates on the machine.

emergency stop

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

lock-out and tag

Disconnect, lockout, and tag the power system, following all applicable rules and regulations, while performing maintenance, inspection, or repair work.

working area

Cordon off your working area widely for the machine.

moving parts

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

chains, flights, and chain sprockets

■

pivot points

■

crawler assemblies and conveyors

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cutter and gathering head assemblies

______________________________________________________________ A6474X337 VLSS/0 2.7

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

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

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

Ensure that the transport safety devices are correctly fitted.

Fix all moving parts with transport locks.

Never stand under unsupported parts or suspended loads.

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

Only use means of attachment which are in good condition and have been designed for the loads to be handled. For round components use transport straps only; never use chains or steel cables for this purpose.

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

mobile handling equipment

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

Pre-start inspection operation

Read this entire manual before attempting to operate this machine.

inspection

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

maintenance instruction and safety tags

Verify that all maintenance has been performed.

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

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

_________________________________________________________________ 2.8 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS

means of attachment

___________________________________________ Safety instructions Installation and start-up inclined face

environmental acceptability

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

When working with oils, greases and other chemical substances, observe the safety regulations applicable to the product. Safety regulations can be found on the container or on the Material Safety Data Sheet (MSDS) for the product.

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

controls

When starting up machine, do not operate any controls located inside the operator’s pit from outside the pit.

starting procedures

Follow the starting procedure instructions in the operations manual.

red zone

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

© BUCYRUS

Operation training

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

before start-up

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

protective devices

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

traveling

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

passengers

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

safety rules

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

problems and malfunctions

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

______________________________________________________________ A6474X337 VLSS/0 2.9

Safety instructions ____________________________________________ Stopping parking

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

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

Maintenance and repair Be sure to observe the prescribed maintenance and inspection intervals.

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

securing

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

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

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

Protect your work area against falling rocks.

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

original parts

Use only spare parts which satisfy the specified technical requirements.

This is only ensured with original Bucyrus spare parts. Please refer to the spare parts lists or parts catalog for the order numbers.

_________________________________________________________________ 2.10 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS

trailing cable uncoupled and locked and tagged out

___________________________________________ Safety instructions lifting

handling of hydraulic fluids

For raising the Continuous Miner use only: ■

crib blocks with adequate load-holding capacity.

■

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

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

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

maintenance/repair

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

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

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

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

© BUCYRUS

Always replace damaged or lost decals and metal instruction plates.

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

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

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

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

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

the hoses are not pinched or trapped.

■

the hoses have no bubbles or blisters.

■

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

■

the outer sheath of the hoses is not damaged.

■

the connectors are securely inserted into the sockets.

■

the connections are leak-tight.

______________________________________________________________ A6474X337 VLSS/0 2.11

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

Flush out the hydraulic lines thoroughly before connecting. permissible hoses

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

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

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

Use only hydraulic hoses approved for the prevailing pressures.

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

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

Never try to repair damaged hydraulic hoses.

Replace hydraulic hoses at the first suspicion of damage. installing hydraulic hoses

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

Always install hydraulic hoses so they: ■

always have a little slack.

Fig. 1: Installing hydraulic hoses, slack Right

Wrong

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© BUCYRUS

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

___________________________________________ Safety instructions ■

are not twisted.

Fig. 2: Installing hydraulic hoses, twisting Right

■

Wrong

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

Fig. 3: Installing hydraulic hoses, bending Wrong

© BUCYRUS

Right

■

always have a little slack.

■

are not kinked.

■

do not have to withstand tensile strains.

■

are protected against thermal radiation.

■

are accessible at all times.

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

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

______________________________________________________________ A6474X337 VLSS/0 2.13

Safety instructions ____________________________________________ When installing the hydraulic hoses, ensure that they cannot be: ■

torn out,

■

kinked,

■

crushed,

■

driven over or

■

twisted by movement of the machine.

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

© BUCYRUS

Right

_________________________________________________________________ 2.14 Bucyrus – Model 30M4-NP Continuous Miner

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3

Storage and transport

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________________________________________ Storage and transport

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

For specific procedures for your environment, contact Bucyrus Engineering.

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

Storage corrosion protection

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

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

Storage of the machine and spare parts

© BUCYRUS

no direct exposure to sunlight dirt and moisture

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

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

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

short-term storage

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

long-term storage

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

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

■

Completely fill the hydraulic oil tank with oil.

■

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

■

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

■

The equipment must be stored in a well ventilated, dry room. Do not store outdoors.

______________________________________________________________ A6474X337 VLSS/0 3.3

Storage and transport _________________________________________ machine electrical components traction drives

Electronic components must be stored at temperatures between -10° C and 55° C (14° F and 131° F).

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

random sample inspection

After a storage period of approximately two years, a random sample inspection must be performed to determine whether the measures taken and the method of storage has prevented damage. On request, the inspection can be carried out by Bucyrus.

natural aging

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

HFA fluids

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

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

Long-term storage of spare components hydraulic components

If a component is to be stored more than six months, the hydraulic component must be completely filled with a corrosion inhibiting fluid. Fill the hollow areas of hydraulic components (e.g. the piston chambers) in horizontal position (ports facing upwards) until they start to overflow then seal the ports with plastic or steel plugs.

miscellaneous components

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

motors

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

fan assembly

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

plastic deformation

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

_________________________________________________________________ 3.4 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS

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

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

dimensions,

■

weights,

■

lifting points, etc.

Additional information on the dimensions and weights can be found in chapter 6 and in the lifting weight guide (Table 1) in this operating section. Fig. 5 illustrates the position of lifting points of the various assemblies of the machine. For detailed lifting instructions, see component hoisting information.

© BUCYRUS

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

Table 1: Lifting weights of continuous miner assemblies Description

Approximate Weight

Tractor Frame

90,000 lbs

Gathering Head

23,158 lbs

Chain & Conveyor

17,000 lbs

Support Frame

50,500 lbs

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

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

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

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

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

______________________________________________________________ A6474X337 VLSS/0 3.5

Storage and transport _________________________________________ Fig. 5: Lifting points

Lifting eye (10 ton)

Lifting eye (10 ton)

Lifting eye (10 ton)

Gathering head lifting points

Lifting eye (30 ton)

Lifting eye (30 ton)

Bumper lifting points

_________________________________________________________________ 3.6 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS

Lifting eye (10 ton)

________________________________________ Storage and transport Fig. 5: Lifting points (continued) Lifting eye (4.5 ton) Lifting eye (4.5 ton)

Lifting eye (4.5 ton) Lifting eye (4.5 ton)

Conveyor lifting points

© BUCYRUS

Lifting eye (16 ton) (both sides)

Cutter head lifting points

______________________________________________________________ A6474X337 VLSS/0 3.7

Storage and transport _________________________________________ Before transport temperatures below freezing

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

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

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

Electrical and electronic components must be protected against harmful environmental influences by a suitable packaging.

The electrical cables remain in the equipment. They must be carefully protected against transport damage and soiling of the connections.

_________________________________________________________________ 3.8 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS

electronic components

_______________________________________________________________

4

Installation

________________________________________________________________

________________________________________________________________

_________________________________________________________________

__________________________________________________Installation

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

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

Work on: ■

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

■

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

■

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

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

© BUCYRUS

Which tools are required for installation? tool box

General tools are required to put the Continuous Miner into service.

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

These include: ■

hoists with adequate lifting capacity

■

means of attachment with adequate lifting capacity

■

unloading dock and crib blocks

■

jacks with adequate lifting capacity

■

impact wrenches, including accessories

______________________________________________________________ A6474X337 VLSS/0 4.3

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

Bucyrus Continuous Miners are shipped to the customer site per customer preference. The Continuous Miner can be shipped to the customer site as a complete machine or in component sections. This depends on mine conditions, transportation weight restrictions/ requirements, or size/weight restrictions at the mine.

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

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

reassembly instructions

_________________________________________________________________ 4.4 Bucyrus – Model 30M4-NP Continuous Miner

__________________________________________________Installation Pre-installation check list

© BUCYRUS

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

However, to ensure that no transit damage has occurred, the following pre-startup checks should be performed: ■

visually inspect all cylinders, gear boxes, tanks, and hydraulic components for leaks or damage.

■

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

■

check the full length of the trailing cable (if applicable) for damage

■

ensure that the trailing cable is properly suspended across intersections and that the trailing cable clamp at the Continuous Miner is secure

■

clean any foreign material from the conveyor and gathering pan

■

check that all covers and guards are in place and secure

■

check that all tags and instruction labels are in place and secure

■

check safety provisions for operational condition on fire suppression system

■

visually inspect all hydraulic hoses and electrical cables for damage

■

start up the machine and check for correct operation of all stop and emergency stop buttons (both on the machine and on the rdio remote)

■

after starting the machine, allow the hydraulic system to warm up for five (5) to ten (10) minutes and then check hydraulic system pressures (refer to the hydraulic schematic supplied for your particular machine for pressure settings)

■

check and operate all control handles and switches to ensure all machine functions are operating properly and are in neutral position

■

check the tension of the conveyor chain and crawler chain

______________________________________________________________ A6474X337 VLSS/0 4.5

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

machine stop button

The machine is equipped with two machine stop buttons, one in the pit and one on the left side of the machine. The machine stop buttons are used to shut down all functions capable of producing movement on the machine. Striking with a small amount of force will actuate the machine stop.

fire suppression (optional)

The machine may be equipped with fire suppression (remote) actuators. If equipped, the location of the actuators may vary. The suppression system (if equipped) is pneumatically actuated and extinguishes with dry chemicals. To actuate the system from the actuators, pull the safety pin and strike downward on the plunger. Immediately after the plunger is struck, dry chemical will be dispensed throughout the machine. The fire suppression system must be completely recharged with dry chemicals and expellants after it has been actuated.

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

Water can be directed to the fire spray nozzles (optional0 manually from a fire spray valve or via solenoid from the radio remote). If equipped, see Chapter 5 for operating instructions and locations of the valves.

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

CAUTION! The mine supply water pressure at the machine should not exceed 500 psi (34 bar) and should supply 20 gpm (76 Lpm)

guards and covers

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

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

cutter boom safety supports

There are two cutter boom safety supports (Fig. 6), one on each side of the cutter boom. The supports are used to block up the cutter boom during maintenance operations.

_________________________________________________________________ 4.6 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS

Safety features include: (Reference Fig. 6)

__________________________________________________Installation There are two conveyor safety supports, one on each side of the conveyor. The supports are used to block up the conveyor during maintenance operations.

methane monitor

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

canopy/cab

The miner was shipped from the factory with a protective canopy/cab.

Ensure that the canopy/cab is in place and secure at all times to protect the operator from falling debris.

© BUCYRUS

conveyor safety supports

______________________________________________________________ A6474X337 VLSS/0 4.7

Installation___________________________________________________ Fig. 6: Safety features on the Continuous Miner

Machine stop

Radio remote emergency “STOP” button

_________________________________________________________________ 4.8 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS

Machine stop

__________________________________________________Installation Fig. 6 (continued): Safety features on the Continuous Miner

© BUCYRUS

Cutter head safety support - installed

Conveyor safety support - typical both sides

______________________________________________________________ A6474X337 VLSS/0 4.9

Installation___________________________________________________ Fig. 7: Overview of the Continuous Miner

Cutter head assembly

Operator’s station Conveyor assembly

Tram assembly

Gathering pan assembly

© BUCYRUS

Stabilizer shoe

_________________________________________________________________ 4.10 Bucyrus – Model 30M4-NP Continuous Miner

_______________________________________________________________

5

Operation

________________________________________________________________

________________________________________________________________

_________________________________________________________________

___________________________________________________Operation

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

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

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

Who is allowed to operate the continuous miner?

© BUCYRUS

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

This also includes: ■

what safety devices are installed on the machine.

■

where these safety devices are located.

■

how these safety devices are to be operated.

When can operation be started?

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

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

______________________________________________________________ A6474X337 VLSS/0 5.3

Operation____________________________________________________ Controls and indicators Operator’s station The operator’s pit (Fig. 8) is located on the right hand side of the machine, near the rear bumper. The controls and indicators used for the normal operation of the machine are located within this pit.

© BUCYRUS

Fig. 8: Operator’s pit

_________________________________________________________________ 5.4 Bucyrus – Model 30M4-NP Continuous Miner

___________________________________________________Operation “MACHINE STOP”

© BUCYRUS

“MINER MODE”

The “MACHINE STOP” button (Fig. 9) is a large red push button located on the top left of the operator’s case. This is one of two (2) machine stop buttons located on the miner. Pushing “MACHINE STOP” will shut down the pump motor, causing the miner to shut down. Follow the normal star up procedure (See Start up procedure in this chapter) to restart the machine after pushing “MACHINE STOP”.

The “MINER MODE” selector switch (Fig. 9) is located to the right of the “MACHINE STOP” button. This switch has four (4) positions: ■

“REMOTE” - This position allows the miner to be operated by radio remote. During normal mining operations, the switch should be in this position.

■

“PIT” - This position allows the miner to be operated from the operator’s pit.

■

“E-TRAM” - This position allows the miner to be trammed from the pendant controls. “E-TRAM” is used in the event that the miner cannot be operated in “REMOTE” mode.

■

“GND CHK” - Placing the operation switch in the ground check position should cause the mine power center to trip, thereby shutting down all power to the miner.

fire spray valve

The fire spray valve (Fig. 9) located to the left of the control case can be operated manually or by remote. To manually operate the valve, pull out to turn on and push in to turn off.

“TRAM BRAKE MODE”

The “TRAM BRAKE MODE” switch (Fig 9) is used to select the mode of operation for the tram brakes. When the switch is in the “NORMAL” position, brakes will be applied as configured in the control system.

When the switch is in the “MANUAL ON” position, the brakes are applied regardless of the control system configuration.

“TRAM SPEED SELECTION”

The “TRAM SPEED SELECTION” switch (Fig. 9) is used to select the maximum tramming speed of the machine when the cutter head is not cutting and both traction drives are healthy. The “LOW” and “HIGH” speed ranges are adjustable ranges that are set in the graphics display screen.

When the cutters are running, the maximum tram speed will be generated by the cutter motor feedback function in the control system.

If only one traction drive is healthy or if the control system reads both “LOW” and ”HIGH” speeds selected (faulty speed selector switch) , the maximum tramming speed will be creep speed (25%).

______________________________________________________________ A6474X337 VLSS/0 5.5

Operation____________________________________________________ Fig. 9: “MACHINE STOP”, “MINER MODE”, “TRAM BRAKE MODE”, “TRAM SPEED SELECTION”, and fire spray valve

“MACHINE STOP” “MINER MODE”

“TRAM SPEED SELECTION”

Fire spray valve

_________________________________________________________________ 5.6 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS

“TRAM BRAKE MODE”

© BUCYRUS

___________________________________________________Operation

“PUMP START”

The “PUMP START” button (Fig. 10) is used to turn on the pump motor. To start the pump motor, press and hold “PUMP START” and “MOTOR START ENABLE” until the motor starts. The pump motor must be running before any other motor can be started.

“PUMP STOP”

The “PUMP STOP” button (Fig. 10) is used to turn off the pump motor.

To stop the pump motor, press “PUMP STOP”.

“CUTTER START”

The “CUTTER START” button (Fig 10) is used to start the cutter head motors. To start the motors, press and hold “CUTTER START” and “MOTOR START ENABLE” until the motors start.

“CUTTER STOP”

The “CUTTER STOP” button (Fig. 10) is used to turn off the cutter head motors. To stop the motors, press “CUTTER STOP”.

“CONVEYOR START”

The “CONVEYOR START” button (Fig. 10) is used to start the conveyor in the forward direction. To start the conveyor, press the “CONVEYOR START” and “MOTOR START ENABLE” buttons.

“CONVEYOR STOP”

The “CONVEYOR STOP” button (Fig 10) is used to stop the conveyor when it is running in the forward direction. To stop the conveyor, press “CONVEYOR STOP”.

“MOTOR START ENABLE”

The “MOTOR START ENABLE” button (Fig. 10) is used with the “PUMP START”, “CUTTER START” and “CONVEYOR START” buttons to start the pump motor.

“CONVEYOR REVERSE JOG”

The “CONVEYOR REVERSE JOG” button (Fig. 10) is used to jog the conveyor in the reverse direction. To jog the conveyor in reverse, press and hold “CONVEYOR REVERSE JOG”. The conveyor will continue to jog in reverse as long as the button is held. Releasing the button will stop the conveyor.

______________________________________________________________ A6474X337 VLSS/0 5.7

Operation____________________________________________________

© BUCYRUS

Fig. 10: “PUMP START”, “PUMP STOP”, “CUTTER START”, “CUTTER STOP”, “CONVEYOR START”, “CONVEYOR STOP”, “MOTOR START ENABLE”, and “CONVEYOR REVERSE JOG”

_________________________________________________________________ 5.8 Bucyrus – Model 30M4-NP Continuous Miner

___________________________________________________Operation circuit breakers

There are four (4) “CONTROL CIRCUIT BREAKERS” and six (6) “MACHINE LIGHTING” circuit breakers (Fig. 11) located on the control panel. For more detailed information on the individual circuit breakers, see the Electrical section in this chapter.

“CONVEYOR HOUR METER”

The “CONVEYOR HOUR METER” (Fig. 11) indicates the hours of running time for the conveyor (CLA) motors.

“CUTTER HEAD HOUR METER”

The “CUTTER HEAD HOUR METER” (Fig. 11) indicates the hours of running time for the cutter motors.

Fig. 11: Circuit breakers and hour meters

“CUTTER HEAD HOUR METER” “CONVEYOR HOUR METER”

© BUCYRUS

Circuit breakers

______________________________________________________________ A6474X337 VLSS/0 5.9

“MAIN CIRCUIT BREAKER”

The “MAIN CIRCUIT BREAKER” is on the left side of the breaker case, which is located below the operator’s control station (Fig 12). This circuit breaker has four (4) positions: "OFF," to de-energize the machine's electrical systems and "ON," for normal operation, “TRIPPED” when the circuit breaker has tripped, and “RESET” to reset the circuit breaker after it has tripped. The main circuit breaker should be in the "OFF" position before the machine is serviced or shutdown.

“CLA/PUMP/FAN CIRCUIT BREAKER”

The “CLA/PUMP/FAN CIRCUIT BREAKER” lever (Fig. 12) is used to control the circuit breaker for the conveyor, pump and fan motors. It is located on the left side of the breaker case, which is located below the operator’s control station. This breaker must be in the “ON” position before the motors will start. To turn the circuit breaker “ON”, move the lever up. To turn the circuit breaker “OFF”, move the lever down. If the circuit breaker trips, The breaker must be reset by moving the lever past “OFF” and then back to the “ON” position.

“TRAM CIRCUIT BREAKER”

The “TRAM CIRCUIT BREAKER” lever (Fig. 12) is used to control the circuit breaker for the tram motors. It is located on the right side of the breaker case, which is located below the operator’s control station.

This breaker must be in the “ON” position before the tram motors will start. To turn the circuit breaker “ON”, move the lever up. To turn the circuit breaker “OFF”, move the lever down. If the circuit breaker trips, The breaker must be reset by moving the lever past “OFF” and then back to the “ON” position.

“CUTTER MOTOR CIRCUIT BREAKER”

The “CUTTER MOTOR CIRCUIT BREAKER” is on the right side of the breaker case, which is located below the operator’s control station (Fig 12). The circuit breaker has four (4) positions: "OFF," to de-energize the machine's electrical systems and "ON," for normal operation, “TRIPPED” when the circuit breaker has tripped, and “RESET” to reset the circuit breaker after it has tripped.

Fig. 12: Circuit breaker levers “TRAM CIRCUIT BREAKER”

“MAIN CIRCUIT BREAKER”

“CLA/PUMP/FAN MOTOR CIRCUIT BREAKER”

“CUTTER MOTOR CIRCUIT BREAKER”

_________________________________________________________________ 5.10 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS

Operation____________________________________________________

___________________________________________________Operation Gauge panel

© BUCYRUS

There is a gauge panel (Fig. 13) consisting of four (4) gauges located to the right of the control case that is used to measure hydraulic and water pressure throughout the miner.

“MAIN PRESSURE”

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

“PILOT PRESSURE”

The first gauge from the operator’s left on the middle row of gauges is “PILOT PRESSURE”. This gauge is used to monitor the supply pressure for all pilot functions. See the Pilot pressure circuit in the Hydraulic section of this chapter for further information.

“MCV PRESSURE”

The “MCV PRESSURE” gauge is used to monitor the low pilot pressure at the Main Control Valve bank. The purpose of the MCV pilot pressure is to provide the necessary force to shift the control valves when the solenoids are energized. When the MCV pilot pressure becomes too low, the machine operations will become “sluggish”. This is typically an indication of a clogged pilot filter and the filter should be changed. See the Main control valve pressure circuit in the Hydraulic section of this chapter for further information.

“INLET WATER PRESSURE”

The “INTAKE WATER PRESSURE” gauge monitors the pressure of the water going into the miner. See the water pressure circuit in the Water section of this chapter for further information.

Fig. 13: Gauge panel Gauge panel

______________________________________________________________ A6474X337 VLSS/0 5.11

“CUTTING HEAD” control lever

The first lever from the operator’s left is the “CUTTING HEAD” control lever (Fig. 14), which is used to raise and lower the cutter head. To lower the cutter head, push the lever forward, away from the operator.

To raise the cutter head, pull the lever back, towards the operator. Positioning the lever in the center position will hold the cutter head in place.

“CONVEYOR” control lever

The second lever from the operator’s left is the “CONVEYOR” raise lever (Fig. 14), which controls the vertical position of the conveyor. To raise the conveyor, pull the lever back, towards the operator. To lower the conveyor, push the lever forward, away from the operator.

“CONVEYOR SWING” control lever

The third lever from the operator’s left is the “CONVEYOR SWING” control lever (Fig. 14), which is used to control the horizontal position of the conveyor. To swing the conveyor right, pull the lever to the right of the operator. To swing the conveyor left, pull the lever to the left of the operator.

“GATHERING HEAD” control lever

The fourth lever from the operator’s left is the “GATHERING HEAD” control lever (Fig. 14), which is used to control the position of the gathering head. To raise the gathering head, pull the lever back towards the operator. To float the gathering head, push the lever forward, away from the operator.

“STAB” control lever

The fifth lever from the operator’s left is the “STAB” control lever (Fig. 14), which controls the position of the stabilizer shoe. To lower the stabilizer shoe, push the lever forward, away from the operator. To raise the stabilizer shoe, pull the lever back, toward the operator.

Fig. 14: Control levers

“CUTTER HEAD”

“CONVEYOR” (raise/lower)

“CONVEYOR” SWING”

“GATHERING HD”

“STABILIZER”

_________________________________________________________________ 5.12 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS

Operation____________________________________________________

___________________________________________________Operation foot switch

There is a foot switch (Fig. 15) in the floor in front of the operator commonly referred to as the man-in-position switch. Depressing the foot switch will enable tramming and will release the tram brakes. This switch must be held in for tramming to be active.

Releasing the foot switch will disable tramming.

“LEFT TRAM”

The first lever from the operator’s left (Fig. 15) controls the left hand crawler functions. To tram in the direction of the cutter head, slowly push the control lever forward, away from the operator. To tram in the direction of the conveyor end of the miner, slowly pull the lever toward the operator.

“RIGHT TRAM”

The second lever from the operator’s left (Fig. 15) controls the right hand crawler functions. To tram in the direction of the cutter head, slowly push the control lever forward, away from the operator. To tram in the direction of the conveyor end of the miner, slowly pull the lever toward the operator.

© BUCYRUS

The tram/steering control levers are used for tramming and positioning the machine. To tram the machine in a straight direction towards the cutter head end of the machine, push both tram control levers forward, away from the operator. To tram the machine in a straight direction towards the conveyor end of the machine, pull both tram control levers back, toward the operator.

To steer left in the direction of the cutter head, push the right tram control forward (away from the operator) while the left tram control lever is in the neutral position. For tighter turns, pull the left tram control lever back (towards the operator) while the right tram control lever is pushed forward (away from the operator).

To steer right in the direction of the cutter head, push the left tram control forward (away from the operator) while the right tram control lever is in the neutral position. For tighter turns, pull the right tram control lever back (towards the operator) while the left tram control lever is pushed forward (away from the operator).

______________________________________________________________ A6474X337 VLSS/0 5.13

Operation____________________________________________________

“LEFT TRAM”

“RIGHT TRAM”

Foot switch

_________________________________________________________________ 5.14 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS

Fig. 15: Tram control levers

___________________________________________________Operation methane monitor display

The methane monitor display (Fig. 16) is located behind operator’s pit.

Consult the manufacturer’s information regarding the setup, operation, and maintenance of the methane monitoring system.

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

Fig. 16: Methane monitor display

© BUCYRUS

“METHANE MONITOR” display location

______________________________________________________________ A6474X337 VLSS/0 5.15

Operation____________________________________________________ Left side controls and indicators (Fig. 17) “MACHINE STOP”

There is a “MACHINE STOP” button located on the left rear side of the machine. There are a total of two (2) machine stop buttons located on the miner. Pushing “MACHINE STOP” will shut down the pump motor, causing the miner to shut down. Follow the normal star up procedure (See Start up procedure in this chapter) to restart the machine after pushing “MACHINE STOP”.

“WASHDOWN HOSE”

The “WASHDOWN HOSE” valve is used to turn on water to the washdown hose.

“FIRE SPRAY”

The “FIRE SPRAY” valve is used to manually turn on water to the fire sprays.

“BACKFLUSH STRAINER VALVE B”

The “BACKFLUSH STRAINER VALVE B” is used to manually backflush the strainer. Valves “A” and “C” must be closed when valve “B” is open.

“SUMP WASHOUT VALVE C”

The “SUMP WASHOUT VALVE C” is used to manually supply water to the sump washout. Valves “A” and “ B” must be closed when valve “C” is open.

scrubber jet pump pressure gauge scrubber sprays pressure gauge

The gauge is used to monitor the output pressure of the scrubber jet pump.

This gauge is used to monitor scrubber spray pressure.

_________________________________________________________________ 5.16 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS

There is a series of manually operated water valves on the left hand side of the machine (Fig. 17):

___________________________________________________Operation Fig. 17: Left side controls and indicators

“VALVE A”

“BACKFLUSH STRAINER VALVE B”

“SUMP WASHOUT VALVE C”

“FIRE SPRAY” “WASHDOWN HOSE” “EMERGENCY STOP”

Scrubber jet pump pressure gauge

Scrubber sprays pressure gauge

© BUCYRUS

Jet pump

______________________________________________________________ A6474X337 VLSS/0 5.17

Operation____________________________________________________ Machine control system An multi-component system is used to control various aspects of the machine and consists of the following main components: ■

Power supply

■

Control module (hub)

■

Input/Output modules

■

Radios remote

■

Graphics display

power supply

There is a 24VDC power supply located inside the controller that provides power to the control and input/output modules in the control system.

control module (hub)

The control module, also known as the hub, is the “brain” of the control system and is located inside the controller. The application software for the machine is stored on the control module. When the system is powered up, the software is used to control the machine. It monitors inputs and controls outputs to other modules.

input/output (I/O) modules

Input/Output modules, located in the controller, are used to read data from and send commands to the following machine functions: ■

Cutter motors (left and right)

■

Gathering head motors (left and right)

■

Scrubber motor

■

Pump motor

■

Hydraulic oil level

■

Methane monitoring

Based on the parameters set and the input received, the control system has the ability to issue error messages, fault messages, and/or shutdown the machine

_________________________________________________________________ 5.18 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS

The following information is presented as a general guide to the capabilities and functions of the control system. Before attempting to operate, service, or troubleshoot the Continuous Miner, training must be completed. For a detailed description of component locations, please see the Bucyrus parts book for your machine.

___________________________________________________Operation radio remote (remote control)

The radio remote (Fig. 18) is used to control the continuous miner during normal mining operations.

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

© BUCYRUS

Fig. 18: Radio remote (typical)

______________________________________________________________ A6474X337 VLSS/0 5.19

Operation____________________________________________________ The radio remote has the following control buttons: IMPORTANT! For operating instructions, including starting, shutting down, tramming, and mining, using the remote control, see the Operating procedures section of this chapter.

Table 1: Radio remote buttons (typical) Button

Primary function

Secondary function

Tram Forward

- Push and hold to increase speed when traveling forward.

- Trams both tracks forward .

- Push and hold to decrease speed when traveling in reverse.

Tram Reverse - Trams both tracks in reverse.

- Push and hold to increase speed when traveling in reverse, - Push and hold to decrease speed when traveling forward.

Emergency Stop - Shuts down all remote functions.



Fire Extinguisher (optional)

None

Lights

Lights

- When pressed with “SHIFT”, turns the head lights on.



Menu

Remote

- Used to access the menu screen

- When pressed with “SHIFT”, returns from the menu screen

Not in use.

Not in use.

Stab

ATRS Up (optional)

- Operates the stab raise solenoid.

- When pressed with “SHIFT”, operates the ATRS raise solenoid.

Turns the head lights off.

_________________________________________________________________ 5.20 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS

When pressed with “SHIFT”, trips the pilot relay.

___________________________________________________Operation Table 1: Radio remote buttons, continued Button

Primary function

Secondary function

Pan

Pan Extend (optional)

- Operates the gathering head raise.

- When held with “SHIFT”, operates plow extend solenoid.

Shear

Shear Extend

- Operates shear up solenoid.

- When held with “SHIFT”, operates the cutter extend solenoid.

Tram Left Forward

- Push and hold to increase speed while travelling forward.

- Trams left track forward.

- Push and hold to decrease speed when traveling in reverse.

Tram Left Reverse

© BUCYRUS

- Trams left track in reverse.

- Push and hold to increase speed while travelling reverse.

- Push and hold to decrease speed when traveling forward.

Not in use.

Not in use.

Stab

ATRS Down (optional)

- Operates stab lower solenoid.

- When pressed with “SHIFT”, operates the ATRS down solenoid.

Pan

Pan Retract (optional)

- Operates gathering head float.

- When pressed with “SHIFT”, operates plow retract solenoid.

Shear Down

Retract

- Operates shear down solenoid.

- When pressed with ‘SHIFT”, operates plow retract solenoid.

Tram Right Reverse

- Push and hold to increase speed while travelling reverse.

- Trams right track in reverse

- Push and hold to decrease speed when traveling forward.

______________________________________________________________ A6474X337 VLSS/0 5.21

Operation____________________________________________________ Table 1: Radio remote buttons, continued Button

Primary function

Secondary function

Tram Right Forward

- Push and hold to increase speed while travelling forward.

- Trams right track forward.

Fan Off

Fan On

- Push to turn scrubber motor off.

- When pushed with “SHIFT”, turns the scrubber motor on.

Pump Off

Pump On

- Push to turn pump motor off.

- When used with “SHIFT”, turns the pump motor on.

Conveyor Off

Conveyor On

- Push to turn conveyor motor off

- When pushed with “SHIFT”, turns the conveyor motor on

Conveyor Raise

None

- Raises the conveyor boom.

Radio Remote On

Radio Remote Off

- Turns the remote control on.

- Turns the remote control off.

Auto

Manual

Water Off

Water On

- Push to turn the water - When pushed with sprays off.

“SHIFT”, turns the water sprays on.

Cutter Off

Cutter On

- Turns the cutter motors off.

- When pressed with “SHIFT”, turns the cutter motors on.

_________________________________________________________________ 5.22 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS

- Push and hold to decrease speed when traveling in reverse.

___________________________________________________Operation Table 1: Radio remote buttons, continued Button

Primary function

Secondary function

Left Boom

None

- Swings the conveyor boom to the left.

Right Boom

None

- Swings the conveyor boom to the right.

Shift

None

- Used in conjunction with any green button.

Boom

Reverse

- Lowers the conveyor boom.

- When pressed with “SHIFT”, runs the conveyor in reverse

Tram enable

None

© BUCYRUS

Tram enable

Tram enable

- Located on top side of remote; used in combination with tram controls

There are six parameters that can be set from the radio remote: ■

Channel: 15 channels available

■

Timeout: Length of time with no activity before remote powers off.

Can vary from two (2) to sixty (60) minutes.

■

Tilt: When enabled, this option allows the radio remote to automatically issue the Radio Stop command when a tilt angle greater than 45° relative to the horizon is detected.

■

Free Fall: When enabled, the radio remote can automatically issue the Radio Stop command for two seconds if a free fall drop fault event is detected. After two seconds, power is automatically removed.

■

Low Battery: Threshold battery voltage, variable in 0.1V increments between 3.1V and 4.2V. It is recommended to select between 3.2V and 3.4V and 3.4V is the default value. When the battery voltage drops to this threshold, a low battery warning will be displayed on the remote LCD.

■

Serial Number: Each remote has a unique serial number that is programmed at the factory. This feature is password protected and is not available to the operator.

______________________________________________________________ A6474X337 VLSS/0 5.23

Operation____________________________________________________ graphics display

The graphics display (Fig. 19) is located in the operator’s pit of the machine. The graphics display is used to monitor machine operating parameters, for diagnosing error and fault codes, and for input of operating parameters A system halt message can appear as a pop-up dialog box in the middle of any screen. This message appears when a critical condition has occurred that prevents continued operation of the machine in a safe manner. The message box cannot be cleared and it is necessary to recycle power to the control system to restore machine operation.

Fig. 19: Graphics display

© BUCYRUS

Graphics display

_________________________________________________________________ 5.24 Bucyrus – Model 30M4-NP Continuous Miner

___________________________________________________Operation Normal display pages When the system is turned on, the main page (Fig. 20) is displayed.

The operator can toggle between three (3) different types of screens in normal operation mode: the main page, the production monitor (Fig. 21), and the individual monitor pages (boom, pump, scrubber, cutters, and gathering head) (Fig. 22). To page left, press “SHIFT” and “CONV LEFT” on the radio remote. To page right, press “SHIFT” and “CONV RIGHT” on the radio remote.

The main page consists of an alarm banner, methane status, oil level status, and input current and temperature readings from the pump, left and right cutter motors, scrubber motor, left and right gathering head motors, and left and right traction motors. It also display voltage on the machine and mode of operation (remote, etram, or maintenance).

A status message is typically only displayed on the main page. It is a brief text description of a event or function that is currently active. A status message is typically not used to indicate any fault or warning condition and are not numbered.

© BUCYRUS

Fig. 20: Main page

Alarm banner

Remote information

Oil level status

Methane status Pump and motor monitoring

Machine voltage

Mode of operation

______________________________________________________________ A6474X337 VLSS/0 5.25

Operation____________________________________________________ Fig. 21: Production monitor

© BUCYRUS

Fig. 22: Function monitor, example

_________________________________________________________________ 5.26 Bucyrus – Model 30M4-NP Continuous Miner

___________________________________________________Operation System Menu The system menu (Fig. 23) allows access to different functions of the control system.

Fig. 23: System menu

© BUCYRUS

Using the radio remote:   To enter the system menu screen, press the MENU key. 

To move the cursor, press the CONV LEFT or CONV RIGHT key.

 To select an option, press the MENU key.  To exit or go back, press the TRAM FORWARD key.

Diagnostic mode Diagnostic mode allows a large number of monitoring screens to be displayed and selected while the machine is operating and includes the following pages: ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■

Main monitor page Production monitor page Boom monitor page Pump Monitor page Scrubber monitor page Cutters monitor page Gathering head monitor page Traction motor monitor page I/O monitor pages - three (3) inputs pages I/O monitor pages - two (2) outputs pages Network monitor page

See Fig. 24 for examples of various diagnostic pages.

______________________________________________________________ A6474X337 VLSS/0 5.27

Operation____________________________________________________

© BUCYRUS

Fig. 24: Diagnostic pages, examples

_________________________________________________________________ 5.28 Bucyrus – Model 30M4-NP Continuous Miner

___________________________________________________Operation Fault log The fault log (Fig. 25) stores the last one hundred (100) faults that have occurred on the machine. The faults are stored in a First In First Out basis (as a new fault is added, the oldest fault is deleted). Each possible fault event is identified by a unique number. Individual faults can be selected to view more detail.

To select a fault from the fault log, from the radio remote:  To move the cursor up, press the CONV UP key.  To move the cursor down, press the CONV DOWN key.  To move up one page, press the SHIFT and CONV UP keys.  To move down one page, press the SHIFT and CONV DOWN keys.  To select a fault, press the MENU key.

© BUCYRUS

Fig. 25: Fault log

______________________________________________________________ A6474X337 VLSS/0 5.29

Operation____________________________________________________ An error message is used by the control system to indicated warning conditions that are currently active but do not necessarily shutdown machine operation. Error messages are set and cleared by the control system automatically in response to real-time system background monitoring. Error messages are typically only visible during normal machine operation on the main page of the control system graphic display screen. Error messages are numbered and use number less than 200.

A fault message is a condition that shuts down a motor or function or that prevents a function from being started. When a fault is detected, a fault screen (Fig. 26) will display over top of the current monitoring screen. The fault message, explaining what is keeping the machine from running, will be displayed. The operator must clear the fault by pressing SHIFT and RESUME on the radio remote unless the system is set to Auto Fault Clear. If the system is set to Auto Fault Clear, the fault is automatically cleared by the next key press.

Fault messages are logged in the control system fault log and are number using numbers greater than 200.

For a complete list of error and fault codes, please see the Troubleshooting section of this chapter.

© BUCYRUS

Fig. 26: Individual fault detail

_________________________________________________________________ 5.30 Bucyrus – Model 30M4-NP Continuous Miner

___________________________________________________Operation Motor hours The motor hours screen (Fig. 27) allows the running time for all hour meters to be viewed. Hour meters are stored in the processor’s nonvolatile memory (NVRAM). If the processor is changed, the correct motor hours must be configured into the system.

© BUCYRUS

Fig. 27: Motor hours display

______________________________________________________________ A6474X337 VLSS/0 5.31

Operation____________________________________________________ pendant controls

The machine can be operated using a pendant control (Fig. 28) connected to the miner by an umbilical cable. This control is used in the event that the operator loses radio link with the mine to safely recover the miner from the face to an area under supported roof for troubleshooting and maintenance.

The pendant controller allows limited operation of the machine: tramming and pump motor activation to provide hydraulic power to raise or lower the cutting head.

In order to use the pendant, it must be connected to the machine via a pigtail. After plugging in the umbilical cord, the “MACHINE” mode of operation switch must be rotated to the “E-TRAM” .

IMPORTANT! The pendant controller and its umbilical cord should be stored in a protected location on the working section, away from the miner, to prevent damage.

© BUCYRUS

Fig. 28: Pendant controls

_________________________________________________________________ 5.32 Bucyrus – Model 30M4-NP Continuous Miner

___________________________________________________Operation Pendant functions “MACHINE STOP”

Depressing the “MACHINE STOP” button will stop all function outputs created by the tram pendant interface module (pump, auger (shear) raise/lower, and left/right tram).

“PUMP START/ENABLE”

The “PUMP START/ENABLE” button is used with the “PUMP ON” button to start the pump motor.

“PUMP ON”

The “PUMP ON” button is used to turn on and off the pump motor.

When pressed by itself, “PUMP ON” will turn off the pump motor.

When used in conjunction with “PUMP START ENABLE”, “PUMP ON” will start the pump motor:  Press and hold the “PUMP START/ENABLE” button.  Press the “PUMP ON” button. Hold both buttons in until the pump starts (approximately one second).

© BUCYRUS

 Release the buttons.

“TRAM ENABLE”

Press “TRAM ENABLE” to activate the tramming function. Once “TRAM ENABLE” is pressed, it remains active unless no tramming button is pressed for five (5) seconds. After the five (5) second time out, the “TRAM ENABLE” button must be pressed to reactivate tramming.

“TRAM FWD”

After pressing “TRAM ENABLE”, press the right “TRAM FWD” button to tram the right track forward, press the left “TRAM FWD” button to tram the left track forward, or press both “TRAM FWD” buttons together to tram both tracks forward.

“TRAM REV”

After pressing “TRAM ENABLE”, press the right “TRAM REV” button to tram the right track in reverse, press the left “TRAM REV” button to tram the left track in reverse, or press both “TRAM REV” buttons together to tram both tracks in reverse.

“AUGER RAISE”

The “AUGER RAISE” button is used to extend the shear cylinders and raise the cutter head. Push to activate, release to deactivate.

“AUGER LOWER”

The “AUGER LOWER” button is used to retract the shear cylinders and lower the cutter head. Push to activate, release to deactivate.

LED lights

There are four (4) LED lights across the top of the pendant: “WDG”: 1/2 second on, 1/2 second off indicates unit powered and processor is running.

“TRME”: Tram action enabled.

“TRML”: Tram left command being sent.

“TRMR”: Tram right command being sent.

______________________________________________________________ A6474X337 VLSS/0 5.33

Operation____________________________________________________ Red zone There are many dangers present when working in or around a continuous miner. The miner operator most make sure he is fully positioned inside the operator’s pit at all times during operation. He must be aware of all personnel working in the area where the miner is being operated. The miner is especially dangerous when it is being maneuvered during mining operations. The miner is capable of slewing when turning, especially when the crawlers are split. The discharge conveyor can also swing. In each of these cases, anyone in the vicinity is in danger of being hit, or worse yet, run over by the machine. Equally dangerous is the possibility of someone being pinned against the rib by the miner.

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

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

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

Fig. 30: Red zones

Tramming the miner red zone

Beginning 1st sump red zone

_________________________________________________________________ 5.34 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS

Fig. 29: Red zone

___________________________________________________Operation Sumping in the left hand side of the cut (Fig. 31). As the miner penetrates the face, new unsupported roof is being exposed. Personnel must stay clear of the haulage vehicle at the rear of the miner as it approaches the miner and while it is loading.

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

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

© BUCYRUS

Fig. 31: Red zones

Sumping on the left hand side red zone

Repositioning miner for right hand cut red zone

Sumping in the right hand cut red zone

______________________________________________________________ A6474X337 VLSS/0 5.35

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

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

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

© BUCYRUS

Fig. 32: Crosscut red zones

Beginning a right hand crosscut red zone

Right hand crosscut development

_________________________________________________________________ 5.36 Bucyrus – Model 30M4-NP Continuous Miner

___________________________________________________Operation Safety precautions for underground operation

© BUCYRUS

In addition to the preceding instructions for operating the continuous miner, observe the following special precautions after the machine is taken underground.

■

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

■

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

■

This machine must be maintained following all applicable laws and regulations.

■

Make a visual check of the continuous miner before energizing.

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

■

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

Tramming safety rules ■

Communicate your intentions to the workmen affected by the movement of the continuous miner.

■

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

■

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

■

Position the cutter and gathering head for tramming.

■

Position the stabilizer shoe and booms for tramming.

■

Position your body completely inside the operator's pit, facing the intended direction of travel.

■

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

______________________________________________________________ A6474X337 VLSS/0 5.37

Operation____________________________________________________ Starting procedure in radio remote WARNING! Read all instructions carefully before attempting to start or operate the machine. Failure to read and understand all operating instructions before starting the continuous miner could result in serious injury or death to the operator or persons around the machine or cause damage to the machine.

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

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

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

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

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

After training, which includes reading and understanding the Controls and Indicators section of this chapter, and becoming familiar with the locations and functions of all machine controls, the operator is ready to operate the continuous miner. An experienced operator should monitor a new operator’s indoctrination to the starting procedure.

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

WARNING! Visually check for other personnel and verbally shout a warning before starting this machine. Make sure all personnel are completely clear of the machine and it’s components and check that the area is clear before starting the machine.

_________________________________________________________________ 5.38 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS

WARNING! Before starting the machine, make sure that no one is in the red zone (see Red zone in this chapter).

___________________________________________________Operation After training, which includes reading and understanding the Controls and Indicators section of this chapter, and becoming familiar with the locations and functions of all machine controls, the operator is ready to operate the Continuous Miner. An experienced operator should monitor a new operator’s indoctrination to the starting procedure.

WARNING! The Continuous Miner is operated by radio remote control. Manual operation is not allowed for production operation. Manual operation is for troubleshooting and maintenance under roof support.

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

WARNING! Visually check for other personnel and verbally shout a warning before starting this machine. Make sure all personnel are completely clear of the machine and it’s components and check that the area is clear before starting the machine.  Turn the main circuit breaker to the “ON” position.

© BUCYRUS

 Turn the “TRAM CIRCUIT BREAKER” to the “ON” position.  Turn the “MINER” mode of operation selector switch to “REMOTE”.  Press the “ON/OFF” button on the radio remote.  Press and hold the “SHIFT” button on the radio remote.  While holding the “SHIFT” button, press the “PUMP/OFF” button. A pre-start warning horn will sound. Hold both buttons in until the pump starts.  Release the “PUMP/OFF” key. The pre-start warning horn will stop.

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

______________________________________________________________ A6474X337 VLSS/0 5.39

Operation____________________________________________________ Shutdown procedure in radio remote The continuous miner must be properly shutdown before leaving the area or before performing any maintenance or service. Some maintenance or service procedures may require additional steps to insure the safety of the maintenance personnel working on or around the machine and will be listed in the maintenance section of this guide.  Back the miner about one foot from the face providing sufficient clearance and shut off the cutter head motors (see Cutter operation in this section).  Turn off the water sprays by pressing the “WATER/OFF” button on the radio remote.  Make sure that the conveyor is empty and then shut down the conveyor motors.  Press and hold the “CONV/OFF” button on the radio remote.

The conveyor motors should shut down immediately.

 Lower the cutter head to the floor.  Lower the conveyor and gathering head.  Press and hold the “PUMP/OFF” button on the radio remote. The pump motor should shutdown immediately.  Release the “PUMP/OFF” button.  Turn the machine circuit breaker to the “OFF” position.  Turn the key switch to the “OFF” position.  Turn off the main power supply.  Turn off the mine water supply.

_________________________________________________________________ 5.40 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS

 Tram the miner to an area of well supported roof. Park the machine in its designated parking area out of traffic and on flat, solid ground.

If it is not possible to park the machine on flat ground, park the machine at a right angle to the slope.

___________________________________________________Operation Machine stop bypass in radio remote (optional) A typical continuous miner is fitted with a mushroom style machine stop button the left side of the machine. The button is used to shutdown the machine in the event of an emergency. It is possible for the button to be stuck in the “ON” position if the left side of the machine becomes jammed against the rib. In this event, there is an optional Machine Stop Bypass function available that allows the pump motor to be started and the machine to be trammed away from the wall. The override feature is only active in thirty second intervals.

To activate the Machine Stop Bypass function: Press and hold the “SHIFT” and “MACHINE STOP” keys together for a continuous five seconds.

© BUCYRUS



______________________________________________________________ A6474X337 VLSS/0 5.41

Operation____________________________________________________ Tramming the miner in radio remote NOTICE! The Continuous Miner has skid type steering: it is capable of turning within its own limits.

WARNING! Tramming requires cooling water to the tram motors. Failure to cool the motors will result in motor damage and premature failure.   Ensure that the pump motor is running (see Start up procedure in this chapter).   Ensure that the stabilizer shoe is away from the mine floor.  Raise cutter boom to best possible position to allow clearance from roof, ribs, and floor.  Raise gathering head away from the mine floor.

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

Be award of people, equipment, and cables.

Remote control - tram enable:  To enable machine tramming, press and release either “TRAM ENABLE” button (the prestart warning horn will sound).  Once enabled, any combination of tram buttons (“LEFT TRAM FWD” , “LEFT TRAM REV”, “RIGHT TRAM FWD”, “RIGHT TRAM REV”) can be used to tram the miner. During tramming, the tramming horn will sound (a slightly different sound than the prestart warning horn). As soon as the tram button is released, the tramming horn will stop but the prestart warning horn will continue to sound.  Once a tram function button has not been pushed for a pre-set amount of time, the prestart warning horn will stop. Once the prestart warning horn stops, no tram function will work.  To re-enable the tram function, press and release either “TRAM ENABLE” button.

_________________________________________________________________ 5.42 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS

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

___________________________________________________Operation Tram direction  Press the “TRAM FWD” button to tram both tracks forward..  Press the “TRAM REV” button to tram both tracks in reverse.  Press the left tram forward button (blue and white button with a black forward arrow located on left side of remote) to tram the left track forward.  Press the left tram reverse button (blue and white button with a black reverse arrow located on left side of remote) to tram the left track in reverse.  Press the right tram forward button (blue and white button with a black forward arrow located on right side of remote) to tram the right track forward.  Press the right tram reverse button (blue and white button with a black reverse arrow located on right side of remote) to tram the right track in reverse.

© BUCYRUS

 Press the left tram forward and right tram reverse buttons at the same time to make a faster right hand turn.  Press the left tram reverse and the right tram forward buttons at the same time to make a faster left hand turn.

Tram speed control Tram speed is increased or decreased while tramming using the tram buttons on the remote control radio remote. See the description in Table 1 in the Controls and Indicators section of this chapter for more information.

______________________________________________________________ A6474X337 VLSS/0 5.43

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

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

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

IMPORTANT! Holding the “SHIFT” button for two (2) seconds or longer will result in a radio switch fault. If this occurs, all buttons must be released and the start re-attempted.  While holding the “SHIFT” button, press the “CUTER/OFF” button.

A pre-start warning horn will sound One cutter motor should start, followed immediately by the second motor.

IMPORTANT! Both cutter motors do not start at the same time. There is a preset timed delay between the left cutter motor starting and the right cutter motor starting.   Release the “CUTER/OFF” button. The pre-start warning horn will stop.

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

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

_________________________________________________________________ 5.44 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS

 Ensure that the pump motor is running as the cutter motors will not run if the pump motor is not running.   Press the “SHIFT” button and wait 1/4 second.

___________________________________________________Operation

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

WARNING! Warn ALL CLEAR before starting the conveyor. Failure to do so may result in serious injury or death.  Ensure that the pump motor is running as the conveyor motors will not start if the pump motor is not running.   Press the “SHIFT” button and wait 1/4 second.  While holding in “SHIFT”, press “CONV/OFF”. A pre-start warning horn will sound. Continue to hold until the conveyor motor turns on and the conveyor starts to run forward.

© BUCYRUS

 Release the “CONV/OFF” button. The pre-start warning horn will stop.

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

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

______________________________________________________________ A6474X337 VLSS/0 5.45

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

WARNING! Warn ALL CLEAR before starting the conveyor. Failure to do so may result in serious injury or death.  Ensure that the pump motor is running. The conveyor motors will not start if the pump motor is not running.   Press “SHIFT” and wait 1/4 second.

IMPORTANT! Holding the “SHIFT” button for two (2) seconds or longer will result in a radio switch fault. If this occurs, all buttons must be released and the start re-attempted.

 The conveyor will continue to run in reverse until the conveyor “REV” or the “SHIFT” key is released.

_________________________________________________________________ 5.46 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS

 While holding in “SHIFT”, press “CONVEYOR OFF” and “REV” buttons. The pre-start warning horn will sound. Continue to hold until the conveyor motor turns on and the conveyor starts to run in reverse.

___________________________________________________Operation

 Scrubber motor in radio remote To start the scrubber fan motor  Ensure that the pump motor is running as the scrubber motor will not start if the pump motor is not running.  Press “SHIFT” and wait 1/4 second.

IMPORTANT! Holding the “SHIFT” button for two (2) seconds or longer will result in a radio switch fault. If this occurs, all buttons must be released and the start re-attempted.  While holding shift, press “FAN/OFF”. The pre-start warning horn will sound. Continue to hold until the scrubber fan motor turns on.  Release the “FAN/OFF” button. The pre-start warning horn will stop.

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

© BUCYRUS

 Release the “SHIFT” button.

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

______________________________________________________________ A6474X337 VLSS/0 5.47

Operation____________________________________________________ Control headlights lights in radio remote To turn on the lights  Press the “SHIFT” and “LIGHTS” button together to turn the front lights on.

When the lights are on, and any reverse tram button is activated, the rear lights will turn on.

To turn off the lights

© BUCYRUS

 Press the “LIGHTS” button to turn the lights off.

_________________________________________________________________ 5.48 Bucyrus – Model 30M4-NP Continuous Miner

___________________________________________________Operation Fire suppression in radio remote (optional) The control system uses a solenoid output to drive the fire suppression system (optional) on the continuous miner. The fire suppression can be activated at any time from the remote control console.

To activate the fire suppression system  Press the fire suppression button. This is a red and white button with a fire extinguisher on the white half of the button. The fire suppression system will activate and, at this time, the fire suppression button can be released.

Shear up/down in radio remote The pump motor must be running in order to raise or lower the cutter head.  Press “SHEAR UP” to move the cutter head up. The shear up solenoid remains energized until the key is released (unless height limiting is in force).

© BUCYRUS

 Press “SHEAR DOWN” to move the cutter head down. The shear down solenoid remains energized until the key is released.

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

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

______________________________________________________________ A6474X337 VLSS/0 5.49

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

To move the conveyor boom  Press the yellow “BOOM L” button to swing the conveyor tail to the left. The solenoid controlling the left conveyor swing will remain energized until the key is released.  Press the yellow “BOOM R” button to swing the conveyor tail to the left. The solenoid controlling the right conveyor swing will remain energized until the key is released.  Press the conveyor down key (half yellow with a black arrow pointing down and half green with “REV”) button to lower the conveyor boom. The solenoid controlling the conveyor lower function will remain energized until the key is released.

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

_________________________________________________________________ 5.50 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS

 Press the yellow conveyor up button (yellow button with a black arrow point up) to raise the conveyor boom. The solenoid controlling the conveyor raise function will remain energized until the key is released.

___________________________________________________Operation Tramming with the pendant controls The miner can be operated with the ETRAM pendant when the radio system needs to be bypassed. To tram with the pendant controls: NOTICE! The Continuous Miner has skid type steering. It is capable of turning within its own limits.

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

DANGER! If the miner is under unsupported roof and tramming with the emergency pendant controls is required, crib out to the miner.

Never go out under unsupported roof. Failure to follow this warning may result in very serious injury or death.  Place the “MINER” mode of operation switch in the “ETRAM” position.

© BUCYRUS

 Press and hold the “PUMP START ENABLE” button.  While holding the “PUMP START ENABLE” button, press the “PUMP ON” button.

IMPORTANT! The miner can be shutdown at any time in “ETRAM” mode by pressing the “MACHINE STOP” button on the emergency tram pendant.  Adjust the cutter head to allow the best possible clearance from the roof, ribs, and floor. Note: The emergency tram pendant can also be used to adjust cutter head position.  Using the left and right “TRAM FWD” and “TRAM REV” buttons or the “TRAM” button, tram the miner.

WARNING! As soon as a tramming function is performed, the stabilizer shoe will raise automatically. If the shoe is being used to lift the miner off of the floor, the rear of the machine will drop as soon as the tram function is performed. Serious injury or death can occur to personnel.

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Operation____________________________________________________ Starting procedure from the operator’s pit WARNING! Read all instructions carefully before attempting to start or operate the machine. Failure to read and understand all operating instructions before starting the continuous miner could result in serious injury or death to the operator or persons around the machine or cause damage to the machine.

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

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

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

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

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

After training, which includes reading and understanding the Controls and Indicators section of this chapter, and becoming familiar with the locations and functions of all machine controls, the operator is ready to operate the continuous miner. An experienced operator should monitor a new operator’s indoctrination to the starting procedure.

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

WARNING! Visually check for other personnel and verbally shout a warning before starting this machine. Make sure all personnel are completely clear of the machine and it’s components and check that the area is clear before starting the machine.

_________________________________________________________________ 5.52 Bucyrus – Model 30M4-NP Continuous Miner

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WARNING! Before starting the machine, make sure that no one is in the red zone (Fig. 22 through Fig. 24).

___________________________________________________Operation  Assure that the trailing cable plug and socket are coupled tightly.  Assure that all other circuit breakers are in the closed position.   Turn the “MINER MODE” switch to the “PIT” position.  Press and hold the “MOTOR START ENABLE” button.  Press and hold the “PUMP START” button until the pump motor starts.

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 Release the “PUMP START” button.

______________________________________________________________ A6474X337 VLSS/0 5.53

Operation____________________________________________________ Shutdown procedure from the operator’s pit The continuous miner must be properly shutdown before leaving the area or before performing any maintenance or service. Some maintenance or service procedures may require additional steps to insure the safety of the maintenance personnel working on or around the machine and will be listed in the maintenance section of this guide.  Back the miner about one foot from the face providing sufficient clearance and shut off the cutter head motors (see Cutter operation in this section).  Make sure that the conveyor is empty and then shut down the conveyor motors.  Press and hold the “CONVEYOR STOP” button. The conveyor motors should shut down immediately.  Tram the miner to an area of well supported roof. Park the machine in its designated parking area out of traffic and on flat, solid ground.

If it is not possible to park the machine on flat ground, park the machine at a right angle to the slope.

 Lower the conveyor and gathering head.  Turn off the pump motor by pressing and holding the “PUMP STOP” button. The pump motor should shutdown immediately.  Turn the “MINER MODE” selector switch to “GND CHK” to remove power from the miner.  Lockout the trailing cable following all regulatory agency rules and regulations.

_________________________________________________________________ 5.54 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS

 Lower the cutter head to the floor.

___________________________________________________Operation Tramming the miner from the operator’s pit NOTICE! The continuous miner has skid type steering: it is capable of turning within its own limits.

WARNING! Tramming requires cooling oil to the tram motors. Failure to cool the motors will result in motor damage and premature failure.   Ensure that the pump motor is running (see Start up procedure in this chapter).   Ensure that the stabilizer shoe is away from the mine floor.  Raise cutter boom to best possible position to allow clearance from roof, ribs, and floor and raise gathering head away from the mine floor. Adjust conveyor boom to best possible position to allow clearance from roof, walls, and floor.  Ensure adequate clearance at all times while tramming machine.

Be aware of people, equipment, and cables.

© BUCYRUS

 Use the “LEFT TRAM” and “RIGHT TRAM” control levers to tram the miner.  Activate the foot switch in order to enable tramming. Foot switch must stay active during tramming operations.

Tram direction  Push both the “LEFT TRAM” and “RIGHT TRAM” levers forward to tram the miner straight forward or push both levers down to tram the miner straight in reverse.  To make a right turn, press the “LEFT TRAM” forward lever up to tram the left track forward and push the lever down to tram the left track in reverse.  Press the “LEFT TRAM” lever forward and “RIGHT TRAM” lever down at the same time to make a faster right hand turn.  To make a left turn, press the “RIGHT TRAM” forward lever up to tram the right track forward and push the lever down to tram the right track in reverse.  Press the “LEFT TRAM” lever down and the “RIGHT TRAM” lever forward at the same time to make a faster left hand turn.

Tram speed control The are two pre-set speed ranges for tramming: low and high. To tram in low speed, turn the “TRAM SPEED SELECTOR” button, located on the front of the operator input case, to the “LOW” position. To tram in high speed, turn the “TRAM SPEED SELECTOR” button to the “HIGH” position.

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

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

WARNING! Warn ALL CLEAR before starting the cutter head. Failure to do so may result in serious injury or death.  Ensure that the pump motor is running (see Start procedure in this chapter) as the cutter motors will not run if the pump motor is not running.

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

To stop the cutter motors   Press and hold the “CUTTER STOP” button. The cutter motors should stop immediately.

_________________________________________________________________ 5.56 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS

 Press and hold the “MOTOR START ENABLE” button.   Press the “CUTTER START” button. The cutter motors should start immediately.

___________________________________________________Operation

 Conveyor operation from the operator’s pit To start the conveyor motors  Place conveyor boom in desired position.  Warn ALL CLEAR before starting the conveyor.

WARNING! Warn ALL CLEAR before starting the conveyor. Failure to do so may result in serious injury or death.  Ensure that the pump motor is running (see Start procedure in this chapter) as the conveyor motors will not start if the pump motor is not running.  Press and hold the “MOTOR START ENABLE” button.   Press and hold the “CONVEYOR START” button until the conveyor motors turn on and the conveyor starts running in the forward direction.  Release the “CONVEYOR START” button.

© BUCYRUS

To stop the conveyor motors - conveyor forward  Press and hold the “CONVEYOR STOP” button. The conveyor motors should shutdown immediately.

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

WARNING! Warn ALL CLEAR before starting the conveyor. Failure to do so may result in serious injury or death.  Ensure that the pump motor is running (see Starting procedure in this chapter). The conveyor motors will not start if the pump motor is not running.  Press and hold the “MOTOR START ENABLE” button.   Press and hold the “CONVEYOR REVERSE JOG” button. The conveyor will continue to run in reverse until the “CONVEYOR REVERSE JOG” key is released.

______________________________________________________________ A6474X337 VLSS/0 5.57

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

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

Main Chassis

■

Mounting of the right and left hand crawler tracks and their independent drive systems and take-up provisions.

■

Independent pivots for mounting the cutting head, gathering head, conveyor components, and their associated hydraulic cylinders for articulation.

■

An integral hydraulic oil tank, along with an electric motor/hydraulic pump assemblies and associated valves and piping.

■

A rear stabilizer and its hydraulic cylinder for improving leverage forces during shear down in the cutting sequence.

■

Mounting provisions for all major electrical system components and their associated wiring.

Fig. 33: Main Chassis Scrubber fan

Conveyor raise cylinder clevis

Cutter head pivot

Gather head cylinder clevis

Oil tank

Rear bumper plate

Cutter head cylinder clevis

Crawler idler guides

Gathering head cylinder clevis Pit area

___________________________________________________________________ 5.58 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS

The main chassis of the machine (Fig. 33) is a heavy duty box type structure of high-strength steel that provides the following:

_______________________________________ Mechanical assemblies Gathering head assembly The gathering head assembly (Fig. 34) is attached to the main chassis at right and left hand pivot points. The assembly is articulated around these pivot points to adjust the gathering head for uneven floor conditions and when tramming the miner. The independent pivots allow removal of the gathering assembly without disturbing the cutting head or discharge conveyor.

The gathering head assembly includes: ■

Upper mounting clevises for the two externally mounted gathering head cylinders.

■

Water cooled electric motors, an input gear case, and a gathering head pot which drives a rotating centrifugal loading arm device.

© BUCYRUS

The gathering head assembly is raised and lowered by two hydraulic cylinders which are mounted to the main chassis at their lower ends and to the gathering head structure at their upper ends. These cylinders allow vertical ranging of the forward edge of the gathering head (see the general arrangement drawing for you machine for dimensions).

The right and left hand gear cases are connected to a common foot shaft which provides proper timing of the CLAs and drive power to a sprocket which drives the conveyor chain. The conveyor chain drives is reversible to aid in clearing debris which might restrict conveyor chain movement. The CLA input case is driven by a shear shaft which is designed to prevent damage to gearing as a result of jamming.

Fig. 34: Gathering head assembly

Gear case and pot assembly (under cover)

Foot shaft

Lift cylinder

Motor (behind cover)

CLA

_________________________________________________________________ A6474X337 VLSS/0 5.59

Mechanical assemblies ________________________________________ Conveyor assembly The conveyor assembly (Fig. 35) is attached to the main chassis at right and left hand independent pivot points. The conveyor is articulated vertically around these pivot points to assist in optimum loading into a haulage vehicle. Independent pivots allow removal of the conveyor assembly without disturbing the cutting head or gathering head components.

■

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

■

A rear conveyor subassembly that includes: –

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

–

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

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

Fig. 35: Conveyor assembly Conveyor chain tensioning cylinder (both sides) Conveyor swing cylinder location

Intermediate conveyor section Rear conveyor section

Conveyor pivot pin

Chassis pivot points

___________________________________________________________________ 5.60 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS

The conveyor assembly includes the following:

_______________________________________ Mechanical assemblies Traction drive system

© BUCYRUS

The traction drive system (Fig. 36) provides the mobility for mining operations and for tramming from place to place. It includes: ■

Independent right and left drive systems, each consisting of a water cooled electric motor mounted to a drive gear case that powers drive sprockets to provide motion to the respective right or left crawler chain.

■

A forward mounted crawler chain idler roller on each side which is equipped with a grease powered piston to adjust the crawler chain tension.

■

A drive system which provides the operator with three variable speed ranges: –

High speed - used mainly for tramming from one working face to another.

–

Intermediate speed - used mainly for rapid repositioning of the miner within the face area.

–

Sump speed - fully adjustable by the operator to a preset value - used for sumping the miner into the face. The adjustable sump speed allows the operator to select an optimum cutting speed based on varying hardness conditions. The sumping speed is maximized through a proportional and differential cutter feedback system.

The traction drive control system provides the operator with the capability to run either right or left hand crawler chain in forward or reverse independently for maximum maneuverability (for example, the miner may be pivoted about its central vertical axis). Both drive trains are equipped with fully enclosed, multiple disc, fail safe, hydraulic flushed parking brakes that are spring applied and hydraulically released.

The crawler chains are manufactured from high alloy, wear resistant steel for maximum life and are equipped with grouser ridges to enhance traction in both hard and soft floor conditions.

Fig. 36: Traction drive system

Idler roller

Crawler track

Electric motor

Drive gear case

_________________________________________________________________ A6474X337 VLSS/0 5.61

Mechanical assemblies ________________________________________ Stabilizer shoe A stabilizer shoe (Fig. 37), located beneath and at the rear of the tractor frame, may be lowered to anchor the back end of the machine and provides a greater downward thrust of the cutter head for hard-cutting while preventing backward creep of the miner. The stabilizer shoe is raised and lowered hydraulically by a double acting cylinder that moves the shoe bracket up or down.

Fig. 37: Stabilizer shoe

© BUCYRUS

Stabilizer shoe

___________________________________________________________________ 5.62 Bucyrus – Model 30M4-NP Continuous Miner

_______________________________________ Mechanical assemblies Cutting head assembly The cutting head assembly (Fig. 38) is attached to the main chassis at right and left hand independent pivot points around which the assembly is articulated for vertical ranging cutting. The independent pivots allow removal of the cutting head assembly without disturbing the gathering head or conveyor components.

The cutting head assembly consists of the following: ■

The cutting head support frame. The frame is a heavy duty box structure which includes the right and left pivot points for attaching to the main chassis, upper mounting clevises for the two cutting head raise cylinders, and a bolting flange to which the cutting head drive assembly mounts.

■

The cutting head gear case assembly, which consists of an input gear case and water-cooled electric drive motor for each of the right and left hand sides, a final drive gear case which includes drive gearing, a main drive shaft, and mounting points for the right, left, and center drums, and a bolting flange for mounting onto the cutting head support frame.

■

Provides for both front and rear flange support of the cutter motors.

© BUCYRUS

The cutting head assembly is raised and lowered by two (2) heavy duty hydraulic cylinders mounted to the main chassis at their lower ends and to the main longitudinal structural members of the cutting head support frame at their upper ends. These cylinders enable the cutting head assembly over a predesigned range (see the general arrangement drawing for you machine for dimensions).

The power train of the cutting head consists of right and left sides, which tie together at the common main drive shaft, allowing the combined power of both electric drive motors to be available at one point on the cutting drums.

Fig. 38: Cutting head assembly

Cutter head pivot

Cutter head cylinder

Cutter head motor

Cutter head gear case

Cutter head drum assembly

_________________________________________________________________ A6474X337 VLSS/0 5.63

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

Fig. 39 gives an overview of hydraulic cylinders located on the 30M4NP Continuous Miner. Fig. 40 shows the location of other hydraulic components.

This section gives general descriptions of the hydraulic components used on the miner along with typical schematics for hydraulic functions.

The schematics in this section are general; always refer to the hydraulic schematic in your Bucyrus parts manual supplied with your machine.

Operation considerations

■

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

■

maintaining a sufficient oil level in the tank;

■

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

■

changing filters and fluids at prescribed intervals.

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

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

_________________________________________________________________ 5.64 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS

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

___________________________________________________ Hydraulic Fig. 39: Hydraulic cylinder location

Gathering head raise cylinder

Gathering head cylinder

Gathering head raise cylinder Cutter head raise cylinder Cutter head raise cylinder

© BUCYRUS

Cutter head raise cylinder

Stabilizer shoe cylinder

Stabilizer shoe cylinder

Stabilizer shoe cylinder

Conveyor lift cylinder

Conveyor lift cylinder Conveyor lift cylinder

Conveyor swing cylinder

Conveyor chain take-up cylinder (optional)

Conveyor swing cylinder

Conveyor chain take-up cylinder (optional)

Conveyor chain take-up cylinder (optional)

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Hydraulic ____________________________________________________ Fig. 40: Hydraulic component locations

Valve, pilot relief

Gathering Head float valve

Filter, pressure Filter, return Filter, pilot

Venturi pump Fill valve

Pump

Breather

Oil Dipstick

Valve, brake control with manifold

Breather

Valve, Anti-chatter/maintenance Switch, pressure

Valve, brake control with manifold Accumulator Pump, jet Valve, ball

Valve, flow control (2)

Solenoids, water, fire, scrubber Valve, control (5-unit) Gauge, pressure - 600 psi Gauge, pressure - 1000 psi Gauge, pressure - 4000 psi

Filter, water

Filter, bypassing pilot

_________________________________________________________________ 5.66 Bucyrus – Model 30M4-NP Continuous Miner

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Valve, pressure reducing Oil level switch

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

Graphic symbols denote the type of function a component performs but do not necessarily s h o w its s h a pe o r c ons tr uc t i on . T h es e schematic symbols are used to trace the system flow from the reservoir to the actual work being performed and then back to the reservoir.

The symbols used are shown individually with a functional description where needed. The study of these symbols helps in understanding the system and thereby aids in troubleshooting the system.

© BUCYRUS

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

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

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

_____________________________________________________________ A6474X337 VLSS/0 5.67

Hydraulic ____________________________________________________ How to read a hydraulic schematic All valves are shown in the neutral position on the hydraulic schematics.

To follow oil flow through a system, visually imagine the valve spool shifting as shown in Fig. 41.

Fig. 41: Oil flow through a spool

MAIN PRESSURE

PILOT PRESSURE

SOLENOID A

SOLENOID B PORT A IS ACTIVATED BY ENERGIZING SOLENOID A. THE SOLENOID WILL SHIFT THE 3-WAY PILOT VALVE WHICH WILL HYDRAULICALLY SHIFT THE MAIN SPOOL ALLOWING FLOW TO PORT A. SEE FIGURE 2

A (RAISE)

PORT B IS ACTIVATED BY ENERGIZING SOLENOID B. THE SOLENOID WILL SHIFT THE 3-WAY PILOT VALVE WHICH WILL HYDRAULICALLY SHIFT THE MAIN SPOOL ALLOWING FLOW TO PORT A. SEE FIGURE 3

B (LOWER)

© BUCYRUS

TO TANK

FIGURE 1 STABLIZER RAISE/LOWER SECTION OF TYPICAL MAIN CONTROL VALVE. CURRENTLY SHOWN IN NEUTRAL POSITION.

MAIN PRESSURE

PILOT PRESSURE

MAIN PRESSURE

PILOT PRESSURE

SOLENOID A

SOLENOID B

TO TANK

A (RAISE)

A (RAISE)

B (LOWER)

B (LOWER)

TO TANK

FIGURE 2

FIGURE 3

PORT A ACTIVATED

PORT B ACTIVATED

_________________________________________________________________ 5.68 Bucyrus – Model 30M4-NP Continuous Miner

___________________________________________________ Hydraulic accumulator

An accumulator (Fig. 42) is essentially a fluid pressure storage chamber in which the potential energy of a fluid under pressure can be stored against a compressible force of a gas to do useful work.

The stored fluid is readily available to perform a given task when called upon by the requirements of the system in which it is used.

breather

A breather (Fig. 42) permits air to move in and out of the oil tank reservoir to maintain atmospheric pressure.

cylinders

Cylinders (Fig. 42) are bored and honed steel tubes enclosing a piston connected to a rod that extends out the end of the cylinder.

Working surfaces are ground and finely finished, with seals and gask ets incorporated to prevent leakage. Fig. 39 illustrates the location of the hydraulic cylinders on the miner.

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

© BUCYRUS

Fig. 42: Accumulator and cylinder hydraulic symbols

Accumulator

Cylinder, single acting with external spring

Breather

Cylinder, single acting

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

Cylinder, double acting

Cylinder, single acting with dry pocket

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

_____________________________________________________________ A6474X337 VLSS/0 5.69

Hydraulic ____________________________________________________ filters

Filters and strainers (Fig. 43) are designed to protect a hydraulic oil system from harmful levels of particulate contamination. High levels of contaminants accelerate wear of components, cause improper functioning, and add to system sluggishness. Other problems such as seizure of parts, higher temperatures due to increased fluid friction, leakage, and loss of control may occur. Contamination also contributes to oxidation and chemical breakdown of the fluid.

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

When a non by-passing filter element starts clogging with trapped particles, the radio system/solenoid functions will slow down, indicating it is time to change the element. For filter element maintenance and changing schedules, see the Maintenance section in this chapter.

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

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

© BUCYRUS

Fig. 43: Filter hydraulic symbols

Filter, bypassing

Filter, non-bypassing

_________________________________________________________________ 5.70 Bucyrus – Model 30M4-NP Continuous Miner

___________________________________________________ Hydraulic flow meter orifice

A flow meter (Fig. 44) is a visual device which indicates the volume of fluid passing through it per unit of time.

An orifice (Fig. 44) is a device that restricts flow.

A pressure manifold (Fig. 44) has one inlet port and many outlet ports to supply flow to many circuits. A return manifold has many inlet ports and only one outlet port for flow to return to tank. Note: You can have the same part number for a pressure or return manifold.

pressure gauge

A pressure gauge (Fig. 44) is a visual device used to indicate the pressure in a hydraulic or water circuit.

pump

The purpose of a pump (Fig. 44) is to produce flow; it does not pump pressure. Pressure is caused by a resistance to flow. All system components have some resistance to flow. Hydraulic cylinders, which power machine functions, are the major components causing this resistance.

Each circuit is protected by a relief valve so that the pressure in the system will not exceed the rating of its components. To ensure that everything works correctly and in proper sequence, relief valve pressure settings closely match the load requirements.

jet pump

The miner is equipped with a multi-section gear-type fixed displacement hydraulic pump assembly. Each section consists of two closely-meshed gears inside a tightly-fitted housing. The miner may be equipped with optional venturi jet pumps (Fig. 44). These pumps have no moving parts and are made from a metal tube that narrows over its full length.

When liquid passes through the narrowing tube, a vacuum is formed according to the “Venturi” principle. This vacuum is used to draw liquid into or out of reservoirs. For more information, reference the detailed circuit descriptions.

© BUCYRUS

pressure/return manifold

quick disconnect

A quick disconnect (Fig. 44) is a coupling which can quickly join or separate lines.

Fig. 44: Hydraulic symbols

Flow meter

Orifice

Pump, hydraulic two section

Pump, jet

Pressure gauge

Pressure/return manifold

Quick disconnect

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Hydraulic ____________________________________________________ Valves The hydraulic symbols for the different types of valves are given in Fig. 45. ball valve check valve

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

A valve that allows fluid flow in one direction only.

flow control valve

A valve with a primary function of controlling flow rate.

load holding valve (load lock valve) (overcenter valve)

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

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

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

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

_________________________________________________________________ 5.72 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS

A load holding valve locks a load in any position without allowing drift. It may provide static overload relief and thermal expansion relief with open-center control valves, as are on the cutter head raise circuit, or be combined with an atmospheric relief, as on the conveyor raise circuit of the miner. Cartridge style valves allow installation directly into the cylinder.

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

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

There are no adjustments required on the load holding valves.

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

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

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

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

relief valve

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

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

_____________________________________________________________ A6474X337 VLSS/0 5.73

Hydraulic ____________________________________________________ There are a number of relief valves in the hydraulic system that are set for individual sub-circuit protection (conveyor elevation, gathering head, etc.). Each pump section also has a main relief valve for protection against over-pressurization. The main hydraulic pump section is typically set at 3,000 psi. The pilot section is typically set at 600 psi. If your system has 3 pump sections, consult your system schematic (in your Bucyrus Parts Manual) for the auxiliary pump section relief valve setting.

For relief valve adjustment procedures, see the Adjustment section of this chapter.

Each section of the main control valve is piloted by a solenoid valve that is mounted adjacent to that particular section. Energizing the solenoid opens the pilot valve to allow the pilot pressure to move the spool in the proper direction to achieve the desired function of the directional control valve.

solenoid valve (with radio option)

These 3-way valves are used to supply pilot pressure that controls a number of functions on the machine. These functions include the control of hydraulically piloted water valves for the Dust/Cooling, Fire, and Scrubber spray system circuits.

© BUCYRUS

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

_________________________________________________________________ 5.74 Bucyrus – Model 30M4-NP Continuous Miner

___________________________________________________ Hydraulic Fig. 45: Valve hydraulic symbols

Check valve

Flow control valve

Needle valve

Ball valve Pressure reducing/ relieving valve

Conveyor chain take-up valve

Gathering head float valve

© BUCYRUS

Relief valve Anti-chatter/maintenance valve

Pilot operated water 2-unit valve 3-way solenoid valve

Brake control valve

_____________________________________________________________ A6474X337 VLSS/0 5.75

Hydraulic ____________________________________________________ Abbreviations and terms Cavitation: Briefly, cavitation means that air bubbles are forming in the liquid that is being pumped. These bubbles are usually formed in the suction line of a pump when an obstruction causes the suction pressure (which is a vacuum) to go significantly below atmospheric pressure. The actuall pressure at which these bubbles form is dependent on the rank fluid level and the integrity of the seal on the suction line components. When these air bubbles are compressed in the pump gears, they can cause surface pitting, corrosion, and/or erosion. These bubbles can also coalesce to create erratic operation or water hammer problems.

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

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

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

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

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

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

PSI (psi): Pounds per square inch (unit of pressure) Open center circuit: A circuit in which flow through the system and back to the oil tank reservoir is open in neutral. Example: the main flow-primary pressure circuit.

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

_________________________________________________________________ 5.76 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS

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

___________________________________________________ Hydraulic Hydraulic pump assembly circuit Hydraulic power for all of the hydraulically actuated functions originates with the pump assembly (Fig. 46). This pump utilizes two working sections designated as follows: main flow and pilot flow. Oil is supplied from the oil reservoir through a suction line.

© BUCYRUS

Fig. 46: Hydraulic pump circuit

Primary pressure circuit The primary pressure circuit is powered by the hydraulic pump main pressure. The main pressure section is rated at 32 gpm at a pressure of 3,000 psi (121 Lpm at 207 bar). This open-center circuit supplies oil flow to the Main Control Valve (MCV). The MCV operates the conveyor raise, conveyor swing, stabilizer (stab) shoe, gathering head cylinders, cutter head raise cylinders. From the pump, oil enters a 10 micron by-passing pressure filter and continues to the MCV, whose main relief valve is set at 3,000 psi (207 bar).

For a more detailed description of this circuit, please refer to the individual circuit descriptions later in this section.

_____________________________________________________________ A6474X337 VLSS/0 5.77

Hydraulic ____________________________________________________ Tank Ports All three pump circuits described above pass through a 10 micron bypassing return filter before returning to tank (hydraulic reservoir).

There are two main connections to the tank; one on the left hand side of the machine (T-14) and one on the right hand side of the machine(T7). The schematic shown in Fig. 47 shows the tank connections for the tank manifolds. Each tank manifold is equipped with a breather. The left hand side tank tower is equipped with a float switch to detect low fluid level in the reservoir.

The schematic shown in Fig. 47 is typical for tank port connections.

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

© BUCYRUS

Fig. 43: Tank port connections

_________________________________________________________________ 5.78 Bucyrus – Model 30M4-NP Continuous Miner

___________________________________________________ Hydraulic Main Control Valve (MCV) The Main Control Valve (MCV) consists of a series of directional control valves assembled in a row. This row of valves is commonly referred to as a valve bank. The MCV directs fluid flow to perform a specific function of work that transforms hydraulic energy into mechanical energy.

Control may be initiated manually or electrically (through the solenoid pilot valve).

The MCV (Fig. 4) is located on the right side of the machine.

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

© BUCYRUS

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

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

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

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

■

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

■

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

_____________________________________________________________ A6474X337 VLSS/0 5.79

Hydraulic ____________________________________________________

© BUCYRUS

Fig. 48: Main control valve

_________________________________________________________________ 5.80 Bucyrus – Model 30M4-NP Continuous Miner

___________________________________________________ Hydraulic Main control valve circuit The main control valve circuit is powered by hydraulic pump. The gear section is rated at 121 Lpm at 207 bar (32 gpm at 3,000 psi).

This circuit supplies oil flow to the main control valve. The main control valve operates the gathering head, conveyor raise and swing, stabilizer, and cutter head cylinders. From the pump, oil enters a 10 micron by-passing pressure filter and continues to the main control valve, whose relief is set at 3,000 psi (207 bar).

Oil exits the main control valve and enters the oil reservoir.

© BUCYRUS

The schematic shown in Fig. 49 is typical. Always refer to the schematic in the Bucyrus parts book for your machine.

_____________________________________________________________ A6474X337 VLSS/0 5.81

Hydraulic ____________________________________________________

© BUCYRUS

Fig. 49: Main control valve circuit

_________________________________________________________________ 5.82 Bucyrus – Model 30M4-NP Continuous Miner

___________________________________________________ Hydraulic Cutter head raise/lower circuit DANGER! The area under and around the raised cutter head is dangerous.

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

Oil is supplied by the hydraulic pump through a 10-micron by-passing pressure filter to the cutter head working section of the main control valve. By manual or remote solenoid control, the valve spool allows oil to enter the cutter head cylinder circuit. The cutter head cylinder is a double acting cylinder with a load holding cartridge. There are two (2) cutter head cylinders, one on each side of the machine.

To manually raise the cutter head (extend cylinders) raise the valve’s handle. Remote operation is achieved by energizing the cutter head raise solenoid (CHU). Oil goes to port “P2” and continues to the extend port of the cylinders, free flowing through the check valve of the load holding cartridge, to extend the cylinders. The cutter head raise circuit is protected by a port relief that is set at 2,800 psi (207 bar).

© BUCYRUS

The anti-chatter/maintenance section has three primary functions: ■

It provides back pressure against the shear cylinder pistons when shearing down to prevent the machine from climbing the face (raising the machine off of the ground).

■

It provides back pressure against the shear cylinder pistons when lowering the cutter head without shearing. This allows for a smooth downward motion without allowing the load for the cutter head to move uncontrollably.

■

It allows for bypassing of the counterbalance valve to eliminate the back pressure against the shear cylinder pistons. This provides the maximum pressure differential between the two sides of the shear cylinders which allows the machine to be raised off the ground (jack-knifed).

Note:

To jack-knife the miner, the stabilizer shoe is first lowered. The cutter head is then lowered with the maintenance valve opened in the anti-chatter/maintenance section of the multipurpose valve. At this point, the machine can be inspected, adjustments can be made to the crawler tracks, and the tram voltage can be adjusted. See stabilizer shoe circuit in this section.

_____________________________________________________________ A6474X337 VLSS/0 5.83

Hydraulic ____________________________________________________ DANGER! Do not adjust, modify, or remove the load holding cartridge valve mounted in the cutter head cylinders. It is a safety feature to prevent accidental lowering of the cutter head.

DANGER! This load holding valve, like those on the stabilizer cylinders is preset. DO NOT ADJUST IT. If it malfunctions, replace it immediately.

WARNING! You could be seriously injured or killed by falling loads. Block the miner before performing maintenance and always observe the safe working load limits of all lifting and blocking devices.

© BUCYRUS

The schematic shown in Fig. 50 is a typical cutter head circuit with high speed raise. Always refer to the schematic in the Bucyrus parts book for your machine.

_________________________________________________________________ 5.84 Bucyrus – Model 30M4-NP Continuous Miner

___________________________________________________ Hydraulic

© BUCYRUS

Fig. 50: Cutter head raise/lower circuit

_____________________________________________________________ A6474X337 VLSS/0 5.85

Hydraulic ____________________________________________________ Conveyor raise/lower circuit Oil is supplied by the hydraulic pump through a 10-micron bypassing pressure filter to the conveyor raise/lower working section of the main valve control. By manual or remote solenoid control, the valve spool allows oil to enter the conveyor raise/lower cylinder circuit. The conveyor raise/lower cylinder is a single acting cylinder with a relief valve and a pilot operated check valve on the extend port. There are two (2) conveyor raise/lower cylinders.

To manually raise the conveyor (extend the cylinders), raise the valve’s handle. Remote operation is achieved by energizing the conveyor raise (CU) solenoid. Oil free flows through pilot operated check valves to the extend port of the cylinders. The conveyor raise circuit is protected by a port relief that is set at 124 bar (1800 psi).

The oil tank fill operates from the conveyor lower circuit. Oil goes to lower the conveyor and tees off to a ball valve that is closed. With the conveyor in the down position, the ball valve is manually opened. By remote solenoid control, the spool allows oil to enter the conveyor lower cylinder circuit and runs the oil tank fill. Oil passes thru the ball valve to a jet pump, which creates a venturi (vacuum) effect, pulling oil from the clean oil reservoir through a check valve joining the return oil.

The schematic shown in Fig. 51 is a typical conveyor raise/lower circuit schematic. Always refer to the schematic in the Bucyrus parts book for your machine.

_________________________________________________________________ 5.86 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS

To manually lower the conveyor (retract the cylinders), lower the valve’s handle. Remote operation is achieved by energizing the conveyor lower (CD) solenoid. Oil is directed to the pilot port on the pilot operated check valve on the cylinders. This “pilots” the check valve open and allows oil to exit the cylinders through the main control valve and return to tank through a 10-micron bypassing return filter to tank. The conveyor lower circuit is protected by a port relief that is set at 97 bar (1,400 psi).

___________________________________________________ Hydraulic

© BUCYRUS

Fig. 51: Conveyor raise/lower

_____________________________________________________________ A6474X337 VLSS/0 5.87

Hydraulic ____________________________________________________ Conveyor swing circuit Oil is supplied by the hydraulic pump through a 10-micron bypassing pressure filter to the conveyor swing working section on the main control valve. By manual or remote solenoid control, the spool allows oil to enter the swing circuit. The conveyor swing cylinder is a doubleacting cylinder. The range on the cylinder will allow the conveyor tail to move 45 degrees off the centerline of the machine in both directions.

The descriptions below for left and right movement are based on an individual standing at the rear of the machine looking forward to the cutter head.

To manually move the conveyor to the right (extend the cylinder), raise the valve’s handle. Remote operation is achieved by energizing the conveyor swing right (CSR) solenoid. Oil free flows to the extend port of the cylinder. The conveyor swing right circuit is protected by a port relief that is set at 1,800 psi (125 bar).

When extending or retracting, the oil from the opposite port exits the cylinders and passes through the main control valve and returns to tank through a 10-micron bypassing return filter.

The schematic shown in Fig. 52 is a typical conveyor swing cylinder circuit. Always refer to the schematic in the Bucyrus parts book for your machine.

_________________________________________________________________ 5.88 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS

To manually move the conveyor to the left (retract the cylinder), lower the valve’s handle. Remote operation is achieved by energizing the conveyor swing left (CSL) solenoid. Oil free flows to the retract port of the cylinder. The conveyor swing left circuit is protected by a port relief that is set at 1,800 psi (125 bar).

___________________________________________________ Hydraulic

© BUCYRUS

Fig. 52: Conveyor swing cylinder circuit

_____________________________________________________________ A6474X337 VLSS/0 5.89

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

To manually raise the stabilizer shoe (retract the cylinder), raise the valve’s handle. Remote operation is achieved by energizing the stabilizer raise (SSU) solenoid. Oil flows to the retract port of the cylinders. The stabilizer raise circuit is protected by a port relief that is set at 1,400 psi (97 bar).

Note:

To jack-knife the miner, the stabilizer shoe is first lowered. The cutter head is then lowered with the maintenance valve opened in the anti-chatter/maintenance valve section of the Multipurpose valve. At this point, the machine can be inspected, adjustments can be made to the crawler tracks, and the tram voltage can be adjusted.

See cutter head circuit description in this section.

The schematic shown in Fig. 53 is a typical stabilizer shoe cylinders circuit. Always refer to the schematic in the Bucyrus parts book for your machine.

_________________________________________________________________ 5.90 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS

To manually lower the stabilizer shoe (extend the cylinders), lower the valve’s handle. Remote operation is achieved energizing the stabilizer lower solenoid (SSD). Oil flows to the extend port of the cylinders.

The stabilizer lower circuit is protected by a port relief that is set at 2,500 psi (172 bar). When extending or retracting, the oil from the opposite port exits the cylinders and passes through the main control valve and returns to tank through a 10-micron bypassing return filter.

___________________________________________________ Hydraulic

© BUCYRUS

Fig. 53: Stabilizer shoe cylinders circuit

_____________________________________________________________ A6474X337 VLSS/0 5.91

Hydraulic ____________________________________________________ Gathering head raise/hold/float-lower circuit Oil is supplied by the hydraulic pump through a 10 micron by-passing pressure filter to the gathering head working section of the main control valve. By manual or remote solenoid control, the main control valve spool allows oil to enter the gathering head raise/hold/float-lower circuit.

The gathering head cylinder is a single acting cylinder. There are two (2) gathering head cylinders, one on each side of the machine.

To manually raise the gathering head pan (extend the cylinder), pullthe main control valve’s handle. Remote operation is achieved by energizing the gathering head up solenoid (GHU). Oil free flows through the check valve in counterbalance valve in the gathering head float valve and is directed to both cylinder extend ports. The counterbalance valve is marked with a stamped “VR” on the Manifold block.

To put the gathering head pan in the float-lower mode, push the main control valve’s handle. Remote operation is achieved by energizing the gathering head down (GHD) solenoid. This vents the port labeled “V” on the gathering head float valve to tank and allows control of the gathering head lower via the valves in the block. Counterbalance valve VR is set to relieve at 1,200 psi (83 bar) to allow the gathering head to drift down at a controlled rate of speed. This valve is adjustable and the rate of retract speed for the cylinders can be increased by decreasing the pressure setting of the valve.

Conversely, the retract speed for the cylinders can be decreased by increasing the pressure setting of the valve. When in the float-lower condition, the cylinders carry some of the gathering head pan weight to prevent the gathering head leading edge from digging into the soft bottom of the mine. This condition also moves the machine’s center of gravity forward when mining.

The relief valve in the gathering head float valve is set to relieve at 1,800 psi (124 bar). This valve is marked with a stamped “CR” on the manifold block. This fixed setting will relieve pressure directly to the tank in the event of a forced movement of the gathering head. This can occur if the cutter head is lowered onto a raised gathering head pan or by some other external force. The “CR” valve will relieve pressure in the circuit regardless of the position of the control valve (raise, hold or floatlower).

The pilot pressure supply for the gathering head float comes from hydraulic pump A2 through a 3 micron non by-passing filter, to the “pilot” port of the gathering head float valve. The pilot pump provides make-up oil for the gathering head cylinders when the pan goes over uneven terrain and raises quickly and extends the gathering head cylinders at a rapid rate.

_________________________________________________________________ 5.92 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS

At any time while raising the gathering head, the operator can stop the gathering head pan by centering the handle on the main control valve (or de-energizing the solenoid) and the pan will hold in position. The gathering head raise circuit is protected by a port relief that is set at 1,700 psi (117 bar) when in the raise and hold position.

___________________________________________________ Hydraulic This temporary condition can create high demand for pilot oil. An orifice is located in the pilot supply circuit of the gathering head float valve to prevent the pilot demand from reducing the pilot pressure to the point where the main control valve may not have sufficient pilot pressure to shift when the solenoids are energized. If this demand were to be too great, it is possible to experience a momentary loss of radio control of the machine. If the counterbalance valve (“VR”) is set to a pressure below the pilot pressure setting, it will create a path for the pilot pressure to return to tank and may result in loss of pilot pressure.

This orifice is protected from contamination by an upstream filter. A downstream check valve keeps system pressure from entering the pilot pressure lines. An adjustable needle valve allows for the bleeding off of pressure for maintenance. This needle valve is to remain closed except for performing maintenance. A gauge port is incorporated into the valve block for maintenance and troubleshooting.

Each single acting gathering head raise cylinder is equipped with a dry pocket to provide additional stroke beyond its normal hydraulic stroke.

This feature provides protection in the event that the gathering head is trammed into an obstruction forcing it to raise beyond its hydraulic stroke limit.

© BUCYRUS

The schematic shown in Fig. 54 is a typical gathering head circuit. Always refer to the schematic in the Bucyrus parts book for your machine.

_____________________________________________________________ A6474X337 VLSS/0 5.93

Hydraulic ____________________________________________________

© BUCYRUS

Fig. 54: Gathering head circuit

_________________________________________________________________ 5.94 Bucyrus – Model 30M4-NP Continuous Miner

___________________________________________________ Hydraulic Pilot pressure circuit descriptions

© BUCYRUS

Pilot pressure is supplied by the hydraulic pump as described in this section. The following functions are controlled using pilot pressure: ■

hydraulic tension conveyor chain take-up

■

gathering head float circuit, and

■

all solenoid valves, which control –

the scrubber

–

dust sprays

–

fires sprays

–

all main control valve functions

–

parking brakes

The pilot gear section A2 is rated at 8 gpm at 600 psi (30L at 41 bar).

From the pump section A2, oil enters a 10-micron by-passing pressure filter. Oil continues to the 8-port pilot pressure manifold where the oil separates to the accumulator, all solenoid valves, and the gathering head float circuit.

The schematic shown in Fig. 55 is a typical pilot pressure circuit. Always refer to the schematic in the Bucyrus parts book for your machine.

Fig. 55: Pilot pressure circuit

_____________________________________________________________ A6474X337 VLSS/0 5.95

Hydraulic ____________________________________________________ Conveyor chain take-up circuit Oil flows from the hydraulic pump to a 10 micron by-passing filter to the pilot pressure filter. From the pilot pressure filter section of the filter manifold, oil flows to a 8-port pressure manifold. From the pressure manifold, oil flows to a pressure reducing valve which maintains a constant pressure of 200 psi in the circuit. The reducing/relieving valve reduces pilot pressure to 200 psi and relieves any pressure spikes caused by forces acting against the conveyor of the miner.

An adjustable needle valve allows for the bleeding off of pressure for maintenance. This needle valve is to remain closed except for performing maintenance. A gauge port is incorporated into the valve block for maintenance and troubleshooting.

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

The schematic shown in Fig. 56 is a typical conveyor chain take up circuit. Always refer to the schematic in the Bucyrus parts book for your machine.

© BUCYRUS

Fig. 56: Conveyor chain take-up circuit

_________________________________________________________________ 5.96 Bucyrus – Model 30M4-NP Continuous Miner

___________________________________________________ Hydraulic Brake control valve From the 8-port manifold, pilot oil is supplied to the pressure port of the brake control valve manifold. The brake control valve is a 3 way, 2 position solenoid operated, spring return valve that hydraulically pilots a higher flow 3 way 2 position valve. When the solenoid is de-energized, the brake control pressure is vented to tank which engages the brake.

Energizing the solenoid applies pilot pressure to the pistons inside the brake which disengages (releases) the brake. The brake pressure required to fully release the brake is 510 psi (35 bar). A pressure switch is connected to the “GA” port of the brake control valve to monitor the brake pressure. Refer to the electrical section for control details of the pressure switch.

The schematic shown in Fig. 57 is a typical brake circuit. Always refer to the schematic in the Bucyrus parts book for your machine.

© BUCYRUS

Fig. 57: Brake circuit

_____________________________________________________________ A6474X337 VLSS/0 5.97

Hydraulic ____________________________________________________ Dust-scrubber-fire sprays circuit This circuit is used to activate the dust sprays, the scrubber sprays, and the fire sprays. From the 8-port manifold, pilot oil is supplied to the pressure port of the solenoid manifold. The manifold is connected to an accumulator that is pre-charged with nitrogen to 300 psi. The difference between the pilot circuit pressure of 600 psi and the accumulator pressure of 300 psi provides a volume of oil to allow for remote operation of the fire suppression when the pump is not operational. There is a gauge for monitoring the accumulator pressure, which should closely track the pilot pressure. If the accumulator pressure falls below 450 psi, shutdown the machine and call for maintenance.

The three solenoids in the manifold operate in the same manner.

When the solenoid coil is energized, it shifts the spool, allowing oil to travel to a 2 way/2 position water valve. The spool in the water valve is shifted, allowing water to pass through it.

When the dust or scrubber spray solenoid cell is de-energized, the hydraulic pilot valve shifts back to its neutral position, which vents the hydraulic pilot pressure on the water control valve. This venting allows the water control valves to return to their normally closed positions.

The schematic shown in Fig. 58 is a typical dust-scrubber-fire sprays circuit. Always refer to the schematic in the Bucyrus parts book for your machine.

_________________________________________________________________ 5.98 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS

The spool in the fire spray water valve has a detent spool which keeps the water valve open if the battery backup dies. This water valve must be manually rest to reset the deluge fire spray circuit.

___________________________________________________ Hydraulic

© BUCYRUS

Fig. 58: Dust-scrubber-fire sprays circuit

_____________________________________________________________ A6474X337 VLSS/0 5.99

Water _______________________________________________________ Water system overview A water supply to the miner is required for the following purposes: ■

cooling water for motors and electrical case

■

water for dust suppression and air scrubber

■

water for washdown hoses

The water supplied by the mine must meet the following requirements: ■

minimum flow rate of 20 gpm for cooling

■

total flow rate - based upon customer dust plan

■

minimum pressure of 250 psi (dynamic)

■

maximum pressure of 500 psi

The water circuits described in this section are for a typical Bucyrus 30M4 miner. The circuit for your machine may vary depending on your dust pan and unique requirements. Always refer to the schematic in the Bucyrus parts book for your machine.

_________________________________________________________________ 5.100 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS

Bucyrus offers straight, left hand, right hand, or bidirectional cutter head spray manifolds.

______________________________________________________ Water Fig. 59: Water component locations Cutting head front sprays

Cutting head front sprays

Cutting head front sprays

Cutting head motor sprays

Cutting head motor sprays

Manifold, LH cutter side spray 7-unit

Manifold, RH cutter side Spray 7-unit

Manifold, GH sprays 5-unit Sprays (3)

Manifold, GH sprays 5-unit

© BUCYRUS

Manifold, throat sprays 6-unit Sprays (6) Manifold, scrubber back flush sprays Manifold, scrubber sprays Nozzle, spray (6) Pump, jet Valve, flow control 1/2 NPT Valve, ball 3/4 NPT Gauge, pressure 0-160 psi

Gauge, pressure 0-400 psi Manifold, washdown Valve, ball 1/2 NPT Strainer, diffuser

Valve, relief Valve, ball 1-1/4 NPT Filter, water

Manifold, water Valve, flow control Switch, flow Switch, pressure Valve, ball 1” NPT Valve, bal 3/4 NPT (2) Valve, ball 1/2 NPT (3) Valve, pressure regulator (3)

Valve, pilot operated (2) Manifold, pressure (5 unit)

______________________________________________________________ A6474X337 VLSS/0 5.101

Water _______________________________________________________ Water supply circuit Mine water is supplied to the miner from a connection located on the right side of the miner (typical). The water supply to the miner is controlled through a two position, manually operated ball valve. Water pressure is monitored by two gauges, located on either side of a bypassing water filter. Immediately after is a connection for an optional washdown hose for the right hand side of the miner.

From the filter, the water is directed to the water distribution manifold.

The supply to the manifold is monitored by a flow switch and a pressure switch. These switches are inputs to the electrical system that are interlocks for the cutter motors to start and/or continue running. See the Electrical section of this chapter for more information on the switches. Water is also directed to the left hand washdown hose prior to entering the distribution manifold.

From the water distribution manifold, water supplies the scrubber sprays, dust sprays, and manual scrubber sprays, dust sprays, scrubber backflush and another water distribution block.

The water supply circuit described above and shown in Fig. 60 is typical. The circuit for your machine may vary depending on your dust plan and unique requirements. Always refer to the schematic in the Bucyrus parts book for your machine.

_________________________________________________________________ 5.102 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS

Gauges measure the pressure of the mine water and the water pressure as it exits the water filter. For component locations, see Fig. 60.

______________________________________________________ Water

© BUCYRUS

Fig. 60: Water supply circuit

______________________________________________________________ A6474X337 VLSS/0 5.103

Water _______________________________________________________ Dust / scrubber spray circuit The scrubber circuit (Fig. 61) uses water supplied by the water distribution manifold and is operated by remote via solenoid control or manually. This circuit includes the scrubber sprays, strainer backflush, and sump washout functions.

When the scrubber spray solenoid is energized, it shifts a spool, allowing hydraulic oil to flow to the hydraulic pilot operated, normally closed water valve. The hydraulic oil shifts the spool, allowing water to pass through it to the scrubber sprays. To manually operate the scrubber sprays, open the 1/2 inch ball valve, “MANUAL SCRUBBER WATER”.

To backflush the scrubber strainer, valves “A” and “C” (“SUMP WASHOUT VALVE”) are closed and valve “B” (“BACKFLUSH STRAINER VALVE) is opened. When valve “A” is closed water exiting the scrubber is directed through a pressure regulator, where pressure is reduced to 75 psi, and then tees in with the backflush scrubber water flowing through valve “B”. The water then flows through a second pressure regulator, where pressure is reduced to 50 psi, through a normally open needle valve, used to adjust water flow as necessary, to the backflush scrubber sprays.

To wash out the sump, valves “A” and “B” must be closed and valve “C” is open. Water flows into the scrubber sump and out via the strainer.

Water then is directed through the 75 psi pressure regulator, through a needle valve, used to adjust water flow as necessary, and to the cleaning sprays.

The scrubber spray circuit described above and shown in Fig. 61 is typical. The circuit for your machine may vary depending on your dust plan and unique requirements. Always refer to the schematic in the Bucyrus parts book for your machine.

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© BUCYRUS

During normal operations, valve “A” is open. After passing through a strainer, water exits the scrubber and flows through valve “A” to be dumped into the sump.

______________________________________________________ Water

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Fig. 61: Dust / scrubber spray circuit

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Water _______________________________________________________ Right hand cutter motor cooling circuit From the secondary dust-cooling water manifold, water is supplied to the right hand cutter motor cooling circuit (Fig. 62) where it supplies cooling/spray water to the right hand cutter motor and the right hand cutter head sprays. There is a relief valve set at 175 psi between the right hand cutter motor and the dust sprays.

The right hand cutter motor cooling circuit described above and shown in Fig. 62 is typical. The circuit for your machine may vary depending on your dust plan and unique requirements. Always refer to the schematic in the Bucyrus parts book for your machine.

© BUCYRUS

Fig. 58: Right hand cutter motor cooling circuit

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______________________________________________________ Water Left hand cutter motor cooling circuit From the secondary dust-cooling water manifold, water is supplied to the left hand cutter motor cooling circuit (Fig. 63) where it supplies cooling/spray water to the left hand cutter motor and the left hand cutter head sprays. There is a relief valve set at 175 psi between the left hand cutter motor and the dust sprays.

The left hand cutter motor cooling circuit described above and shown in Fig. 63 is typical. The circuit for your machine may vary depending on your dust plan and unique requirements. Always refer to the schematic in the Bucyrus parts book for your machine.

© BUCYRUS

Fig. 59: Left hand cutter motor cooling circuit

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Water _______________________________________________________ Left hand chassis cooling circuit From the dust-cooling water manifold, water is supplied to the left hand chassis cooling circuit (Fig. 60) where it supplies cooling/spray water to the electrical case, the left hand tram motor and the pump motor. Water then enters the secondary dust-cooling water manifold, and supplies water to the throat sprays and the right cutting motor sprays.

The left hand chassis circuit described above and shown in Fig. 64 is typical. The circuit for your machine may vary depending on your dust plan and unique requirements. Always refer to the schematic in the Bucyrus parts book for your machine.

© BUCYRUS

Fig. 64: Left hand chassis cooling circuit

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______________________________________________________ Water Right hand chassis cooling circuit From the dust-cooling water manifold, water is supplied to the right hand chassis cooling circuit (Fig. 61) where it supplies cooling/spray water to the electrical case, the right hand tram motor, right hand CLA motor, left hand CLA motor, the throat sprays, the right and left hand chassis sprays and the front cutting head center sprays.

The right hand chassis circuit described above and shown in Fig. 65 is typical. The circuit for your machine may vary depending on your dust plan and unique requirements. Always refer to the schematic in the Bucyrus parts book for your machine.

© BUCYRUS

Fig. 65: Right hand chassis cooling circuit

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Electrical ____________________________________________________ Electrical system The following pages contain a brief description of the electrical components and assemblies located on the 30M4-NP continuous miner.

WARNING! This section is intended only to familiarize the user with the electrical components of the continuous miner. Electrical maintenance should only be performed by a qualified electrician with knowledge of the functions of the components involved.

WARNING! Before removing any cover from an electrical case or attempting any maintenance or troubleshooting, the main power must be disconnected and locked out at the main power center.

An electrical circuit provides a means of changing electrical energy into some other form of energy, such as mechanical energy, as in the case of an electric motor, or into light, as in the case of a light bulb. Just as the components in a hydraulic circuit control the flow of hydraulic fluid, many electrical components are used in an electrical circuit to direct or limit the flow of electrical energy so it can be utilized to do a particular job on the miner. Other components in an electrical circuit are protective devices to avoid damage to equipment and injuries to personnel.

Schematics A schematic diagram is an illustration which shows the electrical relationship of the various components and the circuits. A schematic diagram does not show the physical location of the components. In an electrical schematic, components are shown in their de-energized position. A set of normally open contacts (N.O.) close when the coil is energized and a set of normally closed (N.C.) open when the coil is energized. Related components share the same designation. In tracing a particular circuit, it may be helpful to think of the flow of electricity as being similar to the flow of water through a hose. When a set of contacts are open, the current cannot flow across them, and when contacts are closed, the current can flow. When three (3) lines are connected in a tee, the current will flow in whatever direction that it can. Like water or hydraulic fluid, an electrical current will tend to follow the path of least resistance through a circuit. Finally, for a circuit to work, the electrical current must make a complete loop, similar to hydraulic fluid going through a circuit and returning to a tank.

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Basic principles

___________________________________________________ Electrical

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Fig. 66: Electrical block diagram

1. Left cutter motor 2. Right cutter motor 3. Left CLA motor 4. Right CLA motor 5. Pump motor 6. Left tram motor 7. Right tram motor 8. Scrubber motor 9. Hyd. Oil level switch/temp switch 10. Central processor 11. Left brake release pressure switch 12. Right brake release pressure switch

13. Antenna 14. Water flow switch 15. Pump/tram pre-start alarm 16. Water pressure switch 17. Left tram joystick 18. Right tram joystick 19. Left I.S. junction box 20. Footswitch 21. Left rear machine stop 22. Right I.S. junction box 23. Trailing cable plugs and coupler 24. Methane sensor

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Electrical ____________________________________________________

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Fig. 67: Standard electrical symbols

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___________________________________________________ Electrical Trailing cable A trailing cable with three power conductors, labeled L1, L2, L3, two (2) ground conductors (G), and a ground check conductor (GC) supplies power to the machine. A three-conductor 120mm2 or a 95mm2 cable is typically used with the 1140V nominal machines.

Cables are designed with a fire-proof, tough outer jacket to withstand the constant abuse of flexing, reeling, and exposure to sharp objects on the mine floor. They are not designed to withstand being run over by mobile equipment, especially continuous miners. Trailing cables exposed to moving equipment are required to be hung to prevent damage to insulation.

IMPORTANT! Hang trailing cables to prevent damage from moving equipment!

© BUCYRUS

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

The trailing cable may have breaks in its insulation. These defects in the insulation could cause exposure to high electrical currents. Never handle an energized trailing cable without the properly rated personal protective equipment (electrically insulated gloves and shoes or boots).

Never let the energized trailing cable come in contact with unprotected (uninsulated) parts of your body.

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

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

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Electrical ____________________________________________________ Operator’s case—control breakers

control breaker “CB1”

“CB1” is a 15A breaker for the 120VAC+ supply voltage.

control breaker “CB2”

“CB2” is a 15A breaker for the 120VAC common supply voltage.

control breaker “CB3”

“CB3” is a 15A breaker for the 120VAC+ side of the area light circuit.

control breaker “CB4”

“CB4” is a 15A breaker for the 120VAC- side of the area light circuit.

control breaker “CB5”

“CB5” is a 25A breaker for the 12VAC+ side of the head light circuit.

control breaker “CB6”

“CB6” is a 25A breaker for the 12VAC- side of the head light circuit.

control breaker “CB7”

“CB7” is a 5A breaker for the 12VAC+ side of the motor temp module circuit..

control breaker “CB8”

“CB8” is a 5A breaker on the 12VAC- side of the motor temp module circuit.

control breaker “CB9”

“CB9” is a 5A breaker on the 120VAC+ side of the motor relay circuit.

control breaker “CB10”

“CB10” is a 5A breaker on the 90VDC+ side of the solenoid circuit.

control breaker “CB11”

“CB11” is a 5A breaker on the 24VDC+ side of the controller power circuit.

control breaker “CB12”

“CB12” is a 5A breaker on the 0VDC common side of the controller power circuit.

control breaker “CB13”

“CB13” is a 15A breaker on the 12VAC+ side of the reverse lights circuit.

control breaker “CB14”

“CB14” is a 15A breaker on the 12VAC- side of the reverse lights circuit.

control breaker “CB15”

“CB15” is a 5A breaker on the display communications circuit.

control breaker “CB16”

“CB16” is a 5A breaker on the display communications circuit.

Fig. 68: Operator’s case - control breakers

Control breakers

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Mounted on the front wall of the operator’s case (Fig. 68) are control breakers.

___________________________________________________ Electrical Operator’s case - rear wall The operator’s case is located on the back right hand side of the machine. The rear wall of the operator’s case (Fig. 69) is accessed by opening the case cover and then opening the swing panel.

© BUCYRUS

IMPORTANT! This component location information is typical. Always verify component layout with the information in the Bucyrus parts book for your machine.

“IS1”

“IS1” is an intrinsically safe (IS) barrier that provides an approved IS circuit between the foot switch pedal and the control system.

“IS2”

“IS2” is an intrinsically safe (IS) barrier that provides an approved IS circuit between the water pressure switch and the water flow switch and the control system.

“IS3”

“IS3” is an intrinsically safe (IS) barrier that provides an approved IS circuit between the left brake pressure switch and right brake pressure switch and the control system.

“IS4”

“IS4” is an intrinsically safe (IS) barrier that provides an approved IS circuit between the emergency tram pendant and the control system.

“ISL1”, ISL2”, “ISL3”

“ISL1”, ISL2” and “ISL3” are intrinsically safe (IS) barriers that provide an approved IS circuit between the left tram control and the control system.

“ISR1”. “ISR2”, “ISR3”

“ISR1”, “ISR2” and “ISR3” are intrinsically safe (IS) barriers that provide an approved IS circuit between the right tram control and the control system.

Fig. 69: Operator’s case - rear wall

“IS1”

“ISL1”, “ISL2”, “ISL3”

“IS2”

“ISR1”, “ISR2”, “ISR3”

“IS3”, “IS4”

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Electrical ____________________________________________________ Traction case The traction case (Fig. 70) is typically located on the right hand side of the machine, and is accessed by opening the controller cover and then opening the swing panel. Typically mounted on the rear wall are traction drives and a terminal block.

IMPORTANT! This component location information is typical. Always verify component layout with the information in the Bucyrus parts book for your machine.

Left traction drive “LD” controls the left traction motor.

right traction drive “RD”

Right traction drive “RD” controls the right traction motor.

control transformer “T1”

“T1” is the control transformer that converts the incoming 1140V power supply to 12V and 120V.

tram pendant interface “TPI”

“R1 and R2” “L1”, “L2” and “L3”

The tram pendant interface, “TPI”, is the communication interface between the tram pendant and the control system when the “MINER MODE” selector switch is in the “E-TRAM” position.

“R1” and “R2” are braking resistors on the brake rectifier.

“L1”, “L2” and “L3” are 3-phase AC power connections from the tram breaker to the brake rectifier.

“P1” and “N1”

“P1” and “N1” are brake rectifier connections for the left AC drive motor.

“P2” and “N2”

“P2” and “N2” are brake rectifier connections for the right AC drive motor.

Fig. 70: Traction case “L1”

“L2”

“L3”

“P1”

“P2”

“N1”

“N2”

“T1”

“R1”

“R2” (not shown)

“TPI”

Left traction drive “LD”

Right traction drive “RD”

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left traction drive “LD”

___________________________________________________ Electrical Main controller case - rear wall The rear wall of the main controller case (Fig. 71) is accessed by opening the controller cover and then opening the swing panel. It is typically located on the left side of the machine, midway the tractor frame inside the crawler frame.

IMPORTANT! This component location information is typical. Always verify component layout with the information in the Bucyrus parts book for your machine.

vacuum contactor “A”

Vacuum contactor “A” is the contactor for the left cutter motor.

vacuum contactor “B”

Vacuum contactor “B” is the contactor for the right cutter motor.

vacuum contactor “CF”

Vacuum contactor “CF” is the contactor for the conveyor forward motor.

vacuum contactor “CR”

Vacuum contactor “CR” is the contactor for the conveyor reverse motor.

vacuum contactor “F”

Vacuum contactor “F” is the contactor for the fan motor.

vacuum contactor “P”

Vacuum contactor “P” is the contactor for the pump motor.

© BUCYRUS

Fig. 71: Main controller case - rear wall Vacuum contactor “CF”

Vacuum contactor “F”

Vacuum contactor “CR”

Vacuum contactor “B”

Vacuum contactor “P”

Vacuum contactor “A”

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Electrical ____________________________________________________ Main controller case - front side swing panel The swing panel of the main controller case (Fig. 72) is accessed by opening the controller cover. It is typically located on the left side of the machine, midway the tractor frame inside the crawler frame.

“PCT”

“PCT” is the power center trip relay and is used to open the power relay, ultimately opening the pilot core of the trailing cable to trip the power center. It is controlled by the PLC.

“ETR”

“ETR” is the emergency tram relay. It is used to shut off power to the control system and place the miner in the emergency tram mode. The relay is normally off and is turned on when the “MACHINE” mode of operation switch is placed in the “ETRAM” position.

“PTOL”

The pump e-tram mode overload “PTOL” is the pump thermal overload for ETRAM only. If the pump motor is overloaded during ETRAM operations, “PTOL” will shutdown the pump motor.

“MMR”

Contactor “MMR” is a relay in the methane monitoring circuit.

“ESR”

Contactor “ESR” is a contactor in the emergency stop circuit. When this contactor is open, power is removed from the machine.

“L”

“L” is the head light contactor. When this contactor is closed, the head lights are on.

“RL”

“RL” is the reverse light contactor. When this contactor is closed, the reverse lights are on.

“EL120”

“EL120” is an earth leakage monitor on the 120 V circuit.

“EL1100”

“EL1100” is an earth leakage monitor on the 1100 V circuit.

“PML2” ethernet switch

“OPS”

“PML2” is a power line modem which connects to the processor ethernet port and the DC power supply.

The ethernet switch is a part of the optional outby communication system. It sends information from the power line modem to the OBELIX processor.

“OPS” is the power supply for the outby communication system.

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IMPORTANT! This component location information is typical. Always verify component layout with the information in the Bucyrus parts book for your machine.

___________________________________________________ Electrical Fig. 72: Main controller case - front side swing panel “OPS”

Ethernet switch

Spare breakers

© BUCYRUS

“”PLM2”

“EL120”

“ETR”

“EL1100”

“L”

“RL”

“ESR”

“MMR”

“PTOL”

“PCT”

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Electrical ____________________________________________________ Main controller case - inside swing panel The inside swing panel of the main controller case (Fig. 73) is accessed by opening the controller cover and opening the swing panel. It is typically located on the left side of the machine, midway the tractor frame inside the crawler frame.

IMPORTANT! This component location information is typical. Always verify component layout with the information in the Bucyrus parts book for your machine.

processor module

I/O module

digital module

The power supply module supplies power to the machine control system.

The control system software is stored on the central processor (processor module).

The I/O module receives input from the hydraulic oil level, earth leakage monitors, footswitch, brake, water pressure, motor CTs and tram levers, and sends information to the machine control system.

The digital module receives input from the circuit breakers and the operator’s case and sends information to the control system.

thermistor module

The thermistor module provides receives inputs from the motors and sends information to the machine control system.

solenoid module

The solenoid module receives inputs from the cylinder movements, brakes, dust sprays and fire suppression and sends information to the machine control system.

“XD1”

“XD1” converts machine voltage from 1140V to 4-20 mA.

“MPS”

“MPS” is the intrinsically safe (IS) power supply for the methane system.

Fig. 73: Main controller case - inside swing panel Power supply

Central processor

I/O module

Digital module

Thermistor module

Solenoid module

“MPS”

“XD1”

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power supply module

___________________________________________________ Electrical Circuit breaker case The circuit breaker case (Fig. 74) is located below the operator’s case inside the operator’s pit. The main circuit breaker and the CLA/pump/ fan motor circuit breaker are located on the left side of the case, and the tram circuit breaker and the cutter motor circuit breaker are located on the right side of the case.

IMPORTANT! This component location information is typical. Always verify component layout with the information in the Bucyrus parts book for your machine.

“CB1”

The main circuit breaker, “CB1”, is connected to the feed via the trailing cable from the power center to the main control case.

CB2”

“CB2” is the cutter motor circuit breaker.

“CB3”

Circuit breaker “CB3” is connected to the feed for the CLA/pump/fan motors.

“CB4”

Circuit breaker “CB4” is connected to the feed for the tram motors.

© BUCYRUS

Fig. 74: Control breaker case

“CB1”

“CB3”

“CB4”

“CB2”

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Electrical ____________________________________________________ General The incoming 1040 V power supply is connected to the machine via the cable handler and the incoming main circuit breaker. AC power is then transferred to the main case where it is distributed via contactors to the pump, fan, cutter, and CLA motors. Power to the DC tram motors is distributed from the power supply to a tram transformer (1140/350 V), to the right and left tram drives, and then to the right and left tram motors.

The control transformer steps the incoming voltage down to 120 VAC and 12 VAC for the lighting, methane monitoring, ground check, and controls systems.

The machine is operated by remote control or by controls located in the pit. There is an emergency tram pendant available to tram the machine in the event that the control system loses signal from the remote control.

There are four IS junction boxes that connect the following: tram case to motor/breaker case; main case to left and right cutter motors; main case to pump and fan motors and main case to left and right CLA motors.

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There are two machine stop buttons located on the machine, one on the left side and one on the right side. Pressing any one of these buttons will trip the Power Center, de-energizing the trailing cable. The customer has the option to set up the machine so that pressing any one of these two buttons will remove power to any item capable of creating a movement (motors and solenoids).

___________________________________________________ Electrical Power circuit with control Power is available to the line side of motor starter circuits to the control and 110V transformers (“T1”, and “T5”) as soon as the trailing cable is connected to the machine and the main circuit breaker (“CB1”) is turned on. Power is available to the cutter motor starter when the cutter circuit breaker (“CB2”) is turned on. Power is available to the tram transformer (“PT1”) when the tram breaker (“CB3”) is turned on and the pump contactor closes.

The power schematic shown in Fig. 75 is typical for this miner. Always refer to the schematic in the Bucyrus parts book for your machine.

© BUCYRUS

Fig. 75: Power circuit with control

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Electrical ____________________________________________________ Methane monitor circuit The methane monitor detects gas when the continuous miner is powered up. Before any motor or function can be activated, the methane monitor checks for the presence of methane gas. If the methane gas level is below a preset level, the methane monitor relays will close, resulting in the power center trip relay opening. Power is now available to the machine. The methane monitor is powered by the methane system IS power supply “MPS”.

The methane monitor circuit shown in Fig. 76 is typical for this miner.

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

© BUCYRUS

Fig. 76: Methane monitor circuit

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___________________________________________________ Electrical Machine lighting circuit The machine lighting is powered by both the 120VAC and 12VAC circuits. The head lights and reverse lights are on the 12VAC circuit and the area lights are on the 120VAC circuit. The lights are controlled by sets of miniature circuit breakers on the front of the control case or by the radio remote.

The “LIGHTS” switch on the radio remote will allow the ability to turn off the head lights. The radio remote sends a signal to the microprocessor which energizes the head light relay “L”. The rear lights are a function of the tramming and are controlled by the microprocessor turning on/off the reverse light relay “RL”.

The lighting circuit shown in Fig. 77 is typical for this miner. Always refer to the schematic in the Bucyrus parts book for your machine.

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Fig. 77: Machine lighting circuit

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Electrical ____________________________________________________ Control of the power center trip relay, “PCT” The power supply module contains a special relay for controlling the external pilot relay (outby machine stop relay). The processor module can send a control message to the power supply at any time to drive the pilot relay output and trip the main power supply to the machine.

The schematic shown in Fig. 78 is typical. Always refer to the schematic in the Bucyrus parts book for your machine.

© BUCYRUS

Fig. 78: Power center trip relay control circuit

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___________________________________________________ Electrical Hydraulic low oil level/high temperature circuit The hydraulic low oil level/high temperature circuit indicates when the oil level in the hydraulic oil tank is low or when the oil temperature exceeds a preset value. There are two oil level float switches and a temperature switch located within a permissible switch assembly enclosure. When the oil level reaches the first float switch, the switch will open, removing power from the circuit. The control system will then send a low oil warning to the graphics display. When the oil level reaches the second float switch, the switch will open, removing power from the circuit. The control system will then shut down the machine.

When the oil temperature exceeds the allowable value programmed into the control system, the switch will open, removing power from the circuit. The control system will then shut down the machine.

The low oil/high oil temperature circuit shown in Fig. 79 is typical for this miner. Always refer to the schematic in the Bucyrus parts book for your machine.

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Fig. 79: Hydraulic low oil/high temperature circuit

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Electrical ____________________________________________________ Water flow and pressure circuit The water flow and water pressure inputs are interlocks for the cutter motors. If the water flow and/or the water pressure inputs is below the value programmed into the MCU, the MCU will either prevent the motors from starting or, if the motors are running, will shut down the motors.

The water flow and pressure circuit shown in Fig. 80 is typical for this miner. Always refer to the schematic in the Bucyrus parts book for your machine.

© BUCYRUS

Fig. 80: Water flow and pressure circuit

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___________________________________________________ Electrical Motor control The control system monitors the motor load by reading the current in each phase to the motor. The motor mate (control transformer) takes the current for each phase of the motor and converts it to a 4mA to 20mA signal to the processor.

The schematic shown in Fig. 81 is a typical. Always refer to the schematic in the Bucyrus parts book for your machine.

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Fig. 81: Motor control

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Electrical ____________________________________________________ Machine emergency stop circuit The emergency stop relay, “ESR”, is used to remove power from the machine. The relay is controlled by one of two buttons: one on the right side of the machine and one on the left side. Any one of these two buttons will trip the relay.

The schematic shown in Fig. 82 is typical. Always refer to the schematic in the Bucyrus parts book for your machine.

© BUCYRUS

Fig. 82: Machine emergency stop circuit

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___________________________________________________ Electrical Earth leakage relay circuit

© BUCYRUS

There are two earth leakage relay monitors: EL120, and EL1100 (Fig. 83). earth leakage relay monitor “EL120”

EL120 is the earth leakage monitor for the 120VAC lighting and control circuit. There is a toroid, CT11, located on line X2 of the circuit. The current through CT11 is fed to EL120 by lines E3 and E4. If the 120VAC circuit has a ground, the current flowing through CT11 will increase. When the current exceeds .1 A, earth leakage relay EL120A will open the four EL120A contactors located in lines 803 and 804 (area lights circuit) and 90B and 91B (processor module power circuit), removing power from the area lights and processor module power supply. And input signal is sent to the processor at X1-D (line 108) and a fault message will be displayed.

earth leakage relay monitor “EL1100”

EL1100 is the earth leakage detector on the 1100VDC tram circuit.

There is a toroid, CT10, located in line F6 which comes off of the tram transformer. The current through CT10 is fed to the EL1100 by lines 261 and 262. If there is a ground in the tram circuit, the current through CT10 will increase. When the current exceeds .1 A, earth leakage relay EL1100A will open the two EL1100A contactors located in lines 11A and 12A, interrupting input to the pump relay, P. This will open the pump contactor, shutting down the machine. An input signal is sent to the processor at line 108 and a fault message will be displayed.

earth leakage test switch

The earth leakage test switch, located on the front of the controller, is used to test the earth relay monitors. After a circuit is tested, the switch must be turned to the reset position to reset the monitor.

The schematic shown in Fig. 83 is a typical. Always refer to the schematic in the Bucyrus parts book for your machine.

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Electrical ____________________________________________________

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Fig. 83: Earth leakage circuits

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___________________________________________________ Electrical Tram pendant circuit In the event that there is a loss in communication between the radio remote and the control system, the machine can be operated with limited functions using the tram pendant. The tram pendant can be used to start the pump motor, raise and lower the cutter head, tram the machine.

The schematic shown in Fig. 84 is typical. Always refer to the schematic in the Bucyrus parts book for your machine.

© BUCYRUS

Fig. 84: Tram pendant circuit

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Electrical ____________________________________________________ Thermistor module The thermistor module receives inputs from the motors and sends the information to the control system. The thermistors (resistors whose resistance varies with temperature) monitor all the motors.

The schematic shown in Fig. 85 is a typical. Always refer to the schematic in the Bucyrus parts book for your machine.

© BUCYRUS

Fig. 85: Thermistor module control

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___________________________________________________ Electrical Processor module The processor module contains the software that operates the machine control system. The processor module receives input from the operator’s case, and outputs to I/O system comms, the graphics display, data logger and tram drives.

The schematic shown in Fig. 86 is a typical. Always refer to the schematic in the Bucyrus parts book for your machine.

© BUCYRUS

Fig. 86: Processor module

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Electrical ____________________________________________________ I/O module The I/O module receives input from the hydraulic oil level, earth leakage monitors, footswitch, brake, water pressure, motor CTs and tram levers, and sends information to the machine control system.

The schematic shown in Fig. 87 is a typical. Always refer to the schematic in the Bucyrus parts book for your machine.

© BUCYRUS

Fig. 87: I/O module

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___________________________________________________ Electrical Solenoid control circuit Solenoids are used to control the hydraulic functions (cylinder movement), brakes, dust sprays, and fire suppression.

The schematic shown in Fig. 88 is typical. Always refer to the schematic in the Bucyrus parts book for your machine.

© BUCYRUS

Fig. 88: Solenoid control circuit

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Maintenance _________________________________________________ Instructions on the maintenance Maintenance at regular intervals increases the operational safety and prolongs the service life of the machine.

In particular, observe the safety instructions in chapter 2 “Your safety”.

Important notes

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In order to avoid individual components not being serviced or being only inadequately serviced during maintenance work on the machine as a whole, we recommend that a general maintenance plan be drawn up. You can, for example, draw up a checklist using this maintenance manual and the manuals of the other components.

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Inadequate maintenance can result in machine damage which leads to considerable costs.

■

Use only suitable and approved tools for maintenance work.

■

Use only original Bucyrus spare parts when replacing components.

■

All electrical work must be supervised and inspected by a certified electrician.

■

Anyone performing maintenance on this equipment must be trained to operate it and be familiar with this Bucyrus America, Inc. guide.

Before maintenance Please observe the following: ■

Shutdown the machine on level ground.

■

Disconnect the electrical power. The circuit breaker must be in the “OFF” position and the power should be disconnected at the main power source.

WARNING! Before performing maintenance on the machine, the circuit breakers must be in the “OFF” position and the power should be disconnected at the main power source. Electrical shock and accidental machine movement can cause serious injuries or even death to you or the maintenance person.

■

Test the controls to ensure that the unit will not move.

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

_________________________________________________________________ 5.138 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS

Please observe the following:

________________________________________________ Maintenance ■

Only work on the miner in an area where the roof is properly supported.

■

Block any and all elevated assemblies before working under them.

Make sure that the blocking can support the weight of the assembly without slipping or failing.

■

Relieve all hydraulic pressures and position the levers and controls in neutral or off.

■

Test the controls to ensure that the unit will not move.

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

© BUCYRUS

■

Do not perform maintenance on a circuit while there is a load resting on the hydraulic cylinder. Booms must be securely blocked with the boom in the raised position if maintenance is to be performed.

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

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

■

Do not perform maintenance in a congested area. This could endanger the maintenance person or others in the vicinity.

■

Whenever a potential problem is uncovered during a periodic maintenance check, it is imperative that it be corrected immediately by a qualified maintenance technician.

■

Cleanliness cannot be overemphasized as the essential ingredient of a good maintenance program. Machines should be kept as free as possible of dirt and debris which could impede performance or infiltrate systems and cause premature wear or failure.

______________________________________________________________ A6474X337 VLSS/0 5.139

Maintenance _________________________________________________ Torque values When installing bolts, refer to the torque values on the drawings in the Bucyrus parts book for your machine. If a torque value is not listed, refer to Chapter 6 of this manual

Lubricants and fluid capacities Table 2: Lubricants and fluid capacities Specification

Approximate capacity

Hydraulic oil tank

Spec. 100-1

95 gals. (360 L)

GH Assembly CLA Primary GH Assembly CLA POT

Spec. 100-15 Spec. 100-15

1 gal (3.79 L) 2.5 gal (9.46 L)

Tram Drive Assembly Drum Drive Assembly, high speed (back) Drum Drive Assembly, low speed (front) Motor Lube Hoses

Spec. 100-15 Spec. 100-15

3 gal (11.36 L) 0.5 gallon (1.89 L)

Spec. 100-15

5 gal (18.93 L)

Spec. 100-14

Variable

Notes

1

Notes: 1. All motor lube hoses are to be filled with high temperature electric motor grease (Spec. 100-14) before assembling them to the electric motor to ensure that there are no air gaps between the grease nipple and the point where the grease enters the motor.

_________________________________________________________________ 5.140 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS

Location

________________________________________________ Maintenance Table 3: Lubrication and maintenance schedule Item

© BUCYRUS

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37

Description Every Shift Cutter head lift cylinder pin, upper Cutter head lift cylinder pin, lower Conveyor swing cylinder pin, front Conveyor swing cylinder pin, rear Cutter head pivot pin Cutter head bits Daily Conveyor tail roller Gathering head pivot pin Crawler idler roller Conveyor raise pivot pin Stabilizer shoe cylinder pin, upper Stabilizer shoe cylinder pin, lower Conveyor raise cylinder pin, upper Conveyor raise cylinder pin, lower Conveyor swing pivot pins Gathering head cylinder pin, upper Gathering head cylinder pin, lower CLA head pot assembly (Check) CLA head transfer case (Check) Tram gear case (Check) Input cutter head gear case (Check) Main cutter head gear case (Check) Hydraulic oil level (Check) Stab shoe pivot, frame Weekly Filter, pressure (Change) Filter, return (Change) Filter, pilot, bypassing (Change) Filter, pilot, non-bypassing (Change) Filter, water (Change) Crawler chain Conveyor chain Fasteners (nuts, bolts, screws) Electrical cables, conduits, and glands Hydraulic hoses and connections Lighting Reflectors and warning tags Machine stop switch (Inspect)

Places

Lubricant

Specification

2 2 1 1 2 Inspect

Lithium based grease Lithium based grease Lithium based grease Lithium based grease Lithium based grease

Spec. 100-3 Spec. 100-3 Spec. 100-3 Spec. 100-3 Spec. 100-3

Lithium based grease Lithium based grease Lithium based grease Lithium based grease Lithium based grease Lithium based grease Lithium based grease Lithium based grease Lithium based grease Lithium based grease Lithium based grease High demulsibility EP gear oil High demulsibility EP gear oil High demulsibility EP gear oil High demulsibility EP gear oil High demulsibility EP gear oil AW hydraulic oil Lithium based grease

Spec. 100-3 Spec. 100-3 Spec. 100-3 Spec. 100-3 Spec. 100-3 Spec. 100-3 Spec. 100-3 Spec. 100-3 Spec. 100-3 Spec. 100-3 Spec. 100-3 Spec. 100-15 Spec. 100-15 Spec. 100-15 Spec. 100-15 Spec. 100-15 Spec. 100-1 Spec. 100-3

2 2 2 2 2 2 2 2 8 2 2 2 2 2 2 2 1 2 1 1 1 1 1 Inspect Inspect Inspect Inspect Inspect Inspect Inspect 4

See Parts Book See Parts Book See Parts Book See Parts Book See Parts Book

______________________________________________________________ A6474X337 VLSS/0 5.141

Maintenance _________________________________________________ Table 3 (continued): Lubrication and maintenance Description

Places

Lubricant

Specification

2 2 2 2 Inspect 2 2 2 2 2 2 1

High demulsibility EP gear oil High demulsibility EP gear oil High demulsibility EP gear oil High demulsibility EP gear oil

Spec. 100-15 Spec. 100-15 Spec. 100-15 Spec. 100-15

Sample Sample Sample Sample Sample Sample Sample

See Note 1 See Note 1 See Note 1 See Note 1 See Note 1 See Note 1 See Note 1

4

High temperature lithium complex grease High temperature lithium complex grease High temperature lithium complex grease High temperature lithium complex grease

Spec. 100-14

2

High demulsibility EP gear oil

Spec. 100-15

1 All 1

AW hydraulic oil

Spec. 100-1 See Parts Book

50

Monthly CLA head pot assembly oil (Change) CLA head transfer case oil (Change) Input cutter head gear case oil (Change) Main cutter head gear case oil (Change) CLAs Input cutter head gear case oil Main cutter head gear case oil CLA head pot assembly oil CLA head transfer case oil Tram gear case oil Crawler idler roller oil Hydraulic oil (tank) Every three months Cutter motor

51

Gathering head motor

4

52

Pump motor

2

53

Scrubber motor

2

54 55 56 57 58

Every six months Tram gear case oil (Change) Crawler idler roller oil (Change) Hydraulic oil (Change) Breathers Filter, manual oil fill (Change)

38 39 40 41 42 43 44 45 46 47 48 49

Spec. 100-14 Spec. 100-14 Spec. 100-14

Note 1: When the oil sample and oil change interval are identical, a sample of the old oil is to be taken and sent for analysis prior to changing the oil (see the Oil sampling procedure in this chapter). Always inspect breathers when taking hydraulic oil samples.

_________________________________________________________________ 5.142 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS

Item

________________________________________________ Maintenance Fig. 89: Lubrication and maintenance chart

7 4 31

3

29

59

© BUCYRUS

23, 49, 56

21, 40, 43

22, 41, 44

______________________________________________________________ A6474X337 VLSS/0 5.143

Maintenance _________________________________________________ Fig. 89: Lubrication and maintenance chart, continued

21, 40, 43

51

50

19, 39, 46 18, 38, 45 1

16

9, 48, 55

17

30

2, 5, 8, 10 25. 26, 27, 28

© BUCYRUS

20, 47, 54

12

15

_________________________________________________________________ 5.144 Bucyrus – Model 30M4-NP Continuous Miner

________________________________________________ Maintenance Fig. 89: Lubrication and maintenance chart, continued

15

11, 13, 14, 24, 53

12

20, 47, 54 © BUCYRUS

30

52

9, 48, 55 17 19, 39, 46 16 51 18, 38, 45

50 21, 40, 43

______________________________________________________________ A6474X337 VLSS/0 5.145

Maintenance _________________________________________________ Specific lubrication and maintenance procedures Every shift cutter head lift cylinder pins (upper and lower)

Lubricate the upper and lower cutter head cylinder pins (right and left).

The upper pins are lubricated through the grease fittings located on each pin (Fig. 84). The lower cylinder pins are lubricated through a lubrication block mounted on each side of the machine (Fig. 90). Pump approximately 50 cubic cm (3 cubic inches) into each fitting.

Cutter head lift cylinder pin, upper (typical both sides)

Lower cutting head cylinder pin (One for each side)

_________________________________________________________________ 5.146 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS

Fig. 90: Cutter head cylinder pins (typical both sides)

________________________________________________ Maintenance conveyor swing cylinder pin (front and rear)

Lubricate the front and rear conveyor swing cylinder pins through the grease fittings located on each end of the cylinder (Fig. 91). Pump approximately 50 cubic cm (3 cubic inches) into each fitting.

Fig. 91: Conveyor swing cylinder pin lubrication

© BUCYRUS

Rear conveyor swing cylinder pin

cutter head pivot pin (left and right)

Front conveyor swing cylinder pin

Lubricate left and right cutter head pivot pins through the grease fittings located on the left and right front lubrication blocks (Fig. 92). Pump approximately 3 cu. in. (50 cu. cm) of grease into each fitting.

Fig. 92: Cutter head pivot pins (typical both sides)

Cutting head pivot pin (typical both sides)

______________________________________________________________ A6474X337 VLSS/0 5.147

Maintenance _________________________________________________ cutter head bits

Inspect the cutter head bits to ensure that they will rotate in their holders and for damaged or missing bits (Fig. 93). Replace bits immediately if any are missing or damaged.

Fig. 93: Cutter head bits (typical shown)

© BUCYRUS

Inspect cutter head bits

_________________________________________________________________ 5.148 Bucyrus – Model 30M4-NP Continuous Miner

________________________________________________ Maintenance Daily conveyor tail roller

Lubricate the conveyor take-up shaft through the two (2) grease fittings located on the shaft (Fig. 94). Pump approximately 3 cu. in. (50 cu. cm.) into each fitting.

Fig. 94: Conveyor tail roller

© BUCYRUS

Grease fitting

Grease fitting

gathering head pivot pin (right and left)

Lubricate the left and right gathering head pivot pins through the grease fittings located on the left and right front lubrication blocks (Fig. 95).

Pump approximately 3 cu. in. (50 cu. cm.) of grease into each fitting.

conveyor raise pivot (right and left)

Lubricate the conveyor raise pivot through the grease fitting located on the right and left front lubrications blocks (Fig. 95). Pump approximately 3 cu. in (50 cu. cm) of grease into each fitting.

Fig. 95: Gathering head and conveyor raise pivot pins (typical both sides)

Gathering head pivot lube (typical both sides)

Conveyor pivot lube (typical both sides)

______________________________________________________________ A6474X337 VLSS/0 5.149

Maintenance _________________________________________________ crawler idler roller (right and left)

Lubricate the left and right crawler idler rollers (Fig. 96) through the grease fittings located on the outside face of the crawler idler roller.

Fig. 96: Crawler idler roller

stabilizer shoe cylinder pin, lower (right and left)

Lubricate the lower stabilizer shoe cylinder pins (right and left) through the grease fittings located on the cylinder clevis (Fig. 97). Pump approximately 3 cu. in (50 cu. cm) of grease into each fitting.

Fig. 97: Lower stabilizer shoe cylinder pins (right and left)

© BUCYRUS

Stabilizer shoe cylinder pin grease fitting

Stabilizer shoe cylinder pin grease fitting

_________________________________________________________________ 5.150 Bucyrus – Model 30M4-NP Continuous Miner

________________________________________________ Maintenance stabilizer shoe cylinder pin, upper (right and left)

Lubricate the upper and lower stabilizer shoe cylinder pins (right and left) through the four grease fittings located on the lubrication block in the hydraulic compartment on the left side of the machine (Fig. 98).

Pump approximately 3 cu. in (50 cu. cm) of grease into each fitting.

conveyor raise cylinder pin, lower (left and right)

Lubricate the lower conveyor raise cylinder pins (right and left) through the grease fittings located on the left side of the conveyor (Fig. 98).

Pump approximately 3 cu. in (50 cu. cm) of grease into each fitting.

stabilizer shoe pivot pin

Lubricate the stabilizer shoe pivot pin through the grease fittings located on the lubrication panel (Fig. 98). Pump approximately 3 cu. in (50 cu. cm) of grease into each fitting.

Fig. 98: Upper stab shoe, lower conveyor raise cylinder, and stab shoe pivot pin lubrication Stabilizer shoe pivot pin

Conveyor raise cylinder pin, lower

Stabilizer shoe cylinder pin, upper

Stabilizer shoe pivot pin

Conveyor raise cylinder pin, lower

© BUCYRUS

Stabilizer shoe cylinder pin, upper

______________________________________________________________ A6474X337 VLSS/0 5.151

Maintenance _________________________________________________ conveyor swing pivot pins

Lubricate the conveyor swing pivot pins through the four (4) grease fittings located each side of the conveyor (Fig. 99). Pump approximately 3 cu. in (50 cu. cm) of grease into each fitting.

Conveyor swing pivot pins lubrication fittings (4) (typical both sides)

gathering head raise cylinder pins

Lubricate the upper gathering head raise cylinder pins (Fig. 100) through the grease fittings located on each end of the cylinder. Pump approximately 3 cu. in (50 cu. cm) of grease into each fitting.

Fig. 100: Gathering pan raise cylinder pins (typical both sides)

Upper gathering head cylinder pin lubrication (typical both sides)

Lower gathering head cylinder pin lubrication (typical both side)

_________________________________________________________________ 5.152 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS

Fig. 99: Conveyor swing pivot pin

________________________________________________ Maintenance CLA head pot assembly (right and left)

Level the miner and place the gathering head on grade before checking or adding lubricant. Check the oil level in the pot assembly (Fig. 101).

If oil is needed, add oil through the fill hole until oil comes out the breather.

CLA head transfer case (right and left)

Level the miner and place the gathering head on grade before checking or adding lubricant. Check the oil level in the hydraulic transfer case (Fig. 101). If oil is needed, add oil through the fill hole until oil comes out the breather.

Fig. 101: CLA head pot assembly and transfer case lubrication

© BUCYRUS

Oil fill, pot assembly

Oil fill, transfer case

tram gear case (right and left)

Oil check, pot assembly

Oil check, transfer case

With the miner in a level position, check the oil level in both tram gear cases by looking at the sight glass located on the side of each gear case (Fig. 102). Oil should be visible in each sight glass. If oil level is low, add oil through either the fill pipe (accessed from the top of the machine) or the fill plug hole (accessed from the side of the machine).

Fig. 102: Tram gear case oil level (typical both sides)

Oil fill plug (typical both sides) Breather Oil level sight glass (typical both sides)

______________________________________________________________ A6474X337 VLSS/0 5.153

Maintenance _________________________________________________ input cutter gear case

With the gathering head lowered to ground level and the cutter head boom level with ground, check the oil level in both of the input cutter gear cases by removing the check plug located on each side of the cutter head assembly (Fig. 103). Oil should flow from check plug hole when plug (s) is removed. If oil level is low, add oil through the fill plugs located on each side of the gathering head.

Fig. 103: Input cutter gear case (s) oil level Sight glasses (two per side)

Oil fill plug (typical both sides)

main cutter gear case

With the cutter head boom level with ground, check the oil level in both of the main cutter head gear cases by removing the check plug located on the front of each gear case (Fig. 104). Oil should flow from check plug hole when plug (s) is removed. If oil level is low, add oil through the fill plug hole located on top of each gear case.

Fig. 104: Main cutter head gear case (s) oil level

Oil fill plug (One for each side)

Oil level/check plug (One for each side)

_________________________________________________________________ 5.154 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS

Oil level/check plug (typical both sides)

________________________________________________ Maintenance hydraulic oil level

Check the hydraulic tank oil level (Fig. 105). The oil level dipstick is located on the left hand side of the machine, above the tram case. Remove dipstick from tank and wipe clean. Insert dipstick back into tank and remove. The oil should be level with the full line indicated on dipstick. If oil level is low, add oil until full level is met.

Oil level dipstick

© BUCYRUS

Fig. 105: Hydraulic oil tank level

______________________________________________________________ A6474X337 VLSS/0 5.155

Maintenance _________________________________________________ Weekly The return, main pressure, and non-bypassing pilot pressure filters are located behind a cover on the right hand side of the machine (Fig. 106). return filter

The filter on the left is the return filter. Change the return filter element weekly. If the element is extremely dirty, a more frequent change interval may be required.

main pressure filter

The filter located in the middle is the main pressure filter. Change the main pressure filter element weekly. If the element is extremely dirty, a more frequent change interval may be required.

pilot pressure filter, non-bypassing

The filter on the right is the non-bypassing pilot pressure filter. Change the pilot pressure filter element weekly. If the element is extremely dirty, a more frequent change interval may be required.

© BUCYRUS

Fig. 106: Filter locations

Return filter

Main pressure filter

Pilot pressure filter, non-bypassing

_________________________________________________________________ 5.156 Bucyrus – Model 30M4-NP Continuous Miner

________________________________________________ Maintenance pilot pressure filter, bypassing

The bypassing pilot pressure filter is located on the left hand side of the machine (Fig. 107). Change the pilot pressure filter element weekly. If the element is extremely dirty, a more frequent change interval may be required.

© BUCYRUS

Fig. 107: Pilot pressure element, bypassing

Pilot pressure filter, bypassing

______________________________________________________________ A6474X337 VLSS/0 5.157

Maintenance _________________________________________________ water filter

The water filter is located near the back bumper on the right hand side of the machine (Fig. 108). Change the water filter element weekly. If the element is extremely dirty, a more frequent change interval may be required.

Water filter

_________________________________________________________________ 5.158 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS

Fig. 108: Water filter location

________________________________________________ Maintenance crawler track tension

Check the crawler tracks for proper tension. If adjustment is necessary, see the Crawler track adjustment procedure in this chapter.

To check the track for proper tension:  Raise the complete crawler assembly off of the ground and securely block under the machine. The machine must be securely supported off the ground.

WARNING! Observe the safe working load limits of all blocking devices. You could be seriously injured or killed by falling loads.  Chain sage should be 64 to 89 mm (2-1/2 to 3-1/2 inches (89 mm) at the center of the crawler (Fig. 109).

Fig. 109: Crawler track tension measurement

© BUCYRUS

Bottom of tractor wear shoe

conveyor chain tension

64 to 90 mm gap (2-1/2 to 3-1/2 inches)

Top of tram track

Check the conveyor chain tension with the machine running. The conveyor chain should rise about 51 mm (2 inches) or less above the gathering head foot shaft sprocket as the chain emerges from under the conveyor pan (Fig. 110). If adjustment is necessary, see the Conveyor chain tension adjustment procedure in this chapter.

Fig. 110: Conveyor chain tension measurement

Chain measurement area

______________________________________________________________ A6474X337 VLSS/0 5.159

Maintenance _________________________________________________

electrical cables, conduits, and glands hoses and fittings

The miner is subjected to continual shock loading and vibration and close attention to all mounting bolts and screws is required. Loose fasteners will cause premature wear and failure of bearings, couplings, etc. Inspect the fasteners for the following and tighten as required : ■

Cutter head gear case

■

Cutter head motors

■

Center drums

■

End drums

■

Tram cases

■

Tram motors

■

Gathering head CLAs

■

Gathering head pots

■

Gathering head motors

Visually inspect all electrical cables and glands for signs of wear or damage.

Visually inspect and hydraulic and water hoses and fittings for signs of wear, damage, or leakage. This inspection should be performed with the machine running. Observe the following precautions/procedures while checking for leaks: ■ ■ ■

Relieve pressure before disconnecting hoses.

Check for leaks with a piece of cardboard. Do not use hands.

Do not exceed the working pressure of hydraulic hoses.

WARNING! Use extreme caution when inspecting for leaks with the machine running. Unexpected machine movement, or contact with moving parts, could result in injury.

Escaping fluids under pressure can penetrate skin and cause serious injury. Do not attempt to locate hydraulic leaks be feeling hoses and fittings with bare hands. Pin hole leaks can penetrate the skin. lighting

Turn on the lights and visually inspect for bulbs that need to be replaced.

reflectors and warning tags

Visually inspect the condition and readability of all warning tags, labels, and reflectors for signs of wear or damage. Replace any reflector or tag that is missing or damaged.

machine stop switches

Check the machine stop switches located on each side of the machine for proper operation. Start the machine and strike the switch; the machine pump motor will shutdown, in turn shutting down all other motors.

Repeat for each of the four switch.

_________________________________________________________________ 5.160 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS

fasteners

________________________________________________ Maintenance Monthly CLA head pot assembly

Change the oil in both CLA head pot assemblies (Fig. 111).  Level the miner, raise the gathering head pan, and secure in place.  Clean dirt and debris from around the drain plug located under the gear case.  Remove the drain plug and allow oil to completely drain from the gear case.  Clean and reinstall drain plug.  Clean dirt and debris from around the check plug and remove the plug.  Clean dirt and debris from around the fill plug and remove the plug.  Slowly add oil through the fill plug until oil is visible in the sight glass. Allow sufficient time for the oil to ravel through the gear case when filling.  Clean and reinstall the check and fill plugs.

© BUCYRUS

CLA head transfer case

Change the oil in both CLA head transfer cases (Fig. 105).  Level the miner, raise the gathering head pan, and secure in place.  Clean dirt and debris from around the drain plug located under the gear case.  Remove the drain plug and allow oil to completely drain from the gear case.  Clean and reinstall drain plug.  Slowly add oil through the fill plug until oil begins to flow from the check plug hole. Allow sufficient time for the oil to ravel through the gear case when filling.  Clean and reinstall the fill plugs.

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

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

______________________________________________________________ A6474X337 VLSS/0 5.161

Maintenance _________________________________________________ Fig. 111: CLA pot assembly and input transfer case Oil check, pot assembly

Oil check, transfer case

_________________________________________________________________ 5.162 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS

Oil fill, transfer case

Oil fill, pot assembly

________________________________________________ Maintenance input cutter head gear case

Change the oil in both input cutter head gear cases (Fig. 112).  Position the cutter head horizontally (flat back in a vertical position).

Clean dirt and debris from around the drain plug located under the gear case.  Remove the drain plug and allow oil to completely drain from the gear case.  Clean and reinstall the drain plug.  Clean dirt and debris from around the check plug and remove the plug.  Clean dirt and debris from around the fill plug and remove the plug.  Add oil through the fill plug hole slowly, the lower sight glass is full of oil. Allow sufficient time for the oil to travel throughout the gear case when filling.  Clean and reinstall the check and fill plugs.

Fig. 112: Input cutter head gear case

© BUCYRUS

Oil fill plug (One for each side) Flat back

Sight glasses (Two for each side)

Oil level/check plug (One for each side)

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

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

______________________________________________________________ A6474X337 VLSS/0 5.163

Maintenance _________________________________________________ main cutter head gear case

Change the oil in both main cutter head gear cases (Fig. 113).  Lower the cutter head completely to the ground. Clean dirt and debris from around the drain plug, located under the gear case.  Remove the drain plug and allow oil to completely drain from the gear case.  Clean and reinstall the drain plug.  Clean dirt and debris from around the check plug and remove the plug.  Clean dirt and debris from around the fill plug and remove the plug.  Slowly add oil through the fill plug until oil begins to flow from the check plug hole. Allow sufficient time fro the oil to travel throughout the gear case when filling.  Clean and reinstall the check and fill plugs.

Fig. 113: Main cutter head gear case

© BUCYRUS

Oil fill plug (One for each side)

Oil level/check plug (One for each side)

Oil drain plug (One for each side)

_________________________________________________________________ 5.164 Bucyrus – Model 30M4-NP Continuous Miner

________________________________________________ Maintenance CLAs

Inspect the CLAs (Fig. 114) for damage. If a CLA needs replaced, see CLA removal and installation procedure in this chapter.

Fig. 114: CLAs (typical)

CLA

© BUCYRUS

Oil sampling plan This plan contains specific instructions to be followed in order to correctly collect gear case lubricant samples, and preparation of the samples for laboratory analysis. Adherence to these instructions will insure that all oil sample analysis reports give an accurate picture of the oils condition as well as wear trends of gears, bearings, etc. Accurate reporting and analysis of oil samples will prove extremely beneficial providing a tool to allow planning of scheduled down-time and prevention of costly equipment breakdown.

Preparation prior to sample collection For each machine to be sampled, you will need a supply of sample collection bottles and identification labels (Fig. 115) sufficient to sample each identified gear case (every sixty shifts).

One sample bottle and collection hose is required for each gear case to be sampled. Label each container with the identifying name of the gear case (crawler gear case, left or cutter head gear case, right front, etc.).

Collection of oil samples NOTICE! If the gear case is scheduled for oil drain and refill, obtain the oil sample prior to the oil change.

Each oil sample should be taken while the oil is at normal operating temperature. If the machine has not been operating just prior to sampling, run the machine until oil temperature reaches approximate normal operating temperature. Shutdown the machine and allow 2 - 3 minutes for the oil to drain back and stabilize it’s level.

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

______________________________________________________________ A6474X337 VLSS/0 5.165

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

After taking sample, check and refill gear case back to proper fill level.

Following collection of all oil samples, record the specific brand and product name of the lubricant that has been installed in each gear case.

Recommended gear cases to be sampled: Input cutter head gear case (left and right)

■

Main cutter head gear case (left and right)

■

Input gathering head gear case (left and right)

■

Main gathering head gear case (left and right)

■

Main hydraulic oil tank

■

Crawler idler roller © BUCYRUS

■

Fig. 115: Oil sampling procedure Oil fill plug

Typical siphon pump and bottle

Oil level

Place end of siphon tube approximately half way into sump

Note: Hold sample pump and bottle below oil level

_________________________________________________________________ 5.166 Bucyrus – Model 30M4-NP Continuous Miner

________________________________________________ Maintenance Every three months IMPORTANT! For motor bearings that require high temperature lithium complex grease (Spec. 100-15), Bucyrus provides a special “button” style lubrication fitting (Fig. 108) to prevent the accidental use of multipurpose lithium complex grease at these locations. cutter motor bearings

Lubricate the left and right cutter head motor bearings with high temperature lithium complex grease through the two grease fittings located on each side of the cutter head (Fig. 116) using the following procedure:  Open the cover (Fig. 110) to access the motor.  Inspect the grease fittings on the exit side of the front and rear motor bearing.

If the exit side motor bearing ports are equipped with spring load relief fittings, then

© BUCYRUS

Lubricate both motor bearings until new grease appears out of the relief ports on the exit side of the bearing.  Operate the motor for five (5) minutes and then inspect for grease leaks in the bearing area.

If the exit side motor bearing ports are equipped with plugs, then:  Remove the plug and lubricate both motor bearings until new grease appears out of the relief ports on the exit side of the bearing.  Operate the motor for five (5) minutes and then inspect for grease leaks in the bearing area.  Replace the plugs in the ports.

NOTICE! Incorrect grease or over greasing of the electric motor may cause serious damage to the motor. Follow the greasing procedure outlined above.

______________________________________________________________ A6474X337 VLSS/0 5.167

Maintenance _________________________________________________ Fig. 116: Cutter motor bearing lubrication (typical each side)

Button type grease fitting

Spring loaded grease relief fitting

_________________________________________________________________ 5.168 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS

Cutting head motor grease fittings (two per side)

________________________________________________ Maintenance gathering head motor bearings

Lubricate the left and right gathering head motor bearings with high temperature lithium complex grease through the two grease fittings located on each motor (Fig. 117).

To lubricate the motors:  Open the cover (Fig. 117) to access the motor.  Inspect the grease fittings on the exit side of the front and rear motor bearing.

If the exit side motor bearing ports are equipped with spring load relief fittings (Fig. 109), then Lubricate both motor bearings using the button type grease fitting until new grease appears out of the relief ports on the exit side of the bearing.  Operate the motor for five (5) minutes and then inspect for grease leaks in the bearing area.

If the exit side motor bearing ports are equipped with plugs, then:

© BUCYRUS

 Remove the plug and lubricate both motor bearings using the button type grease fitting until new grease appears out of the relief ports on the exit side of the bearing.  Operate the motor for five (5) minutes and then inspect for grease leaks in the bearing area.  Replace the plugs in the ports.

NOTICE! Incorrect grease or over greasing of the electric motor may cause serious damage to the motor. Follow the greasing procedure outlined above.

______________________________________________________________ A6474X337 VLSS/0 5.169

Maintenance _________________________________________________ Fig. 117: Gathering head motor bearing lubrication (typical each side)

Gathering head motor grease fitting located behind access door (one per side) © BUCYRUS

Gathering head motor grease fitting (one per side)

Button type grease fitting

Spring loaded grease relief fitting

_________________________________________________________________ 5.170 Bucyrus – Model 30M4-NP Continuous Miner

________________________________________________ Maintenance pump motor bearings

Lubricate the pump motor (Fig. 118) with high temperature lithium complex grease (Spec. 100-14) through the two (2) grease fittings located the left side of the machine using the following procedure:  Open the cover (Fig. 118) to access the motor.  Lubricate both bearings using the grease fittings on the side of the miner until new grease appears out of the relief ports on the exit side of the bearing.  Operate the motor for five (5) minutes and then inspect for grease leaks in the bearing area.  Replace the motor access cover.

NOTICE! Incorrect grease or over greasing of the electric motor may cause serious damage to the motor. Follow the greasing procedure outlined above.

© BUCYRUS

Fig. 118: Pump motor bearings

Pump motor grease fitting (2)

______________________________________________________________ A6474X337 VLSS/0 5.171

Maintenance _________________________________________________ scrubber motor bearings

Lubricate the fan motor bearings (Fig. 119) with high temperature lithium complex grease (Spec. 100-14) through the fitting located on the lubrication block located on the rear left side of the machine: IMPORTANT! For motor bearings that require high temperature lithium complex grease (Spec. 100-15), Bucyrus provides a special “button” style lubrication fitting to prevent the accidental use of multi-purpose lithium complex grease at these locations.   Remove the cover to access the motor.  Lubricate both motor bearings using the button type fittings (Fig. 112) until new grease appears out of the relief port on the exit side of the bearing.  Operate the motor for five minutes.  Inspect for any grease leakage in the area around the bearing.  Replace the motor access cover.

© BUCYRUS

Fig. 119: Scrubber motor

Scrubber motor grease fitting

Scrubber motor grease fitting

_________________________________________________________________ 5.172 Bucyrus – Model 30M4-NP Continuous Miner

________________________________________________ Maintenance Every six months tram gear case

Change the oil in both tram gear cases (Fig. 120).  Remove the drain plug and allow oil to completely drain from the gear case.  Clean and reinstall the drain plug.  Replace the breather, located in the fill tube.  Remove the fill plug located on top of the gear case or on the tram brake gear case.  Add oil through the fill plug hole until oil is visible in the sight glass.

When filling, allow sufficient time for the oil to travel throughout the gear case.  Clean and reinstall the fill plug.

Fig. 120: Tram gear case Breather

© BUCYRUS

Oil fill plug

Oil level sight

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Maintenance _________________________________________________ crawler idler roller (s)

Change oil in both crawler idler rollers. (Fig. 121).  Rotate idler roller until the two (2) pipe plugs are positioned at the 3 o-clock and 9 o-clock position.  Remove drain plug and allow oil to completely drain from the crawler idler roller.  Clean and reinstall drain plug.  Remove both fill plugs.  Add oil through either of the fill plug holes until oil begins to flow from the other. Allow sufficient time for the oil to travel throughout crawler idler roller when filling.

Fig. 121: Crawler idler roller oil change Oil fill/check plug (One for each side)

© BUCYRUS

Oil level/check plug (One for each side)

_________________________________________________________________ 5.174 Bucyrus – Model 30M4-NP Continuous Miner

________________________________________________ Maintenance hydraulic oil and breather

Change the oil in the hydraulic oil tank (Fig. 122).  Remove drain plug and allow oil to completely drain from the tank.  Clean and reinstall drain plug.  Remove and replace the breather.  Refill the tank manually with oil to full level indicated on dip stick.  Start the machine and allow the hydraulic pump to run in order to purge air from the system.  Shutdown the machine and recheck the oil level. Add oil if necessary.

Fig. 122: Hydraulic oil tank

© BUCYRUS

Oil level dipstick

gear case breathers

Change the breathers on the tram gear cases.

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Adjustment procedures ________________________________________ Setting hydraulic pressures ■

Always refer to the hydraulic schematic in the Bucyrus parts book supplied with your miner.

■

Most relief valves are set to factory specifications and should require no further adjustment. If a problem occurs which requires the relief valves to be adjusted, make certain the correct procedures are followed and all work is performed by a qualified person.

■

Generally speaking, when adjusting relief valves, turning the adjusting screw in (clockwise) will increase the pressure setting. The instructions in this manual are based on this general principle.

■

If the valve pressure setting is unknown, always adjust the valve fully counterclockwise prior to initiating any action that will create flow and prove the potential for pressure. This will allow the pressure setting to be achieved in a safe, controlled manner.

The miner is equipped with twelve hydraulic pressure gauges to aid in setting relief pressures. Three of the gauges have a redundant gauge: one located in the pit and one located on the hydraulic shelf. The gauges measure the following pressures: ■

cutter head pressure (part of the cutter head/cooling circuit) - 2 gauges

■

main pressure (all functions of the MCV) - 2 gauges

■

pilot pressure - 2 gauges

■

MCV solenoid valve pilot pressure

■

brake cooling pressure

■

cooling circuit (heat exchanger) pressure

■

conveyor chain take-up pressure

■

anti-chatter/maintenance (shear down) pressure

■

gathering head float/relief pressure

There will be occasions when relief valves, or other pressure control valves, must be set or adjusted. Setting relief valve pressure is necessary when a relief valve is replaced with a new unit or when an existing relief valve needs to be adjusted, for example, during the course of troubleshooting a hydraulic system fault. To properly adjust a relief valve, the circuit must be “dead-headed”. This section describes the proper procedure for setting the relief valves.

_________________________________________________________________ 5.176 Bucyrus – Model 30M4-NP Continuous Miner

© Bucyrus

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

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

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

Load holding valve adjustment The load holding valve is factory preset and should not be field adjusted.

Always refer to your parts manual when ordering load holding valves for the cutter, stabilizer, or conveyor cylinders.

Never rely on the load holding valve as a means of supporting the cutter boom or conveyor boom while making repairs. Always support the cutter boom and conveyor boom with adequate material before working around or underneath the cutter or conveyor.

© BUCYRUS

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

The adjustment procedure should start with the pilot pressure circuit because this system is a “closed center” circuit (except for the brake cooling portion) and will build pressure as soon as the pump is started. The cutter head and primary pressure circuits are “open center” circuits and very little pressure is present until a function is activated. The main relief valves on the main control valve (MCV) and cutter head directional control valves, as well as the cooling circuit (heat exchanger) relief valve, should all be adjusted to their lowest settings prior to initial start up and adjustment. Reference circuit descriptions, abbreviations, and terms in the Hydraulic section of this chapter.

______________________________________________________________ A6474X337 VLSS/0 5.177

Adjustment procedures ________________________________________ Pilot pressure circuit relief/reducing valve adjustments The following procedure is for start up of new and rebuilt machines.

IMPORTANT! Reference the Hydraulic section in this chapter for individual circuit information. Always refer to the hydraulic schematic in your Bucyrus parts manual for your miner.

WARNING! Two people are required to adjust pressure settings. One person will make the adjustments while the second person must remain at the machine stop at all times during the adjustment procedure. Failure to do so may result in serious injury or death.  1. Pilot pressure

 b. Remove the hex socket head plug on the conveyor chain take up relief/reducing valve section of the multipurpose valve. Using an Allen wrench, turn the screw fully out (counterclockwise) to ensure that the pressure in this circuit is at its minimum setting.  c.

Loosen the nut on the brake cooling pressure relief/ reducing valve cartridge and, using an Allen wrench, turn the screw full out (counterclockwise) to ensure a low pressure start up condition on this circuit.

 d. Close both needle valves on the brake cooling circuit.  e. Start the pump motor (see Start up procedure in this chapter).  f.

Adjust the pilot pressure relief valve by turning the screw clockwise until the system pilot pressure reaches the setting specified on the hydraulic schematic.

 2. MCV solenoid valve pilot pressure  a. Loosen the nut on the MCV solenoid valve pilot pressure relief valve cartridge. Using an Allen wrench, turn the screw in (clockwise) to increase pressure or out (counterclockwise) to decrease pressure until the pressure reaches the setting specified on the hydraulic schematic.

_________________________________________________________________ 5.178 Bucyrus – Model 30M4-NP Continuous Miner

© Bucyrus

 a. Loosen the nut on the pilot pressure relief valve cartridge and turn the screw fully out (counterclockwise) using an Allen wrench to ensure a low pressure start up condition and to prevent over pressuring the gauge on this circuit.

_______________________________________ Adjustment procedures

  3. Brake cooling pressure  a. Ensure Pilot pressure adjustment steps 1c and 1d have been completed.  b. Adjust the screw on the brake cooling pressure relief/ reducing valve until the pressure reaches the setting specified on the hydraulic schematic. this valve is used to prevent over pressurization of the brake cooling cavity which results in leakage at the shaft seal of the brake.  c.

Open both brake cooling valves approximately 1/4 turn.

 d. If more cooling is required, open the needle valves accordingly to increase the cooling flow rate. To decrease the cooling rate, close the needle valves.  4. Conveyor chain take up pressure

© BUCYRUS

 a. Ensure Pilot pressure adjustment step 1b has been completed.  b. Adjust the screw on the conveyor chain take up pressure reducing/relieving valve until the pressure reaches the setting specified on the hydraulic schematic.

______________________________________________________________ A6474X337 VLSS/0 5.179

Adjustment procedures ________________________________________ Directional control valve pressure adjustments (main control valve and cutter head) Each valve section has two (2) working port reliefs except for the gathering head section. When the handle is pulled (spool in), oil is directed to the work port and relief closest to the handle; this is “A” port. When the handle is pushed in (spool out), oil is directed to the work port and relief farthest from the handle; this is ‘B” port.

Note: Push and pull directions are based on the operator standing outboard and the handle facing inboard.

WARNING! Always allow cylinder functions to bottom out (stop moving) before adjusting any pressure. Pressure adjustments will only be accurate when the cylinder is in this condition.

Main control valve (MCV) adjustment

CAUTION! Do not adjust the main inlet relief over 207 bar (3,000 psi). Destruction of the valve bank and the main pump could result.

CAUTION! Always be alert for any unintended machine movement.

IMPORTANT! Reference the Hydraulic section in this chapter for individual circuit information. Always refer to the hydraulic schematic in your Bucyrus parts manual for your miner.

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

_________________________________________________________________ 5.180 Bucyrus – Model 30M4-NP Continuous Miner

© Bucyrus

IMPORTANT! The main inlet relief is set higher than the port reliefs and will only relieve if a spike occurs in the system or if the port relief does not function properly. This provides protection of the main pump section, A2.

_______________________________________ Adjustment procedures

© BUCYRUS

To properly adjust any relief valve, the hydraulic system must be “dead headed”. Dead heading MCV functions is achieved by actuating a cylinder function and allowing it to travel to its full stroke position (either extended or retracted). To set the main system relief, it is recommended that the stabilizer shoe cylinder be extended until it is dead headed. Since the stabilizer section of the main control valve is equipped with a port relief in the extend circuit, the port relief must be temporarily adjusted to a pressure setting higher than the main relief.

This procedure is described in detail below. Caution must be exercised when performing this procedure with particular attention being paid to the following: ■

The procedure will raise the machine off the ground. Be careful to keep body parts clear from under the machine while it is raised off the ground.

■

During the adjustment procedure, pump output pressure and flow will be relieved past either the main relief or the stabilizer extend port relief which will cause rapid heating of the hydraulic oil. Preparation should be made to perform the adjustment procedure efficiently and in a relatively short period off time. It may be necessary to wait several minutes between adjustment periods.

■

It is critical that the stabilizer extend port relief valve be adjusted back to its proper setting after the main relief is adjusted. This procedure is described in detail below.

MCV Main inlet relief adjustment  Remove the protective cap on the near port relief (stab shoe down) of the stabilizer working section and loosen the nut on the adjusting screw. Turn the adjusting screw in all the way.  Loosen the nut on the main inlet relief cartridge. Turn the main inlet relief adjusting screw two turns clockwise.  Start the pump (see Start up procedure in this chapter) and activate the stabilizer shoe down function. This will raise the back portion of the machine off the ground.

WARNING! Keep body parts clear of machine while in raised position or serious injury could result.  With the stabilizer shoe down function bottomed out, turn the main relief cartridge adjusting screw in (clockwise) until a pressure of 207 bar (3,000 psi) is obtained.  With the stabilizer shoe function in the neutral position, hold the main relief cartridge screw in place and tighten the nut to lock the screw in place. Check the pressure setting to verify that the screw was not moved while tightening the nut.  Adjust the stabilizer shoe down port relief (see Port relief adjustment procedure in this chapter).

______________________________________________________________ A6474X337 VLSS/0 5.181

Adjustment procedures ________________________________________ Note: The pressure settings given in this manual are typical. Always refer to the schematic and/or parts book for your machine.

Port relief valve adjustment - Main control valve Port relief valves are functional when operating the circuit in which they are installed. As the particular function is activated and the pressure reaches the adjusted setting, the port relief will relieve excessive pressure to the tank cavity within the valve bank, preventing damage to the circuit.

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

If the correct pressure reading is not obtained as noted in Items 1 through 4 below, the port relief for that function must be adjusted.

The adjustment procedure for each port relief is the same and is:  Remove the protective cap on the port relief and loosen the nut on the adjusting screw.

 Once the correct pressure reading is obtained, return the function to the neutral position, hold the screw in place, and tighten the lock nut. Check the pressure reading to ensure that the screw did not turn while the lock nut was being tightened.

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

Pressure settings 1. Conveyor raise/lower port relief  Activate the conveyor raise circuit to fully raise the conveyor.

The main control valve pressure gauge should read 145 bar (2,100 psi).  Activate the conveyor lower circuit to fully lower the conveyor.

The main control valve pressure gauge should read 27 bar (400 psi).

Note: Be sure that the ball valve is closed on the tank oil fill part of this circuit.

_________________________________________________________________ 5.182 Bucyrus – Model 30M4-NP Continuous Miner

© Bucyrus

 Turn the port relief screw in (clockwise) to increase pressure and out (counter-clockwise) to decrease pressure.

_______________________________________ Adjustment procedures 2. Conveyor swing port relief  Activate the conveyor swing left circuit to fully swing the conveyor to the left. The main control valve pressure gauge should read 124 bar (1,800 psi).  Activate the conveyor swing right circuit to fully swing the conveyor to the right. The main control valve pressure gauge should read 124 bar (1,800 psi).

3. Stabilizer shoe port relief  Activate the stabilizer shoe raise circuit to fully raise the stabilizer shoe. The main control valve pressure gauge should read 83 bar (1,200 psi).  Activate the stabilizer shoe lower circuit allow to fully lower the stabilizer shoe. The main control valve pressure gauge should read 172 bar (2,500 psi).

4. Gathering head port relief

© BUCYRUS

 Activate the gathering head raise circuit to fully raise the gathering head. The main control valve pressure gauge should read 117 bar (1,700 psi).  If 117 bar (1,700 psi) is not obtainable, check that the relief in the gathering head float valve that is stamped “CR” is set to 124 bar (1,800 psi) (see Gathering head raise/hold/float-lower circuit in the Hydraulic section of this chapter).

Cutter head directional control valve pressure adjustment  Activate the cutter head raise circuit to fully raise the cutter head.

The main control pressure gauge should read 3,000 psi.  Activate the cutter head lower circuit to fully lower the cutter head and raise the front of the machine off the ground. The main control pressure gauge should read 3,000 psi. Note that you must push in on the selector valve of the anti-chatter/maintenance valve to get full reading.

______________________________________________________________ A6474X337 VLSS/0 5.183

Adjustment procedures ________________________________________ Note: Refer to Main Control Valve pressure adjustment procedures for general instructions on main inlet and port relief adjustment methods.

To properly adjust any relief valve, the hydraulic system must be “dead headed”. Dead heading is achieved by actuating a cylinder function and allowing it to travel to its full stroke position (either extended or retracted). The pressure in the cutter head portion of the cutter head/ cooling circuit is controlled by the relief valve located at the main inlet of the manually controlled, pilot operated cutter head directional control valve.

 Since the port reliefs of the cutter head raise and lower circuits are set at a pressure ABOVE the main inlet relief setting (typically 206 bar (3000 psi)), the main inlet relief must be temporarily adjusted to a slightly higher pressure (typically 220 bar (3200 psi)) by turning the screw on the main inlet clockwise. Caution must be exercised when performing this procedure with particular attention being paid to the following: ■

The procedure could raise the machine off the ground. Be careful to keep body parts clear from under the machine while it is raised off the ground.

■

During the adjustment procedure, pump output pressure and flow will be relieved past either the main inlet relief or the cutter head raise/lower port reliefs which will cause rapid heating of the hydraulic oil. Preparation should be made to perform the adjustment procedure efficiently and in a relatively short period off time. It may be necessary to wait several minutes between adjustment periods.

■

It is critical that the cutter head main inlet relief valve be adjusted back to its proper setting after the main relief is adjusted (see Cutter head port reliefs, as follows).

_________________________________________________________________ 5.184 Bucyrus – Model 30M4-NP Continuous Miner

© Bucyrus

 Slowly lower the cutter head until it touches the ground. To deadhead this circuit, continue to lower the cutter head against the ground. The back pressure created by the anti-chatter/ maintenance section of the multipurpose valve should prevent the machine from raising off of the ground (jack-knifing). In this condition, the relief valve located at the main inlet of the manuallycontrolled, pilot-operated cutter head directional control valve can be adjusted to match the pressure specified on the system schematic (typically 193 bar (2800 psi)).

_______________________________________ Adjustment procedures Cutter head port reliefs Note: Refer to the Main Control Valve pressure adjustment procedures for general instructions on port relief adjustment methods.   Activate the cutter head raise circuit to fully raise the cutter head.

The cutter head pressure gauge should read 206 bar (3,000 psi).  Activate the cutter head lower circuit to slowly lower the cutter head against the ground. Fully lower the cutter head against the ground.

The cutter head pressure gauge should read 206 bar (3,000 psi).  Readjust the cutter head main inlet valve to 193 bar (2800 psi) as described above.

Multipurpose Valve Adjustments

© BUCYRUS

The multipurpose has three distinct sections controlling the following functions: ■

Anti-chatter/maintenance (shear down) pressure

■

Gathering head float/relief pressure

■

Conveyor chain take up pressure

The adjustment procedures for these functions are as follows: IMPORTANT! Reference the Hydraulic section in this chapter for individual circuit information. Always refer to the hydraulic schematic in your Bucyrus parts manual for your miner.

Anti-chatter/maintenance (shear down) pressure  To adjust the resistance to a free falling cutter head:  Loosen the nut on the Sun counterbalance valve on the antichatter/maintenance section of the multipurpose valve and turn the screw using an Allen wrench. To increase the resistance (back pressure), turn the screw clockwise. To decrease the resistance, adjust the screw counterclockwise.  Raise the cutter head to its fully raised position. While lowering the cutter head, the “CH DOWN” pressure gauge displays the pressure setting of the counterbalance valve. This back pressure should be kept high enough to prevent the cutter head from chattering (bouncing) during the lower cycle but low enough to allow free movement of the cutter head. This setting is typically around 83 bar (1200 psi).

______________________________________________________________ A6474X337 VLSS/0 5.185

Adjustment procedures ________________________________________ Gathering head float/relief pressure  Remove the hex socket head plugs on the counterbalance valve (VR) and relief valve (CR) located in the gathering head float/relief section of the multipurpose valve. To increase the pressure on these valves, use an Allen wrench to turn the screw clockwise. To decrease the pressure on these valves, turn the screw counterclockwise. Start off with both of these valves at a low pressure setting.  To adjust the gathering head float relief valve (VR):  Eenergize the gathering head raise solenoid (or move the valve handle to the gathering head raise position).  Increase the pressure setting on the gathering head relief valve until the gathering head responds in a crisp manner and is fully extended. The gathering head must be able to maintain its raised position when the telescopic cylinder is fully extended and the gathering head section of the MCV is in the hold (neutral) position.



Energize the gathering head float solenoid (or move the handle to the gathering head float position). To decrease the speed at which the gathering head floats to the ground, increase the pressure setting on the gathering head counterbalance valve (CR). To increase the speed at which the gathering head floats to the ground, decrease the pressure setting on the gathering head counterbalance valve (CR). This back pressure also prevents the pan from digging into the ground during tramming/operation. Adjusting this valve requires a compromise between float speed and the tendency of the pan to dig into the ground.

Conveyor chain take up pressure See Pilot Pressure Adjustment Procedure in this section. To bleed off any pressure in this circuit, open the needle valve to connect the cylinder extend port to tank.

_________________________________________________________________ 5.186 Bucyrus – Model 30M4-NP Continuous Miner

© Bucyrus

 The gathering head float function is adjusted with the gathering head cylinder in its fully extended position. From this position:

_______________________________________ Adjustment procedures Tram track adjustment  1. Lower the conveyor tail section until it is level with the floor.  2. Raise the gathering head and cutter head and block both assemblies following standard blocking procedures.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all blocking devices.  3. Lower the gathering head and cutter head onto the blocking so that the front end of the miner lifts off the floor.  4. Extend the stabilizer completely so that the rear end of the miner lifts off the floor.  5. Securely block under the machine. The machine must be securely supported off the ground with the tram track free to turn.

© BUCYRUS

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load of all blocking devices.  6. Raise the stabilizer, gathering head, and cutter head assemblies so that the weight of the miner rests on the blocking.  7. Disconnect the trailing cable to de-energize the miner. Follow all mine lockout/tagout regulations.

WARNING! Follow all mine lockout/tagout regulations and procedures. Failure to do so could result in machine damage or serious injury or death to personnel.  8. Double check the tractor frame support blocking now that the weight of the tractor frame is completely upon it.  9. Evaluate the tram track for proper tension (Fig. 123). The tram track is at the proper tension when it hangs approximately 64 to 89 mm (2-1/2 to 3-1/2 inches) from the bottom wear shoes when the tractor frame is blocked off the floor. Using this evaluation, determine whether step 13, 14, or 15 provides the appropriate sub-procedure to correct improper track tension.

Fig. 123: Tram track adjustment Bottom of tractor wear shoe

64 to 90 mm gap (2-1/2 to 3-1/2 inches)

Top of tram track

______________________________________________________________ A6474X337 VLSS/0 5.187

Adjustment procedures ________________________________________

  10. Locate the front idler take-up jack grease fitting and attach the grease gun to the fitting (Fig. 124).  11. If the tram track tension is too tight, readjust the idler position using the following steps: ■

Pump grease into the take-up jack to extend the cylinder and remove pusher plate pressure on the idler shims.

■

Remove one or more idler adjustment shims from the idler slide channel.

■

Open the pressure release valve for the front idler take-up jack and allow the jack to contract. The pusher plate will slide backwards until it is stopped by the remaining idler shims.

■

Pump grease into the idler take-up jack to extend the cylinder, move the idler assembly forward and tighten the tram track until it is at the correct tension. The tram track is at the proper tension when it hangs 64 to 89 mm (2-1/2 to 31/2 inches) from the bottom wear shoes when the tractor frame is blocked off the floor.

■

Pump grease into the idler take-up jack to extend the cylinder, move the idler assembly forward and tighten the tram track until it is at the correct location. The tram track is at the proper tension when it hangs 64 to 89 mm (2-1/2 to 31/2 inches) from the bottom wear shoes when the tractor frame is blocked off the floor.

■

Insert shims (Fig. 124) into the idler slide channel until the space between the tractor frame and the pusher plate is filled.

■

Open the pressure release valve for the front idler take-up jack and allow the cylinder to contract. The idler adjustment shims will keep the idler stationary and the track tensioned.

■

Evaluate the resulting track tension and repeat these steps until the track reaches proper tension.

_________________________________________________________________ 5.188 Bucyrus – Model 30M4-NP Continuous Miner

© Bucyrus

 12. If the tram track is too loose, readjust the idler position using the following steps:

_______________________________________ Adjustment procedures

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

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

Fig. 124: Tram track adjustment Crawler chain take-up lubrication

Pressure relief valve

© BUCYRUS

Take-up cylinder

Shims

Idler assembly

______________________________________________________________ A6474X337 VLSS/0 5.189

Adjustment procedures ________________________________________

  13. If the tram track tension is still too loose when the entire 5” shim set is inserted into the idler slide channel, re-adjust the idler position after removing a tram track link using the following steps:  Pump grease into the take-up jack to extend the cylinder and remove the pusher plate pressure on the idler shims.  Remove all of the idler adjustment shims from the idler slide channel.  Open the pressure release valve for the front idler take-up jack and allow the cylinder to contract.  The tram track tension should now be reduced and separation of the tram track will be easier.  Locate a tram track link near the tram idler.  Using the hammer and punch, remove the four roll pins of the two tram track pins (Fig. 125) that secure the tram track link to the track.

 Store the tram track link, one of the tram track pins and two of the roll pins in a safe place.  Connect the two ends of the tram track and using the hammer and punch, secure the two end links together with the remaining tram track pin.  Using the hammer and punch, secure the tram track pin between the two links with the remaining two roll pins.  Pump grease into the idler take-up jack to extend the cylinder, move the idler assembly forward and tighten the tram track until it is at the correct tension. The tram track is at the proper tension when it hangs approximately 64 to 89 mm (2-1/2 to 3-1/2 inches) from the bottom wear shoes when the tractor frame is blocked off the floor.  Insert shims into the idler slide channel until the space between the tractor frame and the pusher plate is filled.  Open the pressure release valve for the front idler take-up jack and allow the cylinder to contract. The idler adjustment shims will keep the idler stationary and the track tensioned.  The idler adjustment shims will keep the idler stationary and the track tensioned.  Evaluate the resulting track tension and repeat until the track reaches proper tension. _________________________________________________________________ 5.190 Bucyrus – Model 30M4-NP Continuous Miner

© Bucyrus

 Using the hammer and punch, remove the tram track pins to disconnect the link from the track. Remove the disconnected link.

_______________________________________ Adjustment procedures Fig. 125: Tram track adjustment Pad

© BUCYRUS

Track retention pin

Capscrew and nut

 14. When the tram track has been adjusted to the proper tension, remove the grease gun from the idler take-up jack grease fitting.  15. Open pressure release to take pressure off of take-up cylinder.  16. Connect the trailing cable to energize the miner.  17. Raise the tractor frame off the blocking by lowering the stabilizer and gathering head and cutter head assemblies.  18. Carefully remove the support blocking from under the tractor frame.  19. Lower the tractor frame onto the floor by raising the stabilizer and gathering head and cutter head assemblies.  20. Carefully remove the blocking from underneath the raised stabilizer, gathering head, and cutter head assemblies.

______________________________________________________________ A6474X337 VLSS/0 5.191

Adjustment procedures ________________________________________ Tail shim adjustment As the conveyor wears the tail section may sag relative to the conveyor front section. The conveyor has been designed to allow correction of the sag by adding shims.  1. Lower the cutter head and gathering head assemblies until they touch the floor.  2. Position the conveyor tail section directly behind the miner and raise it to its highest position.  3. Insert blocking under the tail section and lower the tail onto the blocking. The conveyor should be at an angle with the rear end of the tail section slightly higher than the front.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all blocking devices.  4. Insert blocking between the top of the tractor frame and the bottom of the conveyor, leaving about 51 mm (2 inches) of space between the blocking and the conveyor bottom.

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

6. Loosen the socket head capscrews that secure the shims between the shim retainer and the conveyor lower pivot plate (Fig. 126).

Fig. 126: Shim removal Socket head capscrews

Lower pivot plate

Shim retainer

Shims

_________________________________________________________________ 5.192 Bucyrus – Model 30M4-NP Continuous Miner

© Bucyrus

 5. Disconnect the trailing cable to de-energize the miner. Follow all mine lockout/tagout regulations.

_______________________________________ Adjustment procedures

  7. Connect the trailing cable to energize the miner.

WARNING! The following steps releases the shims, which will fall free. Watch out for falling shims when loosening the capscrews.  8.

Slowly lower the conveyor slightly so that the front section rests on the frame support blocking. The slotted shims will now fall free.

 9.

Disconnect the trailing cable to de-energize the miner. Follow all mine lockout/tagout regulations.

WARNING! Follow all mine lockout/tagout regulations and procedures. Failure to do so could result in machine damage or serious injury or death to personnel.  10. Replace the removed shims (Fig. 127) and add the number of shims required to level the conveyor front and tail sections.  11. Tighten the socket head capscrews.

© BUCYRUS

Fig. 127: Tail shim adjustment

Socket head capscrews

Shim retainer

Shims

Lower pivot plate

 12. Connect the trailing cable to energize the miner.  13. Raise the conveyor tail from the blocking.  14. Remove both sets of blocking and lower the conveyor tail until it is level with the floor.  15. Check the gap and alignment at the juncture of the conveyor front and tail sections for alignment. If the sections are not horizontally aligned, then add or subtract shims as required.

______________________________________________________________ A6474X337 VLSS/0 5.193

Adjustment procedures ________________________________________ Fig. 128: Tail shim adjustment Correct gap and alignment Conveyor tail section

Conveyor front section

Add shims Conveyor tail section

Conveyor front section

Remove shims Conveyor tail section

Conveyor front section

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all blocking devices.  17. Securely retighten the socket head capscrews.

_________________________________________________________________ 5.194 Bucyrus – Model 30M4-NP Continuous Miner

© Bucyrus

 16. Re-insert the blocking between the top of the tractor frame and the bottom of the conveyor following mine standard blocking procedures.

_______________________________________ Adjustment procedures Conveyor chain tension adjustment The conveyor chain is tensioned with a hydraulic take-up cylinder. If the chain tension is not being maintained, then: 1. The conveyor chain take-up valve may need to be adjusted. See the Conveyor chain take-up valve adjustment procedure (Pilot/ auxiliary pump circuit relief valve adjustments) in this section. If the valve adjustment is correct, then

© BUCYRUS

2. The cylinder may be fully extended and, therefore, unable to take up any more chain slack. Remove a link from the chain or replace chain as necessary.

______________________________________________________________ A6474X337 VLSS/0 5.195

Replacement of wear parts _____________________________________ Instructions on the replacement of wear parts It is essential that wear parts be replaced before reaching the lowest wear limit. To ensure that this happens, wear parts must be inspected at regular intervals.

CAUTION! Disassembly and assembly procedures listed in this section are specialized and, as such, should only be performed by qualified personnel.

Cutter head (boom) assembly The cutter head assembly (Fig. 129) is powered by two electric motors mounted on each side of the cutting head support frame. Each motor drives through a torque limiting clutch to an input gear case, which in turn drives a common shaft, allowing the two drive motors to share the cutting load. Each input gear case is removable as a separate unit from the main cutting head gear case. The cutting head is attached to the main frame at a heavy-duty pivot. Two hydraulic cylinders raise and lower the cutting head.

The cutter head assembly can be removed as an assembly or as individual components. © BUCYRUS

Fig. 129: Cutter head assembly

Boom

Input cutter gear case (typical both sides)

Boom pivot pin (typical both sides)

Shear cylinder (typical both sides)

Torque limiting clutch (typical both sides)

Cutter head motor (typical both sides)

Center drum

End drum

Note: Cutter head covers pictured are typical for a 30M4 series continuous miner.

Actual covers may differ.

_________________________________________________________________ 5.196 Bucyrus – Model 30M4-NP Continuous Miner

____________________________________ Replacement of wear parts Cutter head assembly removal and installation cutter head assembly removal

To remove the cutter head assembly (Fig. 130):  Attach an appropriate lifting device to the boom assembly. Take up the slack in the lifting device so that the weight is supported as the assembly is unpinned from the miner.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all lifting and blocking devices and keep a safe distance from suspended loads.  Lower the gathering head and the cutter head to the floor and position the conveyor tail section level with the floor.  Disconnect and lock out the electrical power to the miner. Follow all applicable regulations regarding lockout/tagout procedures.

WARNING! Failure to follow all applicable regulations regarding lockout/ tagout procedures may result in machine damage or serious injury or death of personnel.

© BUCYRUS

 Disconnect and tag the power cables from the motors. Be sure to tape the power cables as power will be restored to the machine.  Disconnect, tag, and cap the lubrication and hydraulic lines going to the cutting head.

WARNING! Never disconnect a hydraulic hose if the circuit is pressurized or if there is a load on the circuit. If a hose is disconnected while the circuit is pressurized or under load, the load will fall. Machine damage or serious injury or death to personnel may result.  Remove the two (2) boom pivot pins.  Remove the two (2) socket head cap screws from the retaining plate on the right and left pivot pins and remove the retaining plate.  On either side, force the main pivot pin inward from the outboard side, using the two (2) tapped jack screw holes, if necessary.  Connect electrical power to the machine.  Extend the shear cylinders to push the boom pivots out of their tractor frame clevises.

______________________________________________________________ A6474X337 VLSS/0 5.197

Replacement of wear parts _____________________________________  Block the boom and shear cylinders to keep them stationary during pin removal.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all lifting and blocking devices and keep a safe distance from suspended loads.  Disconnect and lock out the electrical power to the miner. Follow all applicable regulations regarding lockout/tagout procedures.

WARNING! Failure to follow all applicable regulations regarding lockout/ tagout procedures may result in machine damage or serious injury or death of personnel.  Remove the shear cylinder boom clevis pins.  Remove the two (2) socket head cap screws and lock washers that secure the cylinder pin keeper plates on each side of the machine.  Insert a slide hammer into the threaded hole in the end of the pin and remove the pin from each side of the machine.

 Retract the shear cylinders to pull their bearings free from the boom clevises.  Raise the rear of the boom assembly until it is above the top edge of the gathering head backboard.  Slowly tram the machine backwards until the cutter boom pivot points clear the front of the gathering head.

Fig. 130: Cutter head assembly Shear cylinder clevis pin (2)

Cutter boom

Cutter boom pivot (2) (not shown)

Shear cylinder (2)

_________________________________________________________________ 5.198 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS

 Connect electrical power to the machine.

____________________________________ Replacement of wear parts cutter head assembly installation

To install the cutter head assembly (Fig. 130):  Slowly tram the machine forward towards the raised end of the boom until the pivot pins clear the gathering head backboard.  Lower the boom pivot points until the shear cylinders can reach their clevises. Block the boom to keep it in a secure position.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all lifting and blocking devices and keep a safe distance from suspended loads.  Extend the shear cylinders until the cylinder end bearings can be inserted into the cutter boom clevises.  Disconnect and lock out the electrical power to the miner. Follow all applicable regulations regarding lockout/tagout procedures.

WARNING! Failure to follow all applicable regulations regarding lockout/ tagout procedures may result in machine damage or serious injury or death of personnel.

© BUCYRUS

 Install the shear cylinder boom clevis pin on each side of the machine.  Position the right shear cylinder end bearing in the boom clevis.

WARNING! Do not use your fingers to check the alignment of the rod bearing in the clevis. Shifting of the parts could result in serious injury.   Insert the cylinder end pin through the aligned clevis bushing and cylinder end bearing.   Insert the keeper plate and secure to the boom clevis with the two (2) socket head cap screws lock washers.  Connect electrical power to the machine.  Once the shear cylinders are secured to the cutter boom remove the boom blocking to allow boom movement.  Retract the shear cylinders to pull the cutter boom pivot points into position in the tractor frame boom pivot clevises.

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

______________________________________________________________ A6474X337 VLSS/0 5.199

Replacement of wear parts _____________________________________  Install both cutter boom pivot pins.  Insert the main pivot pin from the inside toward the outboard side of the clevis.  Insert the retainer plate and secure with the two (2) socket head cap screws.  Disconnect and lock out the electrical power to the miner. Follow all applicable regulations regarding lockout/tagout procedures.

WARNING! Failure to follow all applicable regulations regarding lockout/ tagout procedures may result in machine damage or serious injury or death of personnel.  Connect the power cables and cooling cables to the cutter motors (see Cutter motor installation procedure in this chapter).  Connect all hydraulic and lubrication hoses.

© BUCYRUS

 Connect electrical power to the machine.

_________________________________________________________________ 5.200 Bucyrus – Model 30M4-NP Continuous Miner

____________________________________ Replacement of wear parts Shear cylinder assembly removal and installation shear cylinder removal

To remove a shear cylinder (Fig. 131):  Lower the gathering head until it touches the floor. Lower the conveyor tail section until it is even with the floor.  Raise the cutter head assembly and install the cutter boom safety supports (Fig. 131).  Support the shear cylinder so that when it is unpinned from the machine, it does not move.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all lifting and blocking devices.  Disconnect and lock out the electrical power to the miner. Follow all applicable regulations regarding lockout/tagout procedures.

© BUCYRUS

WARNING! Failure to follow all applicable regulations regarding lockout/ tagout procedures may result in machine damage or serious injury or death of personnel.  Remove the shear cylinder frame mounting pin:    Locate the shear cylinder retainer plate and pin inside the front cover in the crawler frame.   Remove the two (2) hex head bolts and lock washers that secure the cylinder pin keeper plate.  Disconnect and cap the grease line going to the pin.  Remove the grease fitting adapter from the end of the pin.  Insert a slide hammer into the threaded hole in the end of the pin and pull the pin.  Connect electrical power to the machine.  Retract the shear cylinder to pull the bearing free from the boom clevis.  Disconnect and lock out the electrical power to the miner. Follow all applicable regulations regarding lockout/tagout procedures.

WARNING! Failure to follow all applicable regulations regarding lockout/ tagout procedures may result in machine damage or serious injury or death of personnel.  Cycle the shear cylinder control lever several times to release hydraulic pressure from the shear cylinder.

______________________________________________________________ A6474X337 VLSS/0 5.201

Replacement of wear parts _____________________________________ WARNING! The following steps will disconnect the shear cylinder from the frame. The shear cylinder is extremely heavy. Make sure that it’s weight is supported and that the cylinder will not swing free or move. Failure to follow this warning may result in machine damage or in severe injury or death to personnel.   Open the front cover on the side of the cylinder by removing the two (2) socket head cap screws.  Disconnect and cap the hydraulic line to the shear cylinder.

WARNING! Never disconnect a hydraulic hose if the circuit is pressurized or if there is a load on the circuit. If a hose is disconnected while the circuit is pressurized or under load, the load will fall. Machine damage or serious injury or death to personnel may result.  Remove the shear cylinder boom clevis pin.  Remove the two (2) socket head cap screws and lock washers that secure the cylinder pin keeper plate.

 Insert a slide hammer into the threaded hole in the end of the pin and pull the pin.

_________________________________________________________________ 5.202 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS

 Remove the grease fitting adapter from the end of the pin.

____________________________________ Replacement of wear parts Fig. 131: Cutter head safety supports

© BUCYRUS

Cutter head safety support (typical both sides)

Cutter head safety support (typical both sides)

______________________________________________________________ A6474X337 VLSS/0 5.203

Replacement of wear parts _____________________________________ Fig. 132: Shear cylinder removal and installation

Shear cylinder frame mounting pin

Note: Cutter head covers pictured are typical for a 30M4 series continuous miner. Actual covers may differ.

_________________________________________________________________ 5.204 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS

Shear cylinder boom clevis pin

____________________________________ Replacement of wear parts shear cylinder installation

To install a shear cylinder (Fig. 133):  Attach an appropriate lifting device to the shear cylinder and position the cylinder so that the cylinder clevis is aligned in the mounting clevis on the cutter head.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all lifting and blocking devices.  Install the boom clevis pin. 

  Install the pin from the outside, toward the inside, of the machine with the threaded hole end of the pin toward the outside of the machine.

IMPORTANT! The pin should be inserted so that it’s retaining channel remains outside the bushing.   Insert the pin keeper plate and secure with two (2) socket head cap screws and lock washers.   Install the grease fitting into the end of the pin.

© BUCYRUS

 Attach the hydraulic hoses to the cylinder.  Connect the trailing cable to energize the machine.  Slowly extend the shear cylinder so that the rod clevis can be inserted into the frame mounting clevis.  Disconnect and lock out the electrical power to the miner. Follow all applicable regulations regarding lockout/tagout procedures.

WARNING! Failure to follow all applicable regulations regarding lockout/ tagout procedures may result in machine damage or serious injury or death of personnel.  Install the frame clevis pin. 

  Install the pin from the outside, toward the inside, of the machine so that the threaded hole end is toward the outside of the machine.

IMPORTANT! The pin should be inserted so that it’s retaining channel remains outside the bushing.   Insert the pin keeper plate and secure with two (2) hex head bolts and lock washers.   Install the grease fitting into the end of the pin.  Attach the grease line to the grease fitting in the pin.  Close and secure the front cover.

______________________________________________________________ A6474X337 VLSS/0 5.205

Replacement of wear parts _____________________________________ Center cutter drum removal and installation center cutter drum removal

To remove the center cutter drum (Fig. 133):  Lower the gathering head until it touches the floor. Lower the conveyor assembly until it is level with the floor.  Slowly rotate the cutter head until on of the center drum seams appears directly in front and one appears directly in the rear of the cutter head.  Lower the cutter head assembly until it is resting on the floor.  Disconnect and lock out the electrical power to the miner. Follow all applicable regulations regarding lockout/tagout procedures.

WARNING! Failure to follow all applicable regulations regarding lockout/ tagout procedures may result in machine damage or serious injury or death of personnel.

 Attach a lifting device to the top half of the center drum and lift the it off of the assembly. It may be necessary to use a pry bar or other force to break the seal between the top and bottom halves of the center drum before the top half can be lifted off.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all lifting and blocking devices and stay clear of suspended loads.  Remove the four (4) alignment keys from the bottom half of the center drum and store for use in reassembly.  Connect the trailing cable to energize the machine.  Slowly raise the cutter head assembly until it is clear of the bottom half of the center drum.  Slowly tram the miner backwards away from the bottom half of the center drum. 



_________________________________________________________________ 5.206 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS

 Remove the twenty-four (24) hex head bolts from that secure the two halves of the center drum to each other. Make sure to collect the bolts, the forty-eight (48) flat washers, and the twenty-four nuts for use in reassembly.

____________________________________ Replacement of wear parts Fig. 133: Center drum removal and installation

Center drum seam

© BUCYRUS

Hex head bolts (24)

Center drum, upper half

Alignment keys (4)

Center drum, lower half

______________________________________________________________ A6474X337 VLSS/0 5.207

Replacement of wear parts _____________________________________ center cutter drum installation

To install the center cutter drum (Fig. 134):  Place the four (4) alignment keys into the keyway slots around the outer edges of the bottom half of the center drum.  Slowly rotate the cutter head until the center drum drive keys are positioned directly on top and bottom of the cutter head assembly.  Slowly lower the cutter head assembly onto the bottom half of the center drum.  Disconnect and lock out the electrical power to the miner. Follow all applicable regulations regarding lockout/tagout procedures.

WARNING! Failure to follow all applicable regulations regarding lockout/ tagout procedures may result in machine damage or serious injury or death of personnel.  Attach a lifting device to the upper half of the center drum.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all lifting and blocking devices and stay clear of suspended loads.  Lower the upper half of the center drum onto the cutter head assembly, making sure that the keyways align with the keys on the bottom half.  Check that the upper half of the center drum is fully seated on the bottom half. Using a rod, check the bolt holes for alignment. Adjust the position of the upper half of the center drum as necessary to align the bolt holes. 

 Install the twenty-four (24) hex head bolts that secure the two halves of the center drum to each other, placing a flat washer under the head of the bolt and between the bolt and the nut. Install the bolt heads in the direction of rotation, if lacing permits.  Torque the bolts appropriately using the pattern shown in Fig. 134.

Fig. 134: Center drum bolt torque pattern

_________________________________________________________________ 5.208 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS



____________________________________ Replacement of wear parts End drum removal and installation end drum removal

To remove an end drum (Fig. 135):  Place the miner so that the cutting head is easily accessible and there is side clearance to pull the end drum off of the cutting head.  Disconnect and lock out the electrical power to the miner. Follow all applicable regulations regarding lockout/tagout procedures.

WARNING! Failure to follow all applicable regulations regarding lockout/ tagout procedures may result in machine damage or serious injury or death of personnel.  There may be an optional cap on the end of the drum. If the end cap is present, remove the eight (8) socket head cap screws that secure it to the drum. Apply heat as necessary to liquify Loctite used when the cap screws were installed.  Using the four puller holes in the end cap and four of the eight socket head screw just removed, remove the end cap.

© BUCYRUS

CAUTION! If the assembly is seized, it may be necessary to pry on the edges.

Care must be taken not to damage the o-ring or its seal land.  Attach a lifting device to the end drum and apply tension so that the weight of the drum is supported by the lifting device.

WARNING! You can be seriously injured or killed by falling loads. Observe the safe working load limits of lifting or blocking devices and keep a safe distance from suspended loads.  Loosen the eighteen (18) socket head cap screws that secure the wedge block assembly and the drum to the cutting head hub.  Match mark both the end drum and the cutting head hub so that the cutting bit arrangement is not disturbed upon reassembly.  Grind the weld off and remove each key retainer plate from the end drum.  Slowly pull the end drum off of the main assembly, maneuvering it away from the miner.

______________________________________________________________ A6474X337 VLSS/0 5.209

Replacement of wear parts _____________________________________

© BUCYRUS

Fig. 135: End drum removal and installation

Socket head cap screw (8) Key plate retainer (2) Puller hole (4)

End cap (optional)

_________________________________________________________________ 5.210 Bucyrus – Model 30M4-NP Continuous Miner

____________________________________ Replacement of wear parts end drum installation

To install an end drum (Fig. 135)  Disconnect and lock out the electrical power to the miner. Follow all applicable regulations regarding lockout/tagout procedures.

WARNING! Failure to follow all applicable regulations regarding lockout/ tagout procedures may result in machine damage or serious injury or death of personnel.  Attach a lifting device to the end drum.

WARNING! You can be seriously injured or killed by falling loads. Observe the safe working load limits of lifting or blocking devices and keep a safe distance from suspended loads.   Using the match marks made when the end drum was removed, align the end drum and the cutting head hub.  Install the two (2) keys and perform an all-around weld to secure.

© BUCYRUS

 Install the eighteen (18) socket head cap screws to secure the wedge block assembly and the drum to the cutting head hub and torque appropriately.  Coat the threads of the eight socket head cap screws with Loctite 242 (blue) and install the eight socket head cap screws to secure the end cap. Torque appropriately.

______________________________________________________________ A6474X337 VLSS/0 5.211

Replacement of wear parts _____________________________________ Cutter drum drive motor removal and installation cutter drum drive motor removal

To remove the cutter drum drive motor (Fig. 136):  Lower the gathering head until the front of the pan rests on the floor.  Lower the cutter head to a comfortable working height. Block it in this position under the support frame.

WARNING! You can be seriously injured or killed by falling loads. Observe the safe working load limits of all lifting and blocking devices.  Disconnect and lock out the electrical power to the miner. Follow all applicable regulations regarding lockout/tagout procedures.

WARNING! Failure to follow all applicable regulations regarding lockout/ tagout procedures may result in machine damage or serious injury or death of personnel.

 Remove the hex head capscrews that secure the side motor cover and remove the cover to expose the side of the motor and the motor’s junction box.

Fig. 136: Cutter drum drive removal and installation

Side cover

Top cover

_________________________________________________________________ 5.212 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS

 Remove the hex head capscrews that secure the top mounting bolts and bottom motor covers and remove the cover to expose the motor.

____________________________________ Replacement of wear parts

  Remove the hex head capscrews that secure the junction box cover and then remove the cover Fig. 136)  Locate the three (3) lug power connections.

IMPORTANT! Before detaching these three (3) lugs, tag the wires to make reconnection easier.  Tag the lugs for correct reconnection and then remove the hex head capscrews that secure the three power cable lugs to the three motor lugs.  Remove the socket head capscrews that secure the global plug to the junction box (Fig. 136).  Slide the global plug out of the junction box. At this point, the power cable should be completely disconnected from the motor.

© BUCYRUS

WARNING! Power should not be reconnected to the miner while the motor power cable is disconnected. Damage to the miner or personal injury or death could result.  To prevent damage to the motor power cable lugs and gland assembly, cover the power cable and secure it to the miner in a safe location.   Disconnect, tag, and cap the two (2) cooling hoses from the motor cooling fittings (Fig. 137).  Remove the two cooling fittings from the motor and store for reuse during installation.  Plug the motor cooling ports to prevent contamination.  Disconnect, tag, and cap the motor bearing grease lines.  Attach an appropriate lifting device to the motor and take up the slack so that the weight of the motor is resting on the lifting device.

WARNING! Always observe the safe working load limits of all lifting devices.

You could be seriously injured or killed by falling loads.  Remove the hex head bolts that secure the cutter motor clutch cover and then remove the clutch cover.  Remove the seal cap and internal retaining ring which restrains the motor input shaft. Remove the motor input shaft from the inside of the motor going into the input gear case.  Remove the motor mounting bolts and the rear support bracket.  Carefully lift motor out of the frame.

______________________________________________________________ A6474X337 VLSS/0 5.213

Replacement of wear parts _____________________________________

Clutch cover

Junction box cover

Mounting bolts

_________________________________________________________________ 5.214 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS

Fig. 137: Cutter drum drive motor removal and installation

____________________________________ Replacement of wear parts cutter drum drive motor installation

To install the cutter drum drive motor (Fig. 138): WARNING! Law requires that mining equipment electrical components must be inspected by a certified electrician before the equipment can be operated.

WARNING! This procedure involves attaching an electrical power cable to a motor. The trailing cable must be disconnected and locked and tagged out to safely perform this operation. Follow all Mine lockout/tagout procedures. Failure to do so may result in serious injury or death.  Block up the cutter head drum drive motor in position against the rear of the boom so that the motor’s mounting holes align with the boom’s motor mounting holes.

WARNING! Observe the safe working load limits of all lifting and blocking devices. You can be seriously injured or killed by falling loads.  Insert the mounting bolts to secure the motor to the boom. Torque appropriately.

© BUCYRUS

 Attach the rear mounting support bracket.  Install the two motor cooling fittings into the cooling ports on the motor.  Attach the cooling hoses to the fittings.  Remove the four (4) hex head capscrews that secure the junction box cover and then remove the junction box cover.  Insert the three lugs of the power cable (with gland and stuffing box already installed) into the motor’s junction box.  Tighten the two socket head capscrews to secure the gland to the junction box.  Inside the junction box, locate the motor’s lug connections.  Match the motor lugs with the corresponding power cable lugs.  Attach the first motor lug to its corresponding power cable lug by inserting a hex head capscrew through the motor lug, the power cable lug, a flat washer, and a lock washer. Secure the capscrew with a hex nut. Repeat for the other two lugs.  When all three connections have been secured, wrap each of the three connections with a layer of rubber tape, then a layer of black tape, and then a layer of glass tape.

______________________________________________________________ A6474X337 VLSS/0 5.215

Replacement of wear parts _____________________________________  Replace the junction box o-ring and cover and secure with the four hex head capscrews.

IMPORTANT! A certified electrician must inspect all work and check for permissibility.  Attach the grease lines to the grease fittings on the motor.  Insert the motor input shaft and then insert the retaining ring and seal cap.  Replace the clutch cover and secure with hex head capscrews.  Replace the top and bottom covers and secure with hex head capscrews.

© BUCYRUS

 Replace the side cover and secure with hex head capscrews.

_________________________________________________________________ 5.216 Bucyrus – Model 30M4-NP Continuous Miner

____________________________________ Replacement of wear parts cutter drum drive gear case removal

The cutter head gear case may be removed with cutter drum installed but it is easier with it removed.

To remove the cutter drum drive gear case (Fig. 138):  Disconnect and lockout the trailing cable. Follow all applicable regulatory lockout/tagout procedures.

WARNING! Failure to follow all regulatory lockout/tagout procedures may result in machine damage or serious injury or death of personnel.  Remove the cutter head center drum (see Center cutter drum removal procedure in this chapter).  Remove the cutter head end drums (see End drum removal procedure in this chapter).  Ensure that the cutter head assembly is adequately blocked.  Securely block the cutter head gear case so that it will not fall when it is unbolted from the frame.

© BUCYRUS

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

IMPORTANT! During the removal of the cap screws that secure the gear case to the frame, it may be necessary to adjust the blocking under the gear case. Ensure that the gear case is securely blocked at all times and that it does not shift as it is unbolted.  Remove the cover off of the clutch.  Remove the snap ring from the motor shaft and then pull the motor shaft out.   Carefully loosen and remove the forty (40) capscrews that secure the cutter head gear case to the cutter head support frame.  Connect the trailing cable to energize the miner.

WARNING! Stand clear of the miner and the gear case while tramming the miner. You could be seriously injured or killed by falling loads.

Do not attempt to start the cutter head motors. You could be seriously injured or killed.

CAUTION! Use care when tramming the miner away from the gear case.

While each cutter motor is supported by a bracket at the rear of the motor, excessive bumping could cause the motor to fall.  Slowly tram the miner away from the gear case. ______________________________________________________________ A6474X337 VLSS/0 5.217

Replacement of wear parts _____________________________________ Fig. 138: Cutter drum drive gear case removal and installation

© BUCYRUS

Mounting capscrew (40)

Cutter drum drive gear case

_________________________________________________________________ 5.218 Bucyrus – Model 30M4-NP Continuous Miner

____________________________________ Replacement of wear parts cutter drum drive gear case installation

To install the cutter drum drive gear case (Fig. 138):  Ensure that the gear case is securely blocked so that the miner can be trammed into position behind it.

WARNING! Observe the safe working load limits of all lifting and blocking devices. You can be seriously injured or killed by falling loads.  Slowly tram the miner into position behind the gear box.  Disconnect and lock out the electrical power to the miner. Follow all applicable regulations regarding lockout/tagout procedures.

WARNING! Failure to follow all applicable regulations regarding lockout/ tagout procedures may result in machine damage or serious injury or death of personnel.  Using a metal rod, check for alignment between the mounting holes on the miner and the mounting holes in the gear case.  Install the forty capscrews that secure the gear case to the miner.

Torque appropriately.

© BUCYRUS

 Insert the motor shaft and secure with the snap ring.  Replace the clutch cover.  Install the end drums (see End drum installation procedure in this chapter).  Install the center drum (see Center drum installation procedure in this chapter).

______________________________________________________________ A6474X337 VLSS/0 5.219

Replacement of wear parts _____________________________________ Gathering head assembly The gathering head assembly (Fig. 139) consists of the gathering pan, the continuous loading arms (CLAs), lift cylinders, and two drive motors connected to an input gear case through a torque shaft.

The gathering head can be removed as an assembly or as individual components.

© BUCYRUS

Fig. 139: Gathering head assembly

Foot shaft

Motor (behind cover)

Gathering pan

CLA

_________________________________________________________________ 5.220 Bucyrus – Model 30M4-NP Continuous Miner

____________________________________ Replacement of wear parts Gathering head assembly removal and installation gathering head assembly removal

To remove the gathering head assembly (Fig. 140):  Place the machine in a position where both sides in front of the crawlers are accessible.  Lower the gathering head until the pan rest on the mine floor.  Raise the cutter head and block it securely.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all lifting and blocking devices and keep a safe distance from suspended loads.  Disconnect and lock out the electrical power to the miner. Follow all applicable mine regulations regarding lockout/tagout procedures.

WARNING! Failure to follow all mine lockout/tagout procedures may result in machine damage or serious injury or death of personnel.

© BUCYRUS

 Remove the motor access cover on the side of the gathering head frame by removing the capscrews that secure it to the frame.  Wash motor compartment thoroughly for easier removal of motor.  Disconnect and tag the power cables to the gathering head motors.

Be sure to tape the power cables as power will be restored to the machine.  Disconnect, tag, and cap the cooling hoses going to the gathering head motors.  Disconnect the conveyor chain (see Conveyor chain removal procedure in this chapter). The chain does not have to be completely removed from the miner. After disconnecting the chain from the foot shaft, the top strand must be pulled back clear of the gathering head conveyor section. The bottom of the chain can be left where it is.  Securely block the gathering head frame. The gathering head frame must be blocked at the rear of the frame, as close to the pivot as possible, to prevent falling when the pivot pins are removed.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all lifting and blocking devices and keep a safe distance from suspended loads.  Support the gathering head raise cylinders.

______________________________________________________________ A6474X337 VLSS/0 5.221

Replacement of wear parts _____________________________________ NOTICE! The gathering head cylinders do not have to be removed from the frame. Rotate them away from the gathering head and securely fasten them to the main frame.   Remove the upper cylinder pins.  Remove the pivot pin retainer.  Force the gathering head hinge pin out from the outboard side going in. If the pin does not come out, check to see that support under the rear of the gathering head is adequate but is not forcing.  Reconnect the trailing cable to energize the miner.

WARNING! Do not attempt to start the cutter head or gathering head motors.

IMPORTANT! Make sure that the lower section of the conveyor chain is free of the foot shaft so that when the miner is trammed away from the gathering head, the chain will pull free of the return deck.

 Lower the cutting head to the floor.  Disconnect and lock out the electrical power to the miner. Follow all applicable mine regulations regarding lockout/tagout procedures.

WARNING! Failure to follow all regulatory lockout/tagout procedures may result in machine damage or serious injury or death of personnel.

_________________________________________________________________ 5.222 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS

 Slowly tram the miner away from the gathering head until the gathering head is clear and the conveyor chain is free.

____________________________________ Replacement of wear parts Fig. 140: Gather head assembly removal and installation

© BUCYRUS

Hinge pin

Motor access cover

______________________________________________________________ A6474X337 VLSS/0 5.223

Replacement of wear parts _____________________________________ gathering head assembly installation

To install the gathering head assembly (Fig. 140):  Reconnect the trailing cable to energize the miner.

NOTICE! When the gathering head was removed, the lower length of the conveyor chain was pulled free of the gathering head. This end of the conveyor chain must be brought forward when the miner is trammed to the gathering head.  Tram the miner to the gathering head frame. Using a puller cable or wire, feed the lower end of the conveyor chain through the gathering head return deck and up to the foot shaft.  Position the miner to align the pivots in the main frame with those on the gathering head.

DANGER! All personnel must stay clear of the miner while it is tramming and being aligned with the gathering head assembly. Standing under the cutter head or in the path of the miner while it is tramming may result in severe injury or death.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all lifting and blocking devices and keep a safe distance from suspended loads.  Disconnect and lock out the electrical power to the miner. Follow all applicable regulations regarding lockout/tagout procedures.

WARNING! Failure to follow all applicable regulations regarding lockout/ tagout procedures may result in machine damage or serious injury or death of personnel.  Coat the pivot pins and their bushings with grease to aid in installation.  Install both the right and left hand pivot pins. Be sure that the pivot bores in the gathering head and the main frame are aligned and that you do not damage the end of the pivot bushing during installation.  Position each pivot pin so that it is flush with the main frame bushing.  Insert the pivot pin retainer and secure with capscrews. Tighten the capscrews to the appropriate torque.

_________________________________________________________________ 5.224 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS

 Once the miner is aligned with the gathering head assembly, block the cutting head in its raised position.

____________________________________ Replacement of wear parts  Align the gathering head frame clevises with the gathering head rod end clevises. Install the upper cylinder pins through the clevises and secure.  Lubricate the cylinder and pivot pins.  Install the conveyor chain (see Conveyor chain installation procedure in this chapter).  Connect all cooling lines to the motors.  Connect the electrical leads to the motor.  Secure the motor access cover to the gathering head frame with the capscrews.

© BUCYRUS

 Check the oil levels in the gathering head pot cases and the gathering head input gear cases.

______________________________________________________________ A6474X337 VLSS/0 5.225

Replacement of wear parts _____________________________________ Gathering head motor removal and installation gathering head motor removal

To remove a gathering head motor (Fig. 141):  Lower the gathering head until the pan rests on the mine floor.  Raise the cutter head and block it securely.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all lifting and blocking devices and keep a safe distance from suspended loads.  Disconnect and lock out the electrical power to the miner. Follow all applicable regulations regarding lockout/tagout procedures.

WARNING! Failure to follow all applicable regulations regarding lockout/ tagout procedures may result in machine damage or serious injury or death of personnel.  Remove the motor access cover on the side of the gathering head frame.

 Disconnect and tag the power cables to the gathering head motors.  Disconnect, tag, and cap the cooling hoses going to the gathering head motors.  Remove the bearing cap cover from the exposed end of the motor.  Remove the snap ring and plug from the end of the motor, exposing the torque shaft.  Remove the torque shaft.  Securely block the motor to prevent it from falling when the mounting bolts are removed.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all lifting and blocking devices and keep a safe distance from suspended loads.  Remove the motor mounting bolts and carefully back the motor out of the frame.

_________________________________________________________________ 5.226 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS

 Wash motor compartment thoroughly for easier removal of motor.

____________________________________ Replacement of wear parts Fig. 141: Gathering head motor removal and installation

© BUCYRUS

Top access cover

Motor access cover

______________________________________________________________ A6474X337 VLSS/0 5.227

Replacement of wear parts _____________________________________ gathering head motor installation

To install a gathering head motor (Fig. 141): Ensure mating surfaces of the frame and motor are clean and free of contaminants.    Carefully position the motor in the frame.  Insert the motor mounting bolts and torque appropriately.  Insert the torque shaft into the motor.  Replace the plug and snap ring over the end of the torque shaft.  Replace the bearing cap cover.  Reconnect the cooling hoses to the motor.  Reconnect the power cable to the motor.

© BUCYRUS

 Replace the motor access cover on the side of the gathering head frame.

_________________________________________________________________ 5.228 Bucyrus – Model 30M4-NP Continuous Miner

____________________________________ Replacement of wear parts Gathering head gear case and pot removal and installation gathering head gear case and pot removal

To remove a gathering head gear case and pot (Fig. 142):  Disconnect and lock out the electrical power to the miner. Follow all applicable regulations regarding lockout/tagout procedures.

WARNING! Failure to follow all applicable regulations regarding lockout/ tagout procedures may result in machine damage or serious injury or death of personnel. Remove the footshaft (see footshaft removal procedure).  Remove the gathering head motor (see Gathering head motor removal procedure in this chapter).

© BUCYRUS

Remove the top access cover and the three (3) covers surrounding the pot case.   Securely block the input gear case in position to prevent the gear case from falling when the capscrews that secure it are removed.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all lifting and blocking devices and keep a safe distance from suspended loads.  Disconnect any oil fill lines connected to the pot.  Remove the CLA (see CLA removal procedure in this chapter).  Attach a lifting device to the top surface of the pot and input gear case.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all lifting and blocking devices and keep a safe distance from suspended loads.  Remove the five (5) hex head bolts which secure the pot case to the gathering head frame.  Loosen the pot case attachment from the frame by removing the hex head capscrews from the four corners of the pot. Removing these screws will also remove the four wedge blocks which secure the pot in position.  Lift the pot and input case from the gathering head frame.  To separate the input gear case from the pot: 

Remove the capscrews that secure the input gear case to the pot and back the input gear case away from the pilot bore in the pot case.

______________________________________________________________ A6474X337 VLSS/0 5.229

Replacement of wear parts _____________________________________ Fig. 142: Gathering head gear case and pot removal and installation

Pot case cover

Pot case cover

© BUCYRUS

Top access cover

Motor access cover

CLA retainer plate

_________________________________________________________________ 5.230 Bucyrus – Model 30M4-NP Continuous Miner

____________________________________ Replacement of wear parts gathering head gear case and pot installation

To install a gathering head gear case and pot (Fig. 142):  Align the input gear case with the pot case (if separated) and secure with capscrews.  Attach a lifting device to the gear case assembly.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all lifting and blocking devices and keep a safe distance from suspended loads.  Ensure that mating surfaces are clean and then position the gear case assembly in the gathering head frame.  Position the four wedge blocks which secure the pot in position and secure to the frame by installing hex head capscrews through the four (4) corners of the pot. Install the five (5) hex head bolts which secure the pot case to the gathering head frame and torque accordingly.  Connect the oil fill lines to the pot.

© BUCYRUS

Install the top access cover and the three (3) covers surrounding the pot case.  Install the gathering head motor (see Gathering head motor installation procedure in this chapter). Install the footshaft (see the footshaft installation procedure).  Install CLA (see CLA installation procedure in this chapter).

______________________________________________________________ A6474X337 VLSS/0 5.231

Replacement of wear parts _____________________________________ Foot shaft removal and installation foot shaft removal

To remove the foot shaft (Fig. 143):  Lower the gathering head assembly until it touches the floor.  Position the conveyor tail section directly behind the miner so that it is level with the floor.  Raise the cutter head assembly to its highest position and block.

WARNING! Observe the safe work load limits of all blocking devices. You can be seriously injured or killed by falling loads.  Open the needle valve to release the oil from the conveyor take-up cylinders. This will relax the tension on the conveyor chain.  Disconnect and lock out the electrical power to the miner. Follow all applicable regulations regarding lockout/tagout procedures.

CAUTION! To avoid injury while relieving tension off of the conveyor chain, wear proper personal protective equipment, to include, at a minimum, safety glasses and gloves.  Using a pry bar, lift the chain off the conveyor deck several times to relieve tension in the chain.  Remove the two retaining pins from the closest connecting pin to the foot shaft and then remove the connecting pin.  Pull the conveyor chain away from the foot shaft sprocket (fold it back).  Remove the four (4) socket head capscrews that secure the two foot shaft covers to the gathering head assembly and remove the covers.  Remove the four socket head capscrews from each clamp ring on the foot shaft assembly and remove the clamp rings.  Slide both adapter shafts from the ends of the foot shat toward the sprocket in the center. This will free the foot shaft from the gear case.  Remove the foot shaft from the gathering head.

_________________________________________________________________ 5.232 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS

WARNING! Failure to follow all applicable regulations regarding lockout/ tagout procedures may result in machine damage or serious injury or death of personnel.

____________________________________ Replacement of wear parts Fig. 143: Foot shaft assembly removal and installation

Sprocket Clamp ring

© BUCYRUS

Adapter shaft

______________________________________________________________ A6474X337 VLSS/0 5.233

Replacement of wear parts _____________________________________ foot shaft installation

To install the foot shaft (Fig. 143):  Slide an adapter shaft onto each end of the foot shaft.  Slide the foot shaft into position between the two gathering head gear case bevel pinions.

IMPORTANT! Position the foot shaft so that it’s sprocket will engage the conveyor chain links when the chain is reconnected.  Align the foot shaft splines with the bevel pinion splines.  Slide the right adapter shaft over the foot shaft spline onto the bevel pinion splines until it touches the gear case seal carrier. Repeat for the left side.  Place a collar onto each end of the foot shaft so that the adapter shaft is secured against the bevel gear case seal carriers.  Insert and tighten the capscrews through both halves of the collars to secure the collars to the foot shaft.

 Reattach the two ends of the conveyor chain by replacing the connecting pin.  Close the needle valve to the conveyor take-up cylinders.  Reconnect the trailing cable to energize the miner.  Start the pump so that the conveyor chain take-up cylinders are pressurized.  Turn on the gathering head motors to run the conveyor chain.  Elevate the conveyor full up and down and swing the discharge conveyor full left and right. Check that the conveyor chain is running smoothly.  Shutdown the machine and check the conveyor chain tension. If adjustment is necessary, see the Conveyor chain adjustment procedure in this chapter.

_________________________________________________________________ 5.234 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS

 Replace the foot shaft covers and secure with the four (4) socket head capscrews.

____________________________________ Replacement of wear parts CLA removal and installation CLA removal

To remove a continuous loading arm (CLA) (Fig. 144):  Lower the gathering head assembly until it touches the floor.  Raise the cutter head assembly to its highest position and block.

WARNING! Observe the safe work load limits of all blocking devices. You can be seriously injured or killed by falling loads.  Disconnect and lock out the electrical power to the miner. Follow all applicable regulations regarding lockout/tagout procedures.

WARNING! Failure to follow all applicable regulations regarding lockout/ tagout procedures may result in machine damage or serious injury or death of personnel.

© BUCYRUS

 Remove the eight (8) socket head capscrews from the CLA retainer plate and remove the retainer plate. There are two puller holes, protected by cup-point set screws, in the retainer plate to assist with it’s removal.  Remove the three capscrews located where the arms meet the CLA hub. There are three puller holes, protected by cup-point set screws, in the arm to assist with it’s removal.  Remove the three dowel pins, which position the CLA to the pot disc and keep for reassembly.  The CLA is now free and can be removed.

______________________________________________________________ A6474X337 VLSS/0 5.235

Replacement of wear parts _____________________________________ Fig. 144: CLA removal and installation

Puller hole (1) Puller hole (2) Puller hole (3)

CLA retainer plate capscrews (8)

CLA tip

© BUCYRUS

CLA arm to hub capscrews (3)

_________________________________________________________________ 5.236 Bucyrus – Model 30M4-NP Continuous Miner

____________________________________ Replacement of wear parts

CLA installation

To install a continuous loading arm (CLA) (Fig. 144):  Install the three dowel pins into the pot disc.   Position the CLA on the gathering head ensuring that CLAs are aligned as shown in Fig. 143.  Insert the three capscrews into the arms and tighten.  Insert the retainer cap into the center of the arm.  Apply Loctite 262 to the eight (8) socket head capscrews and install the capscrews into the retainer plate. Torque incrementally and evenly in a crossing pattern to 734 lb-ft (995 Nm) as follows: Step 1: Snug Step 2: 245 ft-lb (332 Nm) Step 3: 500 ft-lb (678 Nm) Step 4: 734 ft-lb (995 Nm)  Reconnect the trailing cable.

CLA tip replacement

CLA tip replacement

© BUCYRUS

To replace a CLA tip (Fig. 144):  Lower the gathering head assembly until it touches the floor.  Raise the cutter head assembly to its highest position and block.

WARNING! Observe the safe work load limits of all blocking devices. You can be seriously injured or killed by falling loads.  Disconnect and lock out the electrical power to the miner. Follow all applicable regulations regarding lockout/tagout procedures.

WARNING! Failure to follow all applicable regulations regarding lockout/ tagout procedures may result in machine damage or serious injury or death of personnel. Grind off the weld which secures the two (2) keeper plates and save the plates for reassembly.  Remove the two (2) hex head capscrews that secure the tip to the arm and remove the tip.  Slide a new tip onto the arm and secure with two (2) hex head capscrews. Weld the two (2) keeper plates to secure the two (2) hex head capscrews.  Reconnect the trailing cable.

______________________________________________________________ A6474X337 VLSS/0 5.237

Replacement of wear parts _____________________________________ Gathering head cylinder removal and installation gathering head cylinder removal

To remove a gathering head cylinder (Fig. 145):  Raise the gathering head off the ground by fully extending the gathering head cylinder and securely block.  Raise the cutter head and securely block.

WARNING! Observe the safe working load limits of all lifting and blocking devices. You can be seriously injured or killed by falling loads.  Disconnect and lock out the electrical power to the miner. Follow all applicable regulations regarding lockout/tagout procedures.

WARNING! Failure to follow all applicable regulations regarding lockout/ tagout procedures may result in machine damage or serious injury or death of personnel.

 Connect the trailing cable to energize the miner.

WARNING! Stand clear of the blocked cutter head and gathering head assemblies whenever the miner is energized.  Slowly contract the cylinder until the rod eye is free of the gathering head clevis.  Disconnect and lock out the electrical power to the miner. Follow all applicable regulations regarding lockout/tagout procedures.

WARNING! Failure to follow all applicable regulations regarding lockout/ tagout procedures may result in machine damage or serious injury or death of personnel.  Check the cutter head and the gathering head are still securely blocked.  Move the gathering head lift cylinder valve handle to extend and retract the cylinder in order to release any hydraulic pressure from the cylinder.

_________________________________________________________________ 5.238 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS

 Attach a lifting device to the gathering head cylinder so that when the cylinder is unpinned, the lifting device will support the cylinder.   Remove the spiral pin from the upper (rod end) cylinder pin and then remove the pin.

____________________________________ Replacement of wear parts  Disconnect and plug the hydraulic hose from the cylinder.

WARNING! Never disconnect a hydraulic hose if the circuit is pressurized or if there is a load on the circuit. If a hose is disconnected while the circuit is pressurized or under load, the load will fall. Machine damage or serious injury or death to personnel may result.  Remove the two (2) capscrews that secure the pin retainer plate to the frame and the remove the retainer plate.

© BUCYRUS

 Remove the lower (cylinder end) pin from the frame mounting clevis.   The cylinder is now free and can be lifted off of the machine.

______________________________________________________________ A6474X337 VLSS/0 5.239

Replacement of wear parts _____________________________________

Frame mounting pin

Gathering head cylinder

Gathering head clevis pin

_________________________________________________________________ 5.240 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS

Fig. 145: Gathering head cylinder removal and installation

____________________________________ Replacement of wear parts Gathering head cylinder installation

gathering head cylinder installation

To install the gathering head cylinder (Fig. 145):

 Check that the gathering head and cutter head assemblies are securely blocked.  Insert the cylinder end of the gathering head cylinder into the fram mounting clevis.

WARNING! This procedure involves the alignment of cylinder clevises with mounting clevises in order to install retaining pins. Do not check for alignment with your fingers. Shifting of the aligned pieces could cause serious injury.  Insert the retaining pin through the cylinder end and frame mounting clevis.  Insert the pin retaining plate over the end of the pin and secure to the clevis with two (2) capscrews.   Attach the hydraulic hose to the cylinder.

© BUCYRUS

 Connect the trailing cable to energize the miner.

WARNING! Stand clear of the blocked cutter head and gathering head assemblies whenever the miner is energized.  Slowly extend the cylinder so that the rod end can be inserted into the gathering head clevis.

WARNING! Stand clear of the blocked cutter head and gathering head assemblies whenever the miner is energized.  Disconnect and lock out the electrical power to the miner. Follow all applicable regulations regarding lockout/tagout procedures.

WARNING! Failure to follow all applicable regulations regarding lockout/ tagout procedures may result in machine damage or serious injury or death of personnel.  Insert the retaining pin through the rod end and gathering head mounting clevises.  Insert the spiral lock pin through the retaining pin.

______________________________________________________________ A6474X337 VLSS/0 5.241

Replacement of wear parts _____________________________________ Crawler assembly Each (left or right) crawler assembly (Fig. 146) consists of a tram drive motor, a tram drive gear case, a crawler chain, a chain take-up roller, and a grease adjusted, shim lock take-up system. These components are mounted in a crawler frame, which is an integral part of the main frame.

© BUCYRUS

Fig. 146: Crawler assembly

Gear case Roller Motor

Crawler track (chain)

_________________________________________________________________ 5.242 Bucyrus – Model 30M4-NP Continuous Miner

____________________________________ Replacement of wear parts Tram motor removal and installation tram motor removal

To remove a tram motor (Fig. 147):  Position the miner so that there is adequate work space on the side from which the motor is being removed.  Block the miner so that the tram track is clear of the floor and is free to turn. Be sure that the miner is level when blocked.

WARNING! Observe the safe working load limits of all blocking devices. You can be seriously injured or killed by falling loads.  Disconnect and lock out the electrical power to the miner. Follow all applicable regulations regarding lockout/tagout procedures.

© BUCYRUS

WARNING! Failure to follow all applicable regulations regarding lockout/ tagout procedures may result in machine damage or serious injury or death of personnel.  Remove two (2) bolts that secure the top cover to the tram rub rail and slide the cover off the rub rail.   Remove the two (2) rub rail pins that secure the tram rub rail to the two rub rail sections adjacent to it and then remove the tram rub rail to expose the tram gear case.  Remove the capscrews that secure the end cap on the motor.  Remove the snap ring inside the motor shaft.  Remove the shaft plug and o-ring, exposing the quill shaft.  Carefully remove the quill shaft and store in a safe place.  Remove the two (2) bolts that secure the motor to the tram case.

Store the spare for use in motor installation.  Replace the end cap on the motor and secure with the four capscrews.  Disconnect, tag, and cap the cooling hoses from the cooling fittings located on the motor.  Remove the bolts that secure the inspection cover to the motor and remove the cover.  Disconnect the power cable lugs from the motor.  Locate the three taped power connections inside the motor and strip the tape covering each lug connection.  Tag each connection and remove the capscrew, washer, and nut that secures each of the power cable lugs. ______________________________________________________________ A6474X337 VLSS/0 5.243

Replacement of wear parts _____________________________________  Replace the inspection cover on the motor and secure with bolts.  Cover the connection opening in the side of the motor to prevent motor contamination while the power cables are disconnected.

WARNING! Do not reconnect the trailing cable to the miner while the power cable is disconnected from the motor. Serious injury or death may occur.

© BUCYRUS

 Carefully remove the motor from the tram case, be careful not to damage the motor during removal.

_________________________________________________________________ 5.244 Bucyrus – Model 30M4-NP Continuous Miner

____________________________________ Replacement of wear parts Fig. 147: Tram drive motor location

Tram drive motor

© BUCYRUS

Fig. 148: Shaft plug removal

Shaft plug

O-ring Retaining ring

______________________________________________________________ A6474X337 VLSS/0 5.245

Replacement of wear parts _____________________________________ AC drive encoder removal and installation AC drive encoder removal

When removing the AC drive encoder, follow all applicable regulatory agency laws and regulations, including but not limited to: To remove the tram motor AC drive encoder (Fig. 149):  Disconnect and lock out electrical power to the miner.  Remove the cover from end of the tram motor.  Remove the four screws that hold the rotor cover in place and re move the cover to expose the rotor and stator.  Remove the four screws that secure the rotor.  Remove the four screws that secure the stator.  Remove the stator and rotor from the motor.

AC drive encoder installation

To install the encoder (Fig. 150):

 Mount the rotor inside the stator, making sure that the encoder and rotor are aligned on the front most edge (Fig. 3). Apply thread locking compound to the bolts and tighten to greater than 8 N-m (70 inlb).  Ensure the wheel does not have excessive wobble (greater than 0.010 inch). Rotate the motor shaft by hand. It should rotate freely and not touch the frame at any time. If everything is mechanically correct, the resulting stator to rotor air gap will be a nominal 0.019 inches.  Mount the rotor cover and secure with four screws.

_________________________________________________________________ 5.246 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS

 Mount the stator over the motor shaft and secure with four bolts.

Apply thread locking compound to the bolts and tighten to 34 N-m (25 ft-lb).

____________________________________ Replacement of wear parts Fig. 149: Motor encoder

Rotor

Motor shaft

Stator

© BUCYRUS

Rotor

Fig. 150: Encoder rotor and stator alignment

______________________________________________________________ A6474X337 VLSS/0 5.247

Replacement of wear parts _____________________________________ tram motor installation

To install the tram motor (Fig. 151):  Clean the motor and the motor cavity in the tram case thoroughly.  Install a new o-ring (lubricated) on the motor mounting flange (rear bell).  Oil the bore of the input planetary (in the motor cavity) to ease installation.  Carefully position the motor in the tram case, being careful not to damage the motor or the o-ring on the rear bell.  Continue to position the motor into the bore of the input planetary until the spacer is flush with the tram case. If the spacer is not flush within .5 mm (.02 inches), the motor is not seated properly.  Install the motor quill shaft, rotating it until the splines on the end inside the motor mesh with the internal splines of the pinion ear in the input planetary assembly.  Install the shaft plug and o-ring and the snap ring on the end of the shaft.

 Install the two (2) socket head capscrews to secure the motor to the tram case. Tighten to the correct torque.  Refill the tram gear case with high demulsibility, extreme pressure gear oil (Spec. 100-15) to the correct level. Check the oil level using the sight gauge on the outer face of the gear case.  Remove the bolts that secure the inspection cover to the motor and remove the cover.   Reconnect the power cable to the motor.  Locate the motor lug connections inside the motor.  Secure each of the power connections with a capscrew, flat, washer, lock washer, and nut.  When the each of the three connections have been secured, wrap each connections with a layer of rubber tape, a layer of electrical (black) tape, and a layer of glass tape.  Reconnect the cooling lines to the motor.  Reconnect power to the miner and check tram for correct operation.

_________________________________________________________________ 5.248 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS

 Install the motor end cap and secure with capscrews. Tighten to the correct torque.

____________________________________ Replacement of wear parts WARNING! Stay clear of the blocked miner while the machine is energized.

Failure to follow this warning may result in sever injury or death.    Disconnect and lock out the electrical power to the miner. Follow all applicable regulations regarding lockout/tagout procedures.

WARNING! Failure to follow all applicable regulations regarding lockout/ tagout procedures may result in machine damage or serious injury or death of personnel.   Replace the tram rub rail and secure with the two (2) pins.

© BUCYRUS

 Replace the top cover on the tram rub rail and secure.

______________________________________________________________ A6474X337 VLSS/0 5.249

Replacement of wear parts _____________________________________ Tram gear case removal and installation tram drive gear case removal

To remove a tram drive gear case (Fig. 151):  Position the miner so that there is adequate work space on the side from which the motor is being removed.  Block the miner so that the tram track is clear of the floor and free to turn. Make sure the miner is level.

WARNING! Observe the safe working load limits of all blocking devices. You can be seriously injured or killed by falling loads.  Disconnect and lock out the electrical power to the miner. Follow all applicable regulations regarding lockout/tagout procedures.

WARNING! Failure to follow all applicable regulations regarding lockout/ tagout procedures may result in machine damage or serious injury or death of personnel.

 Separate the crawler chain (see Crawler chain removal procedure in this chapter) at a place near the tram gear case and move the chain clear of the drive sprocket. For ease of reconnection, attach a small steel cable to upper crawler pad so that is accessible for pulling the crawler back into place during installation.  Disconnect, tag, and cap all cooling and lubrication lines from the gear case.  The main gear case and final planetary gear case may be drained, if desired, but it is not necessary.  Disconnect and tag the power cable lugs from the motor.

WARNING! Do not reconnect the trailing cable to the miner while the power cable is disconnected from the motor. Serious injury or death may occur.  Remove the tram brake (see the Tram brake removal procedure in this chapter).   Clean out the jacking holes on each side of the gear case.  Remove the socket head capscrews and wedge blocks.

_________________________________________________________________ 5.250 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS

 Remove the two (2) rub rail pins that secure the tram rub rail to the two rub rail sections adjacent to it and then remove the tram rub rail to expose the tram gear case.

____________________________________ Replacement of wear parts  Remove the nine (9) screws from the mounting plate (four (4) on the rear/sprocket side and five (5) on the forward/motor side).  Insert a screw into the two jacking holes and, using these holes, slowly jack the main case free of the frame.  Position a loading device, such as a scoop, at the bottom edge of the main case. Connect a couple of chains between the loading device and the back of the mounting plate.

WARNING! Observe the working load limits of chains. Overstressing the chains could cause the chain to break, resulting in serious injuries.  Slowly maneuver the gear case and motor assembly clear of the machine and onto the loading device.

© BUCYRUS

 Cover the tram case compartment in the crawler assembly to keep out dirt and debris.

______________________________________________________________ A6474X337 VLSS/0 5.251

Replacement of wear parts _____________________________________ Fig. 151: Tram case removal and installation

Tram rub rail

Pin (2)

© BUCYRUS

Tram case

_________________________________________________________________ 5.252 Bucyrus – Model 30M4-NP Continuous Miner

____________________________________ Replacement of wear parts tram drive gear case installation

To install the tram gear case (Fig. 152);  Ensure that the crawler frame mounting area is cleared of dirt and debris. Pay special attention to the keyways and the bore in the inner face of the main frame. Apply a light coating of Molykote G-N past to aid re-installation.  Ensure that the mounting faces on both the tram drive gear case and the crawler frame are clean.  Coat the mounting keys on the gear case and the bearing carrier on the inboard end of the main gear case with Molykote G-N paste.

The bearing carrier serves as a plug to fit into the bore in the main frame.  Slowly maneuver the gear case into position next to the machine, aligning the keys on the gear case with the keyways/slots on the frame.

© BUCYRUS

IMPORTANT! If the miner and the gear case assembly are not both level and aligned correctly, installing the gear case assembly into the machine will be very difficult.  Slowly push the gear case assembly into the crawler frame, allowing the keys on the gear case to engage the keyways in the main frame. Be sure that cap screw mounting holes line up.  Install the nine (9) socket head capscrews and washers and torque appropriately.  Install the wedge blocks and secure with capscrews. Tighten to the correct torque.  Reconnect all cooling and lubrication lines to the gear case.  Reconnect the electrical leads to the motor.  Check the oil level in the gear case and add high demulsibility, extreme pressure gear oil (Spec. 100-15) as required.  Reconnect the crawler chain (see Crawler chain installation procedure in this chapter).

______________________________________________________________ A6474X337 VLSS/0 5.253

Replacement of wear parts _____________________________________  Connect the trailing cable to energize the miner.  Operate the tramming function on the side where the tram gear case assembly was installed. Check for correct operation.  Disconnect and lock out the electrical power to the miner. Follow all applicable regulations regarding lockout/tagout procedures.

WARNING! Failure to follow all applicable regulations regarding lockout/ tagout procedures may result in machine damage or serious injury or death of personnel.

© BUCYRUS

 Replace the tram rub rail, securing it with the two (2) pins.

_________________________________________________________________ 5.254 Bucyrus – Model 30M4-NP Continuous Miner

____________________________________ Replacement of wear parts Crawler chain removal and installation (with grease take-up) crawler chain removal and installation

To remove the crawler chain (Fig. 152):  Position the miner so that there is sufficient clearance to work and enough space to pull the chain off.  Block the machine so that the crawler assembly is off of the mine floor. Do not place blocking under the crawler track.  Raise the gathering head assembly to its highest position and securely block it.

WARNING! Observe the safe working load limits of all blocking devices. You can be seriously injured or killed by falling loads.  Lower the cutter head assembly so that it rests on the gathering head.  Lower the conveyor.

© BUCYRUS

 Disconnect and lock out the electrical power to the miner. Follow all applicable regulations regarding lockout/tagout procedures.

WARNING! Failure to follow all applicable regulations regarding lockout/ tagout procedures may result in machine damage or serious injury or death of personnel.  Attach a grease gun to the crawler grease take-up fitting and pump grease into the take-up cylinder to extend the cylinder and remove pusher plate pressure on the idler shims.  Remove the hex head cap screw securing the shims to the take-up housing and remove all shims and store them in a safe place.  Bleed off pressure in the grease take-up cylinder by opening the needle valve in the grease line. Be sure that the cylinder collapses to relieve tension in the crawler chain.

WARNING! The end of the chain, just forward of the separation point, should be blocked. Personnel should stay clear of the chain during separation to avoid injury when the chain is disconnected.  Locate a tram track link near the track opening at the bottom of the tram case. Remove the two (2) capscrews and nuts, one on each side of the crawler pad, and drive the two crawler pins out of the crawler pad.

______________________________________________________________ A6474X337 VLSS/0 5.255

Replacement of wear parts _____________________________________  Break the chain at the bottom of the drive sprocket.   Unblock the loose length of chain and lower it to the mine floor.

Attach a pull chain or cable to the end of the crawler chain.  Attach new crawler to bottom portion of old crawler.  Attach top of old crawler to a pull vehicle.  Tram crawler in reverse as pull vehicle holds just enough tension to “tram” on new crawler.

© BUCYRUS

 Disconnect the old chain and pin the new chain together.

_________________________________________________________________ 5.256 Bucyrus – Model 30M4-NP Continuous Miner

____________________________________ Replacement of wear parts Fig. 152: Crawler chain removal and installation

Bolt

Nut

© BUCYRUS

Pin

______________________________________________________________ A6474X337 VLSS/0 5.257

Replacement of wear parts _____________________________________ crawler chain installation

To install the crawler chain (Fig. 153):  Ensure that the miner is correctly cribbed.  Lay the crawler chain on the mine floor under the crawler frame and extending forward in front of the mine. The grousers should be facing down.

IMPORTANT! Be sure that the grousers are in the correct direction before installing the chain into the machine. Check the parts book for your machine to verify the correct direction.  Attach a pull cable to the rear of the crawler chain.

 Slowly pull the crawler chain into position on the drive sprocket so that the sprocket teeth engage the pockets in the first crawler pad.

Continue pulling the chain slowly as it engages the rest of the exposed sprocket teeth and moves forward on the upper crawler chain return deck. Pull the end of the chain clear of the take-up roller until it drapes over the roller.  Block the bottom of the chain near the front.  Coat the connecting pins with EP#2 multi-purpose grease.  Remove the pull cable and mate the two ends of the chain using the two connecting pins.  Apply Loctite 271 to the bolts then secure the pins with the flat head socket capscrews and nuts.  Ensure that the needle valve on the grease take-up cylinder has been closed.  Pump grease into the take-up cylinder grease fitting until the proper chain sag is achieved (Fig. 153).

Fig. 153: Crawler chain sag measurement

Bottom of tractor wear shoe

64 to 90 mm gap (2-1/2 to 3-1/2 inches)

Top of tram track

_________________________________________________________________ 5.258 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS

 Feed the loose end of the pull cable around the drive sprocket and into the upper crawler chain return deck. Continue feeding the pull cable forward until it is at the front of the crawler frame and past the take-up roller. Run the cable forward where it can be attached to a vehicle or other pulling device.

____________________________________ Replacement of wear parts Crawler take-up roller removal and installation crawler take-up roller removal

To remove the crawler take-up roller (Fig. 154):  Position the miner so that there is sufficient clearance to work.  Block the machine so that the crawler assembly is off of the mine floor. Block under the crawler chain, just behind the crawler takeup roller.  Raise the gathering head assembly to its highest position and securely block it.

WARNING! Observe the safe working load limits of all blocking devices. You can be seriously injured or killed by falling loads.  Lower the cutter head assembly so that it rests on the gathering head.  Lower the conveyor.

© BUCYRUS

 Disconnect and lock out the electrical power to the miner. Follow all applicable regulations regarding lockout/tagout procedures.  Attach a grease gun to the crawler grease take-up fitting and pump grease into the take-up cylinder to extend the cylinder and remove pusher plate pressure on the idler shims.  Remove the hex head cap screw securing the shims to the take-up housing and remove all shims and store them in a safe place.  Bleed off pressure in the grease take-up cylinder by opening the needle valve in the grease line. Be sure that the cylinder collapses to relieve tension in the crawler chain.

WARNING! Failure to follow all applicable regulations regarding lockout/ tagout procedures may result in machine damage or serious injury or death of personnel.  Separate the crawler chain near the bottom of idler and use a hoist to raise top of crawler off of idler.  Place a lifting device around both sides of the take-up roller and slide the roller forward until it clears the frame.

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

______________________________________________________________ A6474X337 VLSS/0 5.259

Replacement of wear parts _____________________________________

Crawler takeup roller

_________________________________________________________________ 5.260 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS

Fig. 154: Crawler track take-up idler removal and installation

____________________________________ Replacement of wear parts crawler take-up roller installation

To install the crawler chain take-up idler roller (Fig. 154):  Apply a thin coating of grease to the top and bottom take-up slide areas of the crawler frame.  Verify the proper oil fill on the inside of the take-up roller housing.

Place the assembly on its side with the roller shaft vertical. Remove both pipe plugs visible on the side of the roller. Pour gear oil into one hole until it runs out the other hole.  Position the crawler take-up assembly in front of the slide area of the crawler frame.  Slide the assembly into the main frame, then rearward until it stops against the piston of the take-up cylinder.  Ensure that the piston end of the take-up cylinder fits properly into the take-up plug in the roller assembly.  Reconnect the crawler chain.  Unblock the chain and check for proper tension (Fig. 154). If necessary, adjust the shims until the required sag is achieved.

© BUCYRUS

 Connect the trailing cable to energize the miner.  Remove all blocking.  Check the crawler assembly for correct operation.

______________________________________________________________ A6474X337 VLSS/0 5.261

Replacement of wear parts _____________________________________ Tram brake removal and installation tram brake removal

To remove the tram brake:  Disconnect and lock out the electrical power to the miner. Follow all applicable regulations regarding lockout/tagout procedures.

WARNING! Failure to follow all applicable regulations regarding lockout/ tagout procedures may result in machine damage or serious injury or death of personnel.  Remove all necessary covers to access brake (Fig. 155).

Fig. 155: Cover removal Tram brake access cover (left side)

© BUCYRUS

Tram brake access cover

 Thoroughly clean the area around the tram brake to keep debris from getting into the tram gear case once the tram brake has been removed.  Remove, tag, and cap all hydraulic lines to the tram brake.  Where necessary, bleed pressure from hydraulic lines.  Remove and tag all electrical lines to the tram brake.  Remove the six (6) hex head bolts and lock washers and two (2) socket head cap screws and lock washers which secure the tram brake gear case to the tram gear case (Fig. 156). Save these bolts and washers for installation.

_________________________________________________________________ 5.262 Bucyrus – Model 30M4-NP Continuous Miner

____________________________________ Replacement of wear parts Fig. 156: Tram brake gear case removal Socket head cap screw

Socket head cap screw

Hex head bolt (6)

Tram brake

Tram gear case

© BUCYRUS

Tram brake gear case

 Attach a lifting device to the tram brake and tram brake gear case and hoist the assembly off of the machine.

WARNING! You can be seriously injured or killed by falling loads. Always observe the safe working load limits of all lifting devices.  Locate the gasket which goes between the tram brake gear case and the tram gear case for possible reuse during installation.  Remove the four (4) hex head bolts which secure the tram brake to the tram brake gear case (Fig. 157) and put aside for use during installation.  Locate the gasket which goes between the tram brake and the tram brake gear case for possible reuse during installation.

______________________________________________________________ A6474X337 VLSS/0 5.263

Replacement of wear parts _____________________________________ Fig. 157: Tram brake removal Tram gear case

Tram brake

© BUCYRUS

Hex head bolt (4)

_________________________________________________________________ 5.264 Bucyrus – Model 30M4-NP Continuous Miner

____________________________________ Replacement of wear parts tram brake installation

To install the tram brake:  Inspect the gasket which goes between the tram brake and the tram brake gear case for any nicks or damage. If gasket is damaged, replace.  Install the gasket onto the tram brake.  Install the tram brake onto the tram brake gear case in the orientation shown in Fig. 158 using the four (4) hex head bolts from removal.

Fig. 158: Tram brake to tram brake gear case installation Tram brake gear case

© BUCYRUS

Tram brake (note orientation)

Hex head bolt (4)

Tram brake installation orientation  Inspect the gasket which goes between the tram brake gear case and the tram gear case for any nicks or damage, If gasket is damaged, replace.   Install the gasket onto the tram brake gear case.  Verify that power is still disconnected and locked out.  Ensure that the area on top of the tram gear case where the tram brake gear case attaches is clear of debris,.  Attach a lifting apparatus to the tram brake and tram brake gear case assembly and hoist onto the machine.

WARNING! You can be seriously injured or killed by falling loads. Always observe the safe working load limits of all lifting devices.  Lower the tram brake and tram brake gear case onto the tram gear case. Be sure to align the dowel pins on the tram brake gear case with the holes on the tram gear case.

______________________________________________________________ A6474X337 VLSS/0 5.265

Replacement of wear parts _____________________________________  Install the two (2) socket head capscrews and lock washer (Fig. 147) to secure the tram brake gear case to the tram gear case.

Torque to the appropriate value.   Install the six (6) hex head bolts and lock washers (Fig. 159) which secure the tram brake gear case to the tram gear case. Torque to the appropriate value.

Fig. 159: Tram brake gear case to tram gear case installation

Hex head bolt (6)

Socket head cap screw

Tram brake gear case

© BUCYRUS

Tram gear case

 Reconnect all electrical and hydraulic lines to the tram brake.  Install all covers removed during tram brake removal.  Reconnect power to the machine and ensure that the tram brake is working correctly.

_________________________________________________________________ 5.266 Bucyrus – Model 30M4-NP Continuous Miner

____________________________________ Replacement of wear parts Conveyor assembly The conveyor assembly (Fig. 160) can be raised and lowered with hydraulic cylinders. The assembly is attached to the main frame at a pair of raised pivots. The discharge section of the conveyor has a double clevis swing pivot and can swing 45° to the left or right.

Fig. 160: Conveyor assembly

© BUCYRUS

Conveyor pivot

Conveyor attachment pivots

______________________________________________________________ A6474X337 VLSS/0 5.267

Replacement of wear parts _____________________________________ Conveyor chain removal and installation conveyor chain removal and installation

To remove the conveyor chain (Fig. 161):  Position the miner so that the top of the conveyor and both ends of the machine can be reached. Allow sufficient room at the back of the miner to pull the conveyor chain off.  Raise the cutter head and block it following all mine regulations WARNING! Observe the safe working load limits of all blocking devices. You can be seriously injured or killed by falling loads.  Position the discharge conveyor in line with the intermediate conveyor and lower it to it’s lowest point.  Disconnect and lock out the electrical power to the miner. Follow all applicable regulations regarding lockout/tagout procedures.

 Open the needle valve to release tension on the conveyor chain take-up cylinders, thereby relaxing tension on the conveyor chain.

CAUTION! To avoid injury while relieving tension off of the conveyor chain, wear proper personal protective equipment, to include, at a minimum, safety glasses and gloves.  Using a pry bar, lift the chain off the conveyor deck several times to relieve tension in the chain.

_________________________________________________________________ 5.268 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS

WARNING! Failure to follow all applicable regulations regarding lockout/ tagout procedures may result in machine damage or serious injury or death of personnel.

____________________________________ Replacement of wear parts Fig. 161: Conveyor chain removal and installation

Connecting pin

© BUCYRUS

Retaining pin

______________________________________________________________ A6474X337 VLSS/0 5.269

Replacement of wear parts _____________________________________ conveyor chain installation

To install the conveyor chain (Fig. 161):  Ensure that the cutting head is adequately blocked.

WARNING! Observe the safe working load limits of all blocking devices. You can be seriously injured or killed by falling loads.  Lay the new chain, uncoiled and upside down, behind the conveyor with the nearest end near the tail roller.

NOTICE! The conveyor chain does not have a right or wrong running directions, only a correct up and down side. The flat side of the flight chains must run on the deck.  Connect the pulling cable (attached to the old chain still in the machine) to the nearest end of the new conveyor chain.  Pull the conveyor chain under the tail roller and through the return deck, stopping when the chain reaches the foot shaft.

 Disconnect the pulling cable from the front end of the chain and run it along the top conveyor deck to the back of the miner.  Connect the pulling cable to the other end of the conveyor chain on the mine floor. Pull it over the tail roller, through the conveyor deck, and up to the other end of the chain on the gathering pan.  Connect the chain using a connecting pin and two retaining pins. bend the retaining pins opposite the direction of conveyor chain travel.  Close the bleed valve in the conveyor chain take-up circuit so that the circuit can be pressurized when power is reapplied.

WARNING! Make sure all personnel are clear of the miner before performing the following checks. Do not stand behind the conveyor when the chain is running.  Connect the trailing cable to energize the miner.  Start the pump motor.  Swing the discharge conveyor full right and left to ensure that the chain is clear.  Turn on the gathering head motors to run the conveyor. Elevate the conveyor full up and down and swing the discharge conveyor full left and right and check that the chain is running smoothly.

_________________________________________________________________ 5.270 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS

 Pull the conveyor chain up over the foot shaft sprocket and lay it in the gathering pan.

____________________________________ Replacement of wear parts

  Observe the chain as it comes off the foot shaft and ensure that there is no excessive slack and that the chain does not contact the CLA arms.

© BUCYRUS

 If the chain slack is excessive, adjust the chain tension (see Chain tension adjustment procedure in this chapter).

______________________________________________________________ A6474X337 VLSS/0 5.271

Replacement of wear parts _____________________________________ Conveyor assembly removal and installation conveyor assembly removal

To remove the conveyor assembly (Fig. 162):  Disconnect the conveyor chain (see Conveyor chain removal procedure in this chapter) and remove it from the machine.   Raise the conveyor to an elevated position so at to provide access to the upper conveyor raise cylinder pins.  Block the elevated conveyor following all mine regulations.

WARNING! Observe the safe working load limits of all blocking devices. You can be seriously injured or killed by falling loads.  Disconnect and lock out the electrical power to the miner. Follow all applicable regulations regarding lockout/tagout procedures.

 Attach lifting devices to both the intermediate and discharge conveyor sections. Take up slack in the lifting device without raising the conveyor.

WARNING! Observe the safe working load limits of all lifting devices. You may be seriously injured or killed by falling loads.  Support the rod end of each conveyor raise cylinder.  Remove the pins from each upper cylinder pin and remove the cylinder pins.  Appropriately secure the conveyor assembly laterally to prevent it from swinging when the hydraulic lines to the swing cylinders are removed.  Remove and cap the hydraulic lines going to the swing cylinder.

WARNING! Never disconnect a hydraulic hose if the circuit is pressurized. If a hose is disconnected while the circuit is pressurized, machine damage or severe injury may result.

_________________________________________________________________ 5.272 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS

WARNING! Failure to follow all applicable regulations regarding lockout/ tagout procedures may result in machine damage or serious injury or death of personnel.

____________________________________ Replacement of wear parts

  Disconnect, tag, and cap the lubrication lines going to the right and left pivot pins.  Release any pressure that might exist between the lateral sway guides and the guide discs by backing out the set screw on each side.  Remove the capscrews from the conveyor pivot pin retainer and remove the retainer.  Push the conveyor pivot pins toward the center until they are free.

NOTICE! If the pivot pin is tight, be sure the lifting device is not binding the pivot. If the pivot is not in a bind, use the puller hole to aid in pin removal.  With the lifting device, slowly maneuver the conveyor assembly away from the machine.

© BUCYRUS

Fig. 162: Conveyor assembly removal and installation

Conveyor raise cylinder

Main frame pivot

______________________________________________________________ A6474X337 VLSS/0 5.273

Replacement of wear parts _____________________________________ conveyor assembly installation

To install the conveyor assembly (Fig. 162):  Attach a lifting device to the conveyor assembly and slowly maneuver it onto the machine.

WARNING! Observe the safe working load limits of all lifting devices. You can be seriously injured or killed by falling loads.  With the conveyor pivot in position, grease the conveyor pivot pins to ease installation and then drive the pins into the pivot bores.  Install the pivot pin retainer and secure with hex head cap screws.  Reconnect the grease lines to each pivot pin.  Using the lifting device, pivot the conveyor into an elevated position and securely block the conveyor.

 Attach the conveyor raise cylinders to the clevises on the underside of the conveyor by installing the conveyor raise cylinder pins.  Reconnect the conveyor chain (see Conveyor chain installation procedure in this chapter).  Apply nominal pressure of the guide discs to the lateral sway guides.  Clear all tools and debris from the area and remove the lifting and blocking devices.

WARNING! Be sure all conveyor components are correctly installed and that the conveyor chain is properly engaged by the foot shaft before starting the miner.  Connect the trailing cable to energize the miner.  Start the pump motor.  Start the gathering head motors to run the conveyor chain.  Elevate the conveyor full up and down and swing the discharge conveyor full left and right and check that the conveyor chain is running smoothly.

_________________________________________________________________ 5.274 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS

WARNING! Observe the safe working load limits of all lifting and blocking devices. You can be seriously injured or killed by falling loads.   Connect the hydraulic lines to the swing cylinders.

____________________________________ Replacement of wear parts Discharge conveyor removal and installation discharge conveyor removal

To remove the conveyor discharge (Fig. 164):  Position the machine so that the top and bottom of the conveyor can be reached and there is enough room at the back for removal of the conveyor chain and the discharge conveyor.  Raise the conveyor far enough to provide adequate work space under the swing pivot. Securely block the intermediate conveyor section ensuring that the swing pivot remains accessible.

WARNING! Observe the safe working load limits of all blocking devices. You can be seriously injured or killed by falling loads.  Align the discharge conveyor straight with the centerline of the intermediate conveyor.   Disconnect and lock out the electrical power to the miner. Follow all applicable regulations regarding lockout/tagout procedures.

© BUCYRUS

WARNING! Failure to follow all applicable regulatory lockout/tagout procedures may result in machine damage or serious injury or death of personnel.  Relieve the pressure in the conveyor chain take-up circuit (see Conveyor chain removal procedure in this chapter).   Attach lifting devices to the discharge conveyor take up slack in the lifting device without raising the conveyor.

WARNING! Observe the safe working load limits of all lifting devices. You may be seriously injured or killed by falling loads.  Disconnect the conveyor chain at a connecting pin close to the end of the discharge conveyor (see Conveyor chain removal procedure in this chapter).  Disconnect, tag, and cap the hydraulic lines from the conveyor swing cylinders. Cap the ports in the cylinders.

WARNING! Never disconnect a hydraulic hose if the circuit is pressurized. If a hose is disconnected while the circuit is pressurized, machine damage or severe injury may result.  Remove the forward swing cylinder pin at the intermediate conveyor section.  Remove the bolts and stop nuts that attach flexible sideboards to each side of the intermediate conveyor.

______________________________________________________________ A6474X337 VLSS/0 5.275

Replacement of wear parts _____________________________________

  Slide each sideboard from its guide on the discharge conveyor and remove it. If the sideboards are not free to slide, remove the hex head capscrews and spring lock washers from each flexible sideboard guide assembly and remove them from the top of the discharge conveyor on each side.  Remove the capscrews from the top pivot pin and remove the pin.

Two puller holes, protected by set screws and located on the top and bottom of each pivot pin, are provided to aid in removing the pivot pin. A pivot retainer will remain in the top pivot bore. If not already released, this retainer can be tapped loose and removed from the area between the top and bottom conveyor decks.  Repeat this procedure for the bottom pivot pin and pivot retainer. If the bottom pin is not free to come out, check the tension on the lifting device to make sure the pin is not in a bind.

© BUCYRUS

 Slowly and carefully maneuver the discharge conveyor away from the intermediate conveyor section.

_________________________________________________________________ 5.276 Bucyrus – Model 30M4-NP Continuous Miner

____________________________________ Replacement of wear parts Fig. 164: Discharge conveyor removal and installation

Flexible guide

Pivot pin

Bolt (3 each side)

Washer (3 each side)

Sideboard

Nut (3 each side)

© BUCYRUS

Bolt (4 each side)

Conveyor swing cylinder pin

______________________________________________________________ A6474X337 VLSS/0 5.277

Replacement of wear parts _____________________________________ discharge conveyor installation

To install the discharge conveyor (Fig. 164):  Ensure that the trailing cable is still disconnected and properly locked/tagged out. Follow all applicable regulations regarding lockout/tagout procedures.

WARNING! Failure to follow all applicable regulations regarding lockout/ tagout procedures may result in machine damage or serious injury or death of personnel.  Ensure that the intermediate conveyor is still securely blocked.  Attach a lifting device to the discharge conveyor and slowly lift and maneuver it into the intermediate conveyor section.

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

 Install the top pivot pin and pivot retainer. Secure the retainer with capscrews. Note that the pivot pin has an anti-rotation dowel which must be positioned in the slot in the top conveyor deck.  Install the bottom pivot pin and pivot retainer. Secure the retainer with capscrews. Note that the pivot pin has an anti-rotation dowel which must be positioned in the slot in the bottom conveyor deck.  If necessary, use adjustment shims to align the decks of the intermediate and discharge conveyors. Misalignment can occur due to wear or damage of the discharge conveyor.  Using the lifting device, swing the discharge conveyor fully to the left and right to make sure that it does not bind.  Grease the four pivot surface lubrication points (two on each side) until grease is visible on the mating sections of the conveyor. This will lubricate the pivot pins and bushings as well as the large plates which slide on each other.  Using the lifting device, position the conveyor to align the swing cylinder clevises with both swing cylinder eyes. Lubricate the cylinder pins with grease and insert them through the clevises and eyes.

Secure each pin with a cotter pin.  Connect the hydraulic lines to the cylinders.  With the discharge conveyor straight, reconnect the conveyor chain (see Conveyor chain installation procedure in this chapter).

_________________________________________________________________ 5.278 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS

 Check the top and bottom pivot pins and bushings for wear or damage and replace as necessary. Lubricate all pins and bushings with grease prior to installation.

____________________________________ Replacement of wear parts

  Install a flexible sideboard on each side of the conveyor. Secure with carriage bolts and heavy elastic stop nuts.  Connect the trailing cable to energize the miner.  Raise the conveyor and remove the blocking.

© BUCYRUS

 Operate the conveyor raise, lower, swing left, and swing right functions and check for smooth operation.

______________________________________________________________ A6474X337 VLSS/0 5.279

Replacement of wear parts _____________________________________ Tail roller removal and installation tail roller removal

To remove the tail roller (Fig. 165):  1. Position the machine so that the tail roller can be comfortable reached and there is enough room available for its removal.  2. Align the discharge conveyor straight with the centerline of the intermediate conveyor.  3. Lower the conveyor to a comfortable working height and then securely block.

WARNING! Observe the safe working load limits of all blocking devices. You can be seriously injured or killed by falling loads.  4. Disconnect and lock out the electrical power to the miner. Follow all applicable regulations regarding lockout/tagout procedures.

 5. Relieve the pressure in the conveyor chain take-up circuit (see Conveyor chain removal procedure in this chapter).   6. Use a pry bar to lift the chain off the conveyor deck several times to relieve tension in the chain.  7. Disconnect the conveyor chain at a connecting pin close to the tail roller (see Conveyor chain removal procedure in this chapter) and clear the chain from the roller.  8. Attach a lift device to the tail roller and take up the slack so that the weight of the tail roller is supported by the lifting device.  9. Remove the cover over each side of the tail roller by removing the capscrews from each cover.  10. Remove the cotter pin from the end of the take-up cylinder.  11. Remove the attachment block by removing the two (2) socket head bolts that secure it.  12. Slide the take-up cylinder back and out of the tail roller assembly.  13. Repeat steps 9 through 12 for the other side.  14. Drive out the roll pin on each end of the tail roller to free the inserts.

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© BUCYRUS

WARNING! Failure to follow all applicable regulations regarding lockout/ tagout procedures may result in machine damage or serious injury or death of personnel.

____________________________________ Replacement of wear parts  15. Slide the insert of each end of the tail roller.  16. The tail roller should now be free of the conveyor.

Fig. 165: Conveyor tail roller removal and installation

© BUCYRUS

Tail roller

Cover Socket head capscrew (2)

Capscrew (4)

Take-up cylinder

Insert

Attachment block

Roll pin

______________________________________________________________ A6474X337 VLSS/0 5.281

Replacement of wear parts _____________________________________ tail roller installation

To install the tail roller (Fig. 165):  Position the tail roller in in the conveyor.  Slide the insert into each end of the tail roller.  Insert a roll pin into each end of the tail roller to secure the insert to the roller.  Slide the take-up cylinders back into position with the end of the cylinder sliding through the hole in the tail roller insert.  Insert a cotter pin into the end of each take-up cylinder rod  Secure the attachment block to the end of each cylinder with socket head capscrews (two (2) on each side).  Install the side cover over each side of the tail roller and secure with four (4) capscrews.  Make sure the valve is closed in the conveyor chain take-up circuit.  Reconnect the conveyor chain (see Conveyor chain installation procedure in this chapter).

 Operate the conveyor and check for correct chain tension.

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 Connect the trailing cable to energize the miner.

_____________________________________________ Troubleshooting Troubleshooting procedures The following section lists possible problems encountered when servicing the Continuous Miner and can aid in locating and correcting these problems.

This section covers basic components, with each listed in a troublecause-remedy format.

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

© BUCYRUS

For maintenance procedures and tests that DO NOT require the controller to be energized, precautions include: ■

Before removing the controller covers, remove power from the system by disconnecting the trailing cable. Follow all applicable regulations regarding the lockout/tagout of electrical power.

■

Use insulated gloves and tools where possible.

■

All connections must be tight and care must be taken to prevent bolts, nuts, washers and other small metal fasteners from being dropped or lost inside the controller. These lost fasteners could cause electrical shorts inside the controller.

For procedures that DO require that the controller be energized while the cover is off: ■

At no time should you reach inside the controller while it is energized. If it becomes necessary to make adjustments or to replace parts inside the controller, the “POWER OFF” button must be pushed.

■

Use insulated gloves and tools where possible.

■

All connections must be tight and care must be taken to prevent bolts, nuts, washers and other small metal fasteners from being dropped or lost inside the controller. These lost fasteners could cause electrical shorts inside the controller.

_____________________________________________________________ A6474X337 VLSS/0 5.283

Troubleshooting ______________________________________________ WARNING! Never disconnect a hydraulic hose if the circuit is pressurized or there is a load on the circuit. If a hose is disconnected while the cylinder is supporting a load, the load will fall.

Typical hydraulic problems

■

contaminated oil or poor oil quality

■

low or insufficient oil in the system

■

using the wrong type of oil or wrong viscosity grade

■

air in the hydraulic system

■

internal or external leakage of the hydraulic system

■

improper mechanical adjustments, such as reliefs

■

mechanical or structural damage leading to component failure

■

components by-passing (internal leaking or inability to hold pressure) which leads to erosion of bushings, valve spools, and other costly, critical components

The greatest aid to troubleshooting a hydraulic system is the confidence that comes with knowing the intended operation of the system, along with a fundamental understanding of basic hydraulic principles. Every component in the system has an intended purpose. The construction and operating characteristics of each of these components should be clearly understood before attempting to troubleshoot the machine. For example, understanding that a solenoid controlled directional valve can be manually actuated will save considerable time in isolating a defective solenoid. Please familiarize yourself with the operational descriptions of the hydraulic circuits given in the Hydraulics section of this chapter.

It is also important to know the capabilities of the system. Each component in the system has a maximum rated speed, flow, torque, or pressure. If the system is loaded beyond the specifications, the possibility of failure is greatly increased. The correct operating pressures of a system must be known and must always be checked and set with a pressure gauge. Refer to the hydraulic schematic in the Bucyrus parts manual supplied with your machine for the correct operating parameters.

When in doubt, always assume that the correct pressure is the lowest pressure that will allow adequate performance of the system function(s) while remaining below the maximum rating of the machine’s components.

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© BUCYRUS

The most common causes for improper function are:

_____________________________________________ Troubleshooting The ability to recognize trouble indicators in a specific system is usually acquired with experience. the gaining of this experience can be greatly enhanced by developing a logical sequence for determining the cause of a hydraulic problem and implementing the proper remedy. Refer to the general troubleshooting charts in this section that illustrate the logical sequence for shutdown, troubleshooting, and restarting the machine. The charts cover: ■

general safety procedure for shutting down the machine

■

troubleshooting excessive noise

■

troubleshooting excessive heat

■

troubleshooting incorrect flow

■

troubleshooting incorrect pressure

■

troubleshooting faulty movement/operation

■

general restart checklist and procedure

© BUCYRUS

This general information is intended to enhance the understanding of basic hydraulic principles which will lead to the development of a logical troubleshooting procedure. Specific troubleshooting checklists for each hydraulic circuit are given directly after the very important “Contaminants in hydraulic systems” section.

Contaminants in hydraulic systems The primary cause of hydraulic component failure is SYSTEM CONTAMINATION! Cleanliness must be a high priority when servicing the hydraulic system. Even very small particles can damage system components by scoring valves, clogging orifices, and wearing seals prematurely. It is not the intent of this operation manual to outline a contamination control program but some of the most effective steps that have been identified in successful programs are given below: 1. Ensure that bulk oils are at acceptable cleanliness levels.

Areas where Bucyrus customers have made improvements in the past include: –

implementing ISO Cleanliness Code standards for bulk hydraulic oils

–

evaluating bulk oil shipments for cleanliness by conducting particle counts and maintain records

–

minimizing drum usage by utilizing tote tanks and five gallon pails

–

utilizing plastic versus steel storage tanks, if possible

–

installing desiccant breathers on all bulk tanks

–

using sealed plastic containers for adding oil to small sumps

–

locating bulk tanks near equipment and pump directly to reservoirs

_____________________________________________________________ A6474X337 VLSS/0 5.285

Troubleshooting ______________________________________________ –

utilizing filter carts to maintain oil cleanliness standards

–

properly training personnel on the importance of clean oil and best practices for storage and handling

–

monitoring the program closely and looking for continuous improvement

–

always clean the area around the component that is to be removed and inspected

–

store components in a plastic bag after inspection and prior to replacement on machine

–

cap off all open hoses/fittings

–

never touch a filter with bare hands when installing it back onto the machine

–

pay close attention to the filler/breather cap and replace it when damaged or in the recommended time frame

Contact your Bucyrus representative for more information on implementing an effective program to ensure that your oil and maintenance practices are not contributing to your equipment failure.

Specific hydraulic circuit troubleshooting Multi-function failure If more than one function fails to operate on the machine, check the output of the pumps. Since this is an “open center” circuit, the normal pressure (with all directional control valves in the center position) should be less than 100 psi. This pressure reading illustrates the necessary pressure to circulate the oil through the system. If the pressure reading under these conditions is significantly greater than 100 psi, it is likely that one of the control valves is trying to direct oil to one (or more) of the circuits on the machine.

The next step in troubleshooting a multi-function failure is to check the pilot pressure on the main control valve manifold. This pressure should be between 400 - 500 psi. If the pilot pressure is significantly below 350 psi, start with the General Troubleshooting Flow Chart IV - Incorrect Pressure. Another step to resolve multi-function failure is to have an electrician check for power to the solenoid circuits.

Check for correct pump rotation if electrical work has been performed (such as trailing cable replacement).

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© BUCYRUS

2. Eliminate contamination source through “clean” maintenance practices. This is best achieved by understanding the primary sources of contamination during maintenance and troubleshooting which are given below:

_____________________________________________ Troubleshooting Individual hydraulic circuit failures Perform the following checks on the individual circuits in conjunction with the general troubleshooting: Cutter head raise Check pilot supply pressure at remote control valves.  Check pilot pressure at the Raise pilot cylinder on the cutter head directional control valve when the remote control valve is in the Raise position.  Check the directional control valve for proper operation.  Check to see that piping has not been crossed, especially if the problem occurs after maintenance or repair work.  Check that the "in-line" counterbalance holding valve is piloted and shifting to direct retract port cylinder oil flow back to tank.  Check to see that there is no mechanical bind.  Check cylinders for bypassing.

© BUCYRUS

 Check for pilot pressure on the cutter head cylinder’s holding valves. Also check that the valves are shifting to send oil back to the tank. (Note: cylinder removal will be required to safely achieve this) Cutter head lower Check pilot supply pressure at remote control valves.  Check pilot pressure at the Lower pilot cylinder on the cutter head directional control valve when the remote control valve is in the Lower position.  Check the direction control valve for proper operation.  Check to see that piping has not been crossed, especially if the problem occurs after maintenance or repair work.  Check to see that there is no mechanical bind or hydraulic block.  Check flow control valve cartridge.  Check cylinders for bypassing.  Check for pilot pressure on the cutter head cylinder's holding valves. Also check that the valves are shifting to send (extend port) oil back to the tank. Note: cylinder removal will be required to safely achieve this.

_____________________________________________________________ A6474X337 VLSS/0 5.287

Troubleshooting ______________________________________________ Gathering head raise  Check the directional control valve for proper operation.  Check to see that piping has not been crossed, especially if the problem occurs after maintenance or repair work.  Check to see that there is no mechanical bind.  Check cylinders for bypassing.  Check needle valve on pilot circuit to verify that it is not open or leaking off.  Check in-line counterbalance valve for proper operation or blockage.

Gathering head float  Check the control valve for proper operation.  Check to see that piping has not been crossed, especially if the problem occurs after maintenance or repair work.  Check to see that there is no mechanical bind.  Check cylinders for bypassing (they will leak out the top).

 Check counterbalance valve for proper operation (see the schematic in the Bucyrus parts book supplied with your machine for the proper setting).

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© BUCYRUS

 Check needle valve on pilot circuit to verify that it is not open or leaking off.

_____________________________________________ Troubleshooting Conveyor Raise  Check the directional control valve for proper operation.  Check to see that piping has not been crossed, especially if the problem occurs after maintenance or repair work.  Be sure that the built-in atmospheric-vented reliefs on the cylinders are not dumping oil.  Check to see that there is no mechanical bind.  Verify that cylinders are not bypassing.

Conveyor Lower  Check the directional control valve for proper operation.  Check to see that piping has not been crossed, especially if the problem occurs after maintenance or repair work.  Verify that pilot pressure is being applied to open the piloted builtin checks.  Verify that cylinders are not bypassing.

Conveyor Swing

© BUCYRUS

 Check the directional control valve for proper operation.  Check for any mechanical bind or any obstruction blocking movement, either to the cylinder itself, the main pivot area, or to some point along or under the discharge conveyor itself. Also check to ensure that the pivot bushings have not frozen up from lack of lubrication.  Verify that the cylinder is not bypassing.

_____________________________________________________________ A6474X337 VLSS/0 5.289

Troubleshooting ______________________________________________ Stabilizer Raise  Check the directional control valve for proper operation.  Check to see that piping has not been crossed, especially if the problem occurs after maintenance or repair work.  Check the lubrication network for bound bushings.  Check for any mechanical bind or any obstruction blocking movement.  Check cylinder for bypassing.

Stabilizer Lower  Check the control valve for proper operation.  Check to see that piping has not been crossed, especially if the problem occurs after maintenance or repair work.  Check the lubrication network for bound bushings.  Check for any mechanical bind or any obstruction blocking movement.  Check cylinder for bypassing.

When shutting down the machine for maintenance:  lower or mechanically secure (block) all suspended loads  exhaust any pressure locked in the system  drain down all accumulators  isolate the electrical control system  isolate the electrical power supply Follow all procedures listed in the Shutdown procedure in this chapter.

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General safety procedure for shutting down machine

_____________________________________________ Troubleshooting Table 4: Flow chart I for troubleshooting excessive noise

Pump Noisy Cause

Motor Noisy Remedy

Cause

Relief/Counterbalance Valve Noisy Remedy

Cause

Remedy

Cavitation

A

Coupling misaligned

C

Setting too low or too close to another valve setting

D

Air in fluid

B

Motor or coupling worn or damaged

E

Worn poppet and seat

E

Coupling misaligned

C

Pump worn or damaged

E

Remedies

© BUCYRUS

A. Any or all of the following:        

replace dirty filters wash strainers in solvent compatible with system fluid clean clogged inlet line clean reservoir breather vent change system fluid change to proper pump drive motor speed check fluid temperature check fluid level

B. Any or all of the following:  tighten leaky inlet connections  fill reservoir to proper levels: with few exceptions, all return lines should be below fluid level in the reservoir  bleed air from system  replace pump shaft seal; also replace shaft if worn at seal journal  replace pump C. All of the following:  align unit, ensure that mounting hardware is correct and tight  check condition of seals, bearings, and coupling D.  install and/or adjust pressure gauge E.  overhaul or replace defective parts

_____________________________________________________________ A6474X337 VLSS/0 5.291

Troubleshooting ______________________________________________ Table 5: Flow chart II for troubleshooting excessive heat Pump Heated

Motor Heated Cause

Relief Valve Heated

Cause

Remedy

Remedy

Cause

Remedy

Fluid heated

See Fluid Heated

See Fluid Heated

System pressure too high

D

Cavitation

A

Relief or unloading valve set too high

D

Valve setting incorrect

D

Unloading valve set too high

D

Air in fluid

B

Excessive load

C

Worn or damaged valve

E

Fluid dirty or low supply

F

Relief or unloading valve set too high

D

Worn or damaged motor

E

Incorrect fluid viscosity

F

Excessive load

C

Faulty fluid cooling system

G

Worn or damaged pump

E

Worn pump, valve motor, cylinder, or other component

E

Fluid heated

Remedy See Fluid Heated

Cause

Fluid Heated

Fluid heated

A. Any or all of the following:      

replace dirty filters clean clogged inlet line clean reservoir breather vent change system fluid change to proper pump drive motor speed overhaul or replace supercharge pump

F.  change filters  check system fluid viscosity; change if necessary  fill reservoir to proper level G.  clean cooler and/or strainer  replace cooler control valve  repair or replace cooler

B. Any or all of the following:  tighten leaky inlet connections  fill reservoir to proper levels: with few exceptions, all return lines should be below fluid level in the reservoir  bleed air from system  replace pump shaft seal; also replace shaft if worn at seal journal C. All of the following:  align unit  check condition of seals, bearings, and coupling  locate and correct mechanical binding  check for workload in excess of circuit design D.  install and/or adjust pressure gauge; keep at least 125 psi difference between valve settings E.  overhaul or replace defective parts

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Remedies

_____________________________________________ Troubleshooting Table 6: Flow chart III for troubleshooting incorrect flow No Flow Cause

Low Flow Remedy

Cause

Excessive Flow Remedy

Cause

Remedy

Pump not receiving fluid

A

Flow control set too low

D

Flow control set too high

D

Pump drive motor not operating

E

Relief or unloading valve set too low

D

RPM of pump drive motor incorrect

H

Pump to drive coupling sheared

C

Flow by-passing thru partially open valve

E of F

Improper size pump used for replacement

H

Pump drive motor turning in wrong direction

G

External leak in system

B

Directional control set in wrong position

F

RPM of pump drive motor incorrect

H

Entire flow passing over relief valve

D

Worn pump, valve, motor, cylinder, or other component

E

Damaged pump

C

Pilot filter clogged

A

Improperly assembled pump

E

Pilot filter clogged

A

Remedies

© BUCYRUS

A. Any or all of the following:     

replace dirty filters clean clogged inlet line clean reservoir breather vent fill reservoir to proper level overhaul or replace supercharge pump

F. Any or all of the following   check position of manually operated controls  check electrical circuit on solenoid operated controls  repair or replace pilot pressure pump G.  reverse rotation

B. Any or all of the following: H.  replace with correct unit  tighten leaky inlet connections  bleed air from system C. All of the following:  check for damaged pump or pump drive  replace and align coupling D.  adjust setting on valve E.  overhaul or replace part

_____________________________________________________________ A6474X337 VLSS/0 5.293

Troubleshooting ______________________________________________ Table 7: Flow chart IV for troubleshooting incorrect pressure No Pressure

Low Pressure

Erratic Pressure

Cause

Remedy

Cause

Remedy

No flow

See Table 5

Pressure relief path exists

See Table 5

Pressure reducing valve set too low

Cause

Excessive Pressure

Remedy

Cause

Remedy

Air in fluid

B

Pressure reducing, relief, or unloading valve misadjusted

D

D

Worn relief valve

E

Pressure recuing, relief, or unloading valve worn or damaged

E

Pressure reducing valve damaged

E

Contamination in fluid

A

Damaged pump, motor, or cylinder

E

Accumulator defective or has lost charge

C

Worn pump, motor, or cylinder

E

Remedies A.  replace dirty filters and system fluid

C.  gas valve for leakage  charge to correct pressure  overhaul if defective D.  adjust valve E.  overhaul or replace part

_________________________________________________________________ 5.294 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS

B.  tighten leaky connections  fill reservoir to proper level and bleed air from system

_____________________________________________ Troubleshooting Table 8: Flow chart V for troubleshooting faulty operation No Movement Cause

© BUCYRUS

No flow or pressure

Slow Movement

Remedy

Cause

See Table Low flow 5

Erratic Movement

Excessive Speed or Movement

Remedy

Cause

Cause

See Table 5

Erratic pressure

See Table Excessive flow 6

See Table 5

Air in fluid

See Table Feedback 3 transducer malfunctioning

E

Remedy

Remedy

Limit or sequence device (mechanical, electrical, or hydraulic) inoperative or misadjusted

E

Fluid viscosity too high

A

Mechanical bind

B

Insufficient control pressure for valves

See Table 6

No lubrication of machine ways or linkage

G

Misadjusted or malfunctioning valve amplifier

C

No command signal to valve or amplifier

F

No lubrication of machine ways or linkage

G

Erratic command signal

F

Overriding work load

H

Inoperative or misadjusted valve amplifier

C

Misadjusted or malfunctioning valve amplifier

C

Misadjusted or malfunctioning valve amplifier

C

Inoperative solenoid or proportional valve

E

Sticking valve

D

Malfunctioning feedback transducer

E

Worn or damaged cylinder or motor

E

Worn or damaged cylinder or motor

E

Sticking valve

D

Pilot filter clogged

See Table 5

Worn or damaged cylinder or motor

E

Remedies A.  check fluid temperature  check system fluid viscosity; change if necessary B.  locate bind and repair C.  adjust, repair, or replace part D.  clean and adjust or replace part  check condition of system fluid and filters E.  overhaul or replace part F.  repair command console or interconnecting wires G.  lubricate H.  adjust, repair, or replace counterbalance valve

_____________________________________________________________ A6474X337 VLSS/0 5.295

Troubleshooting ______________________________________________ Table 9: Restarting checklist Has the cause of the failure been remedied?

No

Carry out further investigation.

Yes

Clean or flush the system as required.

Yes Can dirt have entered the system by the unit failure or during replacement?

No Is the unit the correct one?

No

Modify or replace with correct unit.

No

Remedy installation.

No

Remedy installation.

Yes

Is the unit adjusted to a safe condition for start up?

Yes Are all hydraulic connections correct?

Are all electrical connections correct?

Yes Is the unit adjustable?

No

Adjust to a safe condition.

Yes No Have the cases of pumps and motors been filled?

No

Fill case.

Yes

Bleed or prime as necessary.

No

Remove safety interlocks.

No

Sound alarm or inform personnel.

Yes Will the system require bleeding or priming?

No Have all safety interlocks been removed

Yes Are all personnel aware the machine is restarting?

Yes Start machine (see Startup procedure in this chapter).

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© BUCYRUS

Yes

_____________________________________________ Troubleshooting Bearings Table 11: Bearing troubleshooting Trouble, symptom or cause

Probable cause

© BUCYRUS

overheating bearing  Wrong type of grease or oil.

Test, check and/or remedy  Consult the lubrication chart for the proper lubricant.

 Low oil level; loss of lubricant through seal; excessive grease.

 Oil level should normally be at the center of lowest ball or roller in bearing; check seals for signs of leaking.

 Insufficient clearance in bearing.

 Replacement bearing should be identical to original equipment to ensure proper internal clearance.

 Housing bore out of round; housing warped; excessive distortion of housing; undersized housing bore.

 Check and scrape housing bore to relieve pinching of bearing; be sure pedestal surface is flat and shims cover entire area of pillow block base when applicable.

 Shaft out of line.

 Correct alignment and be sure shafts are coupled in a straight line.

noisy bearing  Insufficient clearance in bearing.

 Replacement bearing should be identical to original equipment to ensure proper internal clearance.

 Foreign matter acting as abrasive.

 Clean bearing housing and replace worn seals.

 Housing bore out of round; housing warped; excessive distortion of housing; undersized housing bore.

 Check and scrape housing bore to relieve pinching of bearing; be sure pedestal surface is flat and shims cover entire area of pillow block base when applicable.

 Shaft and other parts of bearing assembly distorted.

 Replace bearing, shaft and other parts as needed.

vibrating bearing  Enlarged housing bore causing spinning of outer ring in housing.

 Re-bore housing and press steel bushing in bore, then machine bore to correct size.

 Foreign matter acting as abrasive.

 Clean bearing housing and replace worn seals.

 Unbalanced loading

 Check balance of rotating parts and rebalance as needed.

unsatisfactory performance  Chip in bearing housing; insufficient clearance in bearing; Ball or roller dented from extreme loading.

 Replace with OEM bearing; do not hammer on any part of bearing; clean housing and use fresh lube.

_____________________________________________________________ A6474X337 VLSS/0 5.297

Troubleshooting ______________________________________________ Control system troubleshooting The control system has visual troubleshooting aids to allow operators and maintenance personnel to quickly determine the cause of most operating faults.

IMPORTANT! All troubleshooting beyond observing the fault must be performed by qualified individuals.

The troubleshooting aids available are:  View panel display with both graphic and text messages.  Fault messages that appear for ten (10) seconds when the system detects a fault.  A permanent, time-stamped fault log that is a record of faults that have occurred. The fault log is a separate menu page.  Error messages that appear on the display whenever an action is prevented from execution due to a fault condition.  LED indicators located on various control system components.

 The remote control system does not recognize hydraulic system problems that are not related to the pump motor.  Most faults only affect one machine function. If multiple faults occur, the most significant fault is displayed first, then the next, and so on.  The system does not recognize power lost to the machine unless initiated by the machine control unit. If the system initiates the power loss, it will indicate such action when power is restored.

IMPORTANT! The following troubleshooting information is not intended to imply breaching any safety devices (methane barriers, hazardous isolation barriers, etc.). Do not attempt to access troubleshooting indicators (LEDs) or take measurements that may result in an unsafe working environment. All laws and regulations must be strictly adhered to.

WARNING! Only qualified personnel with approved training on this equipment and knowledge of MSHA safety requirements are permitted to perform troubleshooting on this system.

_________________________________________________________________ 5.298 Bucyrus – Model 30M4-NP Continuous Miner

© BUCYRUS

When troubleshooting the system, note the following:

_____________________________________________ Troubleshooting Emergency tram pendant LEDs The emergency tram pendant is used during times when the remote control is inoperable. The tram pendant cannot be used unless the MCU is disabled by turning the “MINER MODE” switch to the “OFF/ETRAM” position. There are LEDs in the upper right corner of the pendant (Fig. 266). The functions of these LEDs are given in Table 16.

Fig. 166: Tram drive LEDs

LEDs

© BUCYRUS

Table 16: Emergency tram pendant LED descriptions LED

Function

Description

MODE

Mode

Blinks green when power is present indicating the unit has power and is on.

TRME

Tram Enable

Note: Tram enable is not possible unless all tram motion buttons are in the idle (inactive) position.

The LED is normally unlit. When the tram motions buttons are in the idle position and the “TRAM” button is pressed, tramming is enabled and the LED lights yellow. Tram enable will be active for a preset amount of idle time or as long as a tramming function is being performed. If no tramming function is performed during the preset amount of time, tram enable is turned off and the LED turns off.

TRML

Tram Left

Default for the LED is unlit. If the tram left function is initiated while the TRME LED is yellow (tram enabled), the TRML LED will light red, indicating directional movement is granted. The operator can select “TRAM FWD” or “TRAM REV”.

TRMR

Tram Right

Default for the LED is unlit. If the right tram function is initiated while the TRME LED is yellow (tram enabled), the TRML LED will light red, indicating directional movement is granted. The operator can select “TRAM FWD” or “TRAM REV”.

_____________________________________________________________ A6474X337 VLSS/0 5.299

© BUCYRUS

Troubleshooting ______________________________________________

_________________________________________________________________ 5.300 Bucyrus – Model 30M4-NP Continuous Miner

_______________________________________________________________

6

Technical data

________________________________________________________________

________________________________________________________________

_________________________________________________________________

_______________________________________________ Technical data

Technical data This chapter contains the most important technical data on the 30M4NP Continuous Miner. Further data can be found in the spare parts lists. At the end of this chapter you will find information on the bolt tightening torques, HFA fluids, greases, etc. Read this chapter through carefully and pay particular attention in particular to the safety instructions.

IMPORTANT! The technical data listed in this chapter is for stock machines only. Customer specials may not be listed.

Components of the 30M4-NP Continuous Miner Note: All dimensions and rates are based on a 44 inch diamter cutting drum and a ground clearance of 14 inches.

© BUCYRUS

Technical data sheet operating dimensions

Recommended mining range............................... approx. 90 to 183 in Minimum height over cutter boom assembly ....... approx. 85 in Maximum mining height ....................................... approx. 185 in Minimum mining height (Zero Cut) ...................... approx. 84 in Maximum reach ................................................... approx. 183 in Ground clearance (without 3 in lift kit) approx. 14 in Length (bumper to face)....................................... approx. 325 in (27 ft)

transport dimensions

Width (outside of rub rails) ................................... approx. 132 in (11 ft) Overall length....................................................... approx. 443 in (37 ft) Weight (total)........................................................ approx. 160,000 lbs

cutter unit

loading unit

traction unit

Cutter drum diameter ........................................... approx. 44 in Cutter drum width................................................. approx. 156 in (13 ft) Cutter head speed ............................................... approx. 675 fpm Loading method ................................................... 3 finger CLA Conveyor width .................................................... approx.30 in Conveyor speed................................................... approx. 442 fpm Conveyor depth (without sideboards) .................. approx. 12 in Loading capacity .................................................. approx. 12 to 30 tpm Crawler chain width.............................................. approx. 22 in Crawler assembly length...................................... approx. 107 in Ground pressure (average) ................................. approx. 34 psi Crawler speed...................................................... 0 - 65 fpm

______________________________________________________________ A6474X337 VLSS/0 6.3

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

IMPORTANT! Use a calibrated torque wrench for accuracy!

Bolt size (inches) 1/4 5/16

Dry ft-lbs 12 25

Lubricated ft-lbs 6 12

3/8

44

22

7/16

70

35

1/2

107

53

9/16

154

77

5/8

212

106

3/4

376

188

7/8

606

303

1

909

454

1-1/8

1287

644

1-1/4

1875

938

1-3/8

2382

1191

1-1/2

3161

1581

1-3/4

4988

2494

2

7500

3750

2-1/4

10969

5484

2-1/2

15000

7500

2-3/4

17794

8897

3

23507

11753

3-1/4

30286

15143

3-1/2

38266

19133

3-3/4

47545

23773

4

58100

29085

© BUCYRUS

Table 12: Grade 8 bolt torque specifications (calculated at 75% proof load)

_________________________________________________________________ 6.4 Bucyrus – Model 30M4-NP Continuous Miner

___________________________________________ Tightening torques Table 13: Metric bolt torque specifications (calculated at 75% proof load)

© BUCYRUS

Property Class

8.8

10.9

12.9

M6 - M16: 800 M20 - M30: 830

1040

1220

Minimum Tensile Strength (MPa) Nominal Size and Thread Pitch

Dry ft-lbs (in-lbs)

Lubricated ft-lbs (in-lbs)

Dry ft-lbs (in-lbs)

Lubricated ft-lbs (in-lbs)

Dry ft-lbs (in-lbs)

Lubricated ft-lbs (in-lbs)

M5 X 0.80 M6 X 1.00

(54) (92)

(41) (69)

(78) (133)

(59) (99)

(91) (156)

(68) (116)

M7 X 1.00

(156)

(116)

(222)

(167)

(260)

(195)

M8 X 1.25

(2250

(169)

(333)

(242)

(377)

(284)

M10 X 1.50

37

28

53

40

62

47

M12 X 1.75

65

49

93

69

108

81

M14 X 2.00

104

78

148

111

173

130

M16 X 2.00

161

121

230

172

269

202

M18 X 2.50

222

167

318

238

372

279

M20 X 2.50

314

235

449

337

525

394

M22 X 2.50

428

321

613

460

716

537

M24 X 3.00

543

407

776

582

908

681

M27 X 3.00

796

597

1139

854

1331

998

M30 X 3.50

1079

809

1543

1158

1804

1353

M33 X 3.50

1468

1101

2101

1576

2455

1842

M36 X 4.00

1886

1415

2699

2024

3154

2366

______________________________________________________________ A6474X337 VLSS/0 6.5

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

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

© BUCYRUS

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

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

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

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

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

_________________________________________________________________ 6.6 Bucyrus – Model 30M4-NP Continuous Miner

___________________________________________ Permissible media Approved suppliers: Table 14: Anti-wear hydraulic oil (Spec 100-1) 1 2 3 4 5 6 7 8 9 10 11 12 13

14 15 16 17 18

Supplier Amoco Oil Company Gulf Oil Mobil Oil Corporation Chevron U.S.A. Sun Oil Company Unocal 76 Shell Oil Company Century Lubricating Oils, Inc. Atlantic Richfield Company Texaco Lubricants Company Exxon Pennzoil Standard Oil Company Standard Oil Co. of Ohio Boron Oil Company BP Oil Inc. Lubricating Engineers Conoco Inc. Hydrotex Phillips Miners Oil

Brand name Amoco AW Oil No. 68 Harmony 68 AW Mobil DTE-16 Chevron hydraulic Oil Aw ISO 68 Sunvis 868 Unax AW 68 Shell Hydraulic Oil #33 Hydraulic AW 68 Duro AW S-315 Oil Texaco Rando Oil HD 68 Nuto 68 Pennzbell AW 68 Hydraulic Oil Industron 54 Industron 53 Energol HLP-C68 6120 Monolec Hydraulic Oil Super Hydraulic oil 68 Systems 5K 68 Maginus A Oils 81350 Hydraulic Oil 68AW

© BUCYRUS

Table 15: Extreme pressure gear oils (Spec. 100-2) 1 2 3

Supplier Amoco Oil Company Gulf oil Mobil Oil Corporation

4

Chevron U.S.A.

5 6

Sun Oil Company Unocal 76

7 8

Shell Oil company Century Lubricating Oils, Inc.

9 10 11

Texaco Lubricants Company Exxon Pennzoil

12

Lubricating Engineers

13 14 15

Conoco Inc. Hydrotex Phillips

16

Miners Oil

Brand name Amoco Permagear EP 460 EP Lubricant HD 460 Mobil Gear 634 Mobil Gear 636 Chevron Gear Compound EP ISO 460 Sunep 460 Extra Duty NL Gear Lube 7 EP Extra Duty NL Gear Lube 8 EP Shell Omala 680 Hulbest EP-7 Powergear 460 Meropa 680 Spartan EP 460 Super Maxol EP 460 Gear Lube Super Maxol EP 460 Gear Lube 608 Almosal Vari-Purpose Gear Lubricant Gear oil 460 933 Industrial Gear Lubricant All Purpose Gear Oil 85W-90 5EP Gear Oil EP460

______________________________________________________________ A6474X337 VLSS/0 6.7

Permissible media ____________________________________________ Table 16: Extreme pressure motor bearing grease (Spec. 100-3)

1

Supplier Amoco Oil Company

2 3 4

Gulf Oil Mobil Oil Corporation Chevron U.S.A.

5 6 7 8

Sun Oil Company Unocal 76 Shell Oil Company Century Lubricating Oils, Inc.

9 10 11 12 13

Texaco Lubricants Company Exxon Pennzoil Lubricating Engineers Conoco Inc.

14 15 16

Hydrotex Phillips Atlantic Richfield

Brand name Amolith Grease 2 EP Rykon Premium Grease 2 EP Gulfcrown Grease EP#2 Mobilux EP-2 Chevron Dura-Lith Grease EP-2 NLGI 2 Sun Prestige 742EP Multiplex EP2 Alvania EP-2 Hullith EP2 Multipurpose Grease, or Replex2, or Uniwrl 2, or Uniwrl EMB, or Hullith GP 2, or Hullith EP 2 Texaco Multifak EP 2 Lidok EP 2 Pennlith EP 712 Grease 3752 Almagard Vari-Purpose Lubricant EP Conolith Grease No. 2 or Super Sta Grease No. 2 LC-65 Hyplex Philube EP Grease Litholine H EP-2 Grease

1 2 3 4 5 6

Supplier Texaco Lubricants Company Century Oils Limited Hydrotex Pennzoil Unocal Exxon

Brand name Novatex EP 000 Joy Loader Semi-Fluid Grease MPD-60 Ultra E.P. 000 Semi-Fluid 760 Grease MM Grease Lidok E.P. 000

© BUCYRUS

Table 17: Semi-fluid grease (Spec. 100-4)

_________________________________________________________________ 6.8 Bucyrus – Model 30M4-NP Continuous Miner

___________________________________________ Permissible media Table 18: Invert emulsion hydraulic fluid (Spec. 100-5)

10 11

Supplier Unocal 76 Conoco Inc. Atlantic Richfield Company Brooks Oil Company Cincinnati – Vulcon Company Cities Service Oil company Century Oils Limited Fiske Bros. Refining Company Getty Oil Company (Veedol, Tidewater) Gulf Oil Company E.F. Houghton

12 13 14 15 16 17

Century Lubricating Oils Imperial Oil and Grease Mobil Oil Corporation National Oil and chemical Co. Pennzoil Quaker Chemical Company

18

22 23 24 25

Henery E. Sanson and Sons MFGE Company Southwest Grease and Oil Company, Inc. Southwest Petroleum Corp.

Standard Oil Company of Ohio (Boron Sohio) Sun Oil Company Tower Oil Company Wynn Oil Company Lubrication Engineers

26

Hydrotex

1 2 3 4 5 6 7 8 9

19

© BUCYRUS

20 21

Brand name FR Fluid FR Hydraulic Fluid Duro FR-HD Brooks fire Resistant Hydraulic Fluid B Vulcon FR Fluid #1 Citgo Pacemaker Invert FR Fluid Aquacent Light Lubriplate HO-Retard Veedol Auburn FRH FR Fluid Houghto-Safe 5046 Houghto-Safe 5046W Hulsafe 600 Astrol 587 Pyrogard D Erifon 1, 2, and 3 Maxmul FRP/G Quintolubric 958 Series Quintolubric 958 Series Hydra-Mul Premium Emulsion Fluid Invert Emulsion Fire Resistant Hydraulic Fluid Swepco Fire Resistant Hydraulic oil #718 Staysol FR Sunsafe F Safoil Anti-Wear Hydraulic Fluid Hydra-Safe heavy Medium 6455 Monolec Fire Resistant Hydraulic Fluid HY-Guard

Table 19: Extreme pressure gear oil, SAE 90 (Spec. 100-6) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Supplier Amoco Oil Company Gulf Oil Mobil Oil Corporation Chevron U.S.A. Sun Oil Company Unocal 76 Shell Oil Company Century Lubricating Oils, Inc. Texaco Lubricants Company Exxon Pennzoil Lubricating Engineers Conoco Inc. Hydrotex Phillips Atlantic Richfield Cities Service Pennzoil Miner Oil Texaco, Lubricants Company

Brand name Amoco Premagear EP 320 EP Lubricant HD 320 Mobil Gear 632 Chevron Gear Compound EP ISO 320 Sunep 320 Extra Duty NL Gear Lube 6EP Omala 75 Hulbest EP-6 Meropa 320 Spartan EP 320 Super Maxol EP 220 Gear Lube 605 Almasol Vari-Purpose Gear Lubricant Gear Oil 320 932 Industrial Gear Lube Philube All Purpose Gear Oil 85W-90 Pennant NL S-1000 Citgo EP Compound 110 Pen Gear #320 Gear Oil EP220 Texaco Multigear EP 80W-90

______________________________________________________________ A6474X337 VLSS/0 6.9

Permissible media ____________________________________________ Table 20: Hydraulic and general purpose oil medium-heavy/R&O inhibited (Spec. 100-7) 1 2 3 4

Supplier Amoco Oil Company Gulf Oil Mobil Oil Corporation Chevron U.S.A.

5 6

Sun Oil Company Unocal 76

7 8 9 10 11 12 13

Shell Oil Company Century Lubricating Oils, Inc. Texaco Lubricants Company Exxon Pennzoil Lubricating Engineers Conoco Inc.

14 15 16 17 18

Hydrotex Atlantic Richfield Cities Service Miner Oil Texaco, Lubricants Company

Brand name American Industrial Oil No. 68 Harmony 68 DTE Heavy – Medium Chevron Turbine Oil ISO 68 or Chevron Machine Oil R&O ISO 68 Sunvis 754 Unax RX68 or Turbine Oil 68 Turbo 68 Centraulic R&O 68 Regal Oil R&O N-68 Tresstic 68 Pennzbell RO 68 6120 Monolec Turbine Oil Detol R&O 68 or Turbine Oil 68 Systems 1, System 5K 68 Duro 5.315 Citgo Pacemaker A/W68 Hydraulic Oil AW68 TDH 1893

1 2 3 4

Supplier Amoco Oil Company Gulf Oil Mobil Oil Corporation Chevron U.S.A.

5 6

Sun Oil Company Unocal 76

7 8

Shell Oil Company Century Lubricating Oils, Inc. Atlantic Richfield Company Texaco Lubricants Company Exxon Pennzoil Cities Service Lubrication Engineers Conoco Inc. Hydrotex Phillips Miner Oil

9 10 11 12 13 14 15 16 17 18

Brand name American Industrial oil No. 150 Harmony 150 DTE Oil EX. Heavy Chevron Machine Oil AW ISO 150M or Chevron Machine Oil R&O ISO 150 Sunvis 961 Unax RX 700 or Turbine Oil 700 Turbo 150 Centraulic R&O 150

© BUCYRUS

Table 21: Hydraulic and general purpose oil heavy/R&O inhibited (Spec. 100-8)

Duro 600 or S-700 Regal Oil R&O 150 Teresstic 150 Pennzbell RO 150 Citgo Pacemaker 150 6405 Monolec Turbine Oil Dectol R&O 76 System 1 150, System 5k 150 Magnus Oils 700 ISO 150

_________________________________________________________________ 6.10 Bucyrus – Model 30M4-NP Continuous Miner

___________________________________________ Permissible media Table 22: Worm gear lubricant, compounded cylinder oil (Spec. 100-9) 1 2 3 4 5 6 7 8 9 10 11

Supplier Amoco Oil Company Mobil Oil Corporation Chevron U.S.A. Sun Oil Company Unocal 76 Century Lubricating Oils, Inc. Atlantic Richfield Company Texaco Lubricants Company Exxon Pennzoil Conoco Inc.

Brand name Cylinder oil No. 1000 Extra Hecla Super Cylinder Oil Chevron Cylinder Oil W ISO 1000 Sun Steam Cylinder Oil Worm gear Lube 250 or Stevalc Garwal 680 Modoc 195 650 T Cylinder Oil 1000 Cylesstic TK-1000 Cylinder Oil #1000 Inca Oil 1000

© BUCYRUS

Table 23: Light gear oil, SAE 40 motor oil (Spec. 100-10) 1 2 3 4 5 6 7

Supplier Amoco Oil Company Gulf Oil Mobil Oil Corporation Chevron U.S.A. Sun Oil Company Unocal 76 Shell Oil company

8 9 10

Century Texaco Lubricants Company Exxon

11 12 13

Pennzoil Lubricating Engineers Conoco Inc.

14 15

Hydrotex Phillips

Brand name Amoco 300 SAE 40 Super Duty 40 Delvac 1340 Chevron RPM Heavy Duty Motor Oil 15W-40 Sunoco Super C 40 Guardol Motor Oil SAE 40 Rotella Oil 40 (Automotive) Turbo Oil 150 (Industrial) Rimula CT40 (Foreign) Rotela SX40 (Foreign) Flexe SAE 40 Ursa Super plus SAE 40 XD-3 Extra SAE 40 or XD-3 SAE 40 Long Life SAE 40 Motor Oil 8440 Monolex GFS Engine Oil Fleet Heavy Duty Motor Oil SAE 40 Hyfilm SAE 40 Super HD II Motor Oil SAE 15W-40

Table 24: Synthetic EP gear lubricants (Spec. 100-11) 1

Supplier Century Lubricants Company

Brand name Synthetic EP Gear Lubricants

Table 25: Multi-purpose tractor hydraulic fluid (Spec. 100-12) 1 2 3 4 5 6 7

Supplier Exxon / Mobil Century / Fuchs Shell Chevron BP Lubricants Quaker State Conoco

Brand name Mobilfluid 424 Multitran Donax TD Tractor Hydraulic Fluid Tractran UTH Quaker State FCI HD Powertran Fluid

______________________________________________________________ A6474X337 VLSS/0 6.11

Permissible media ____________________________________________ Table 26: Extreme pressure gear oil (Spec. 100-13) 1

Supplier Century Lubricants

Brand name Powergear H680

Table 27: High temperature lithium complex motor bearing grease (Spec. 100-14) 1 2 3

Supplier Mobil Conoco Phillips Shell

Brand name Mobilith SHC 100 Triton 100 Albida EMS 2

Table 28: High demulsibility EP gear oil (Spec. 100-15) Supplier Conoco

Brand name GLW Gear Oil 220

© BUCYRUS

1

_________________________________________________________________ 6.12 Bucyrus – Model 30M4-NP Continuous Miner

_______________________________________________________________

7

For your information

________________________________________________________________

________________________________________________________________

_________________________________________________________________

_________________________________________________ Our service

For your information Our service If you need to order spare parts or if technical problems occur, please contact our after-sales service personnel or contact us direct.

© BUCYRUS

Service address Beckley, WV 200 George Street, Suite 4 Beckley, WV 25801 Phone: (304) 256-5927 Fax: (304) 256-5928

Craig, CO 400 Mack Lane Craig, CO 81625 Phone: (970) 824-3249 Fax: (970) 824-8851

Pulaski, VA 4041 Wurno Road Pulaski, VA 24301 Phone: 540-980-4530 Fax: 540-980-6211

Washington, PA 255 Berry Road Washington, PA 15301 Phone: (724) 743-1200 Fax: (724) 228-2177

Duffield, VA P.O. Box 847 6808 Fraley Avenue Duffield, VA 24244 Phone: (276) 431-7000 Fax: (276) 431-2464

Houston, PA 2045 West Pike Street Houston, PA 15342 Phone: (724) 743-1200 Fax: (724) 743-1201

Carrier Mills, IL 9580 State Route 13 West Carrier Mills, IL 62917 Phone: (618) 982-9000 Fax: (618) 982-9912

Oak Hill, WV P.O. Box 60 843 Lochgelly Road Oak Hill, WV 25901 Phone: (304) 469-3302 Fax: (304) 465-0450

Paonia, CO P.O. Box 566 719 Second Street Paonia, CO 81428 Phone: (970) 527-3151 Fax: (970) 527-6846

______________________________________________________________ A6474X337 VLSS/0 7.3

Our service __________________________________________________ Rebuild facility address Huntington, UT P.O. Box 1190 Route 10, 1Mile North Huntington, UT 84528 Phone: (435) 687-9831 Fax: (435) 687-2522

Norris City, IL 635 Illinois Highway 1 Norris City, IL 62869 Phone: (618) 378-3441 Fax: (618) 378-3106

© Bucyrus

Pearisburg, VA P.O. Box 463 222 Industrial Park Drive Pearisburg, VA 24134 Phone: (540) 921-2111 Fax: (540) 921-2711

_________________________________________________________________ 7.4 Bucyrus – Model 30M4-NP Continuous Miner