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ThismanualisintendedtoprovideGENERALproductinformation. Theillustrations,descriptionsandprocedurescontainedinthispublicationapplyonlytoTHISmachine.Bucyrusreservestherighttorevise modelsanddesignswithoutpriornotice.
Thismachinewasmanufacturedundertheguidelines,proceduresand requirementsoftheappropriategovernmentregulatoryagencies.
Atthecompletionofthemanufacturingprocess,thisunitwasissued theappropriateapprovalnumbersandnameplatesindicatingitmetthe technicalrequirementsoftheseregulatoryagencies.Anychangeto thedesignorstructureofthisunit,withouttheconsentofBucyrusand theseregulatoryagencies,oranyrepairorreplacementofpartscontrarytoBucyrus’instructions,mayinvalidatetheseapprovalsandrenderthisunitunsafetooperate.
Strictcompliancewithalllaws,regulationsandpracticesregardingthe safeoperationandmaintenanceofundergroundminingequipmentand strictadherencetotheinstructionsinthismanualisnecessaryforthe personalsafetyofthoseworkingonoraroundthisunit.
Whilethismanualattemptstoanticipatethemostimportantoperations andmaintenanceneedsforthisunit,unforeseencircumstancesmay arisethathavenotbeenaddressedinthismanual.Ifanyconcernsor questionsarise,pleasecontactyourBucyrusServiceRepresentative immediately
Thisworkcontainsinformationprotectedundertradesecretandother intellectualpropertylaws,andisprotectedundertheU.S.Copyright Actof1976,asamended.Thisworkisprovidedunderlicenseandthe licenseisnon-transferable.Distributionandaccessislimitedonlyto authorizedpersonnel.Disclosure,reproduction,distributionorunauthorizedusemaybeaviolationoffederalandstatelawsandmaysubjecttheunauthorizedusertocriminalliability.
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Safetyinstructions
SafetyPrecautions
Thefollowingsafetyprecautionsshouldbeobservedwheneveroperatingor performinganymaintenance,repair,oradjustmentprocedureonthismachine. Additionalprecautionsmayappearineachsectionofthisbook.Allprecautions listedapplicabletothismachine,aswellasallapplicableregulatoryagency rulesandregulationsmustbefollowedatalltimes.
Failuretomaintainthehydraulicsystemwillresultindamagetoitshydrauliccomponentswhichwillresultinincreasedwearandprematurefailure.
Duringdisassemblyofcontrolvalves,giveparticularattentiontoidentificationofparts forreassembly.Spoolsareselectivelyfittedtovalvebodiesandmustbereturnedtothe samebodiesfromwhichtheywereremoved.SpoolsareNOTinterchangeablebetween valvebodies.
Donotsalvagespoolsorvalvebodiesforlaterusein“new”combinations.Damagedor impropercomponentsusedduringassemblymayresultininternalleakageorin “sticking"(hangingup)ofthespoolinthevalvebody.Incorrectcomponentcombinationsmayresultinimproperoperationofthevalvesection,possiblycausingunexpected machineoperationthatcouldresultinmachinedamageorinjurytopersonnel.
Thetwoinchlockingballvalvebetweenthepumpandmaincontrolvalvemustbe lockedopeninnormaloperation.
Neverruntheconveyorwithouttheneedlevalveclosed.Injuryordeathmayoccur.
Theareaunderandaroundtheraisedcutterheadisdangerous.Securelyblockthe headbeforeperformingmaintenanceonorbelowit.Failuretoblocktheraisedcutter headcouldresultinseriousinjuryorevendeath.
Donotadjust,modify,orremovetheloadholdingcartridgevalvemountedinthecutter headcylinders.Itisasafetyfeaturetopreventaccidentalloweringofthecutterhead.
Thisloadholdingvalve,likethoseonthestabilizercylindersispreset. DONOTADJUST IT.Ifitmalfunctions,replaceitimmediately.
Youcouldbeseriouslyinjuredorkilledbyfallingloads.Blocktheminerbeforeperformingmaintenanceandalwaysobservethesafeworkingloadlimitsofallliftingandblockingdevices.
Useextremecautionwhenperformingtestproceduresandmakingadjustments.Unless notedintheprocedures,allcontrolsaretobeintheneutralposition.
Alwaysusethepropertoolswhenadjustingvalvecartridges.
Donotstartanymotors - CLA,cutterhead,pump,ortractionmotors - untilallpressures areset.Startthepumpmotorasdirected.
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IMPORTANT
Neverrelyontheloadholdingvalveasameansofsupportingthecutterorconveyor boomwhilemakingrepairs.Severeinjuryordeathcouldresult.
Twopeoplearerequiredtoadjustpressuresettings.Onepersonwillmaketheadjustmentswhilethesecondpersonmustremainatthemachinestopatalltimesduringthe adjustmentprocedure.Failuretodosomayresultinseriousinjuryordeath.
Beforemakinganyfurtheradjustments,verifythatthehydraulicoilisatoperating temperature.
Alwaysallowcylinderfunctionstobottomout(stopmoving)beforeadjustingany pressure.Pressureadjustmentswillonlybeaccuratewhenthecylinderisinthiscondition.
Themainreliefissethigherthantheportreliefsandwillonlyrelieveifaspikeoccursin thesystemoriftheportreliefdoesnotfunctionproperly.Thisprovidesprotectionof themainpumpsection.
Donotadjustthemainreliefover3,000psi(207bar).Destructionofthevalvebankand themainpumpcouldresult.
Alwaysbealertforanyunintendedmachinemovement.
ReferencetheHydraulicsectioninthischapterforindividualcircuitinformation.AlwaysrefertothehydraulicschematicinyourBucyrusAmerica,Inc.partsmanualfor yourminer.
Keepbodypartsclearofmachinewhileinraisedpositionorseriousinjurycouldresult.
Someproceduresmustbecarriedoutwiththecoveroftheelectricalcontrollerremoved andsomeproceduresrequirethecontrollertobeenergizedduringthetests.Itisextremelyimportantthatyoutakeallnecessaryprecautionstopreventaccidentalelectricalshockwhileworkingwithinthecontroller.Ancertifiedelectricianmustsupervise andinspectallworkperformed.
Neverdisconnectahydraulichoseifthecircuitispressurizedorthereisaloadonthe circuit.Ifahoseisdisconnectedwhilethecylinderissupportingaload,theloadwill fall.
Hydraulicpowerforallhydraulically-actuated functionsoriginateswiththe pumpassembly.Thisincludespowerforcylinders,hydraulic motors,controlvalves,andpilotvalves.
Fig.1givesanoverviewofhydrauliccylinderslocatedonthe35M3LContinuousMiner.Fig.2showsthelocationofotherhydrauliccomponents.
Thissectiongivesgeneraldescriptionsofthehydrauliccomponentsusedon themineralongwithtypicalschematicsforhydraulicfunctions.Theschematics inthissectionaregeneral;alwaysrefertothehydraulicschematicinyourBucyrusAmerica,Inc.partsmanualsuppliedwithyourmachine.
Inorderforahydraulicsystemtofunctioncorrectly,itmustbeproperlymaintained.Maintenanceofthehydraulicsystemincludes:
1. maintainingatmosphericpressureinthetankbykeepingthebreatherclean andfreeofobstructions;
2. maintainingasufficientoillevelinthetank;
3. maintainingtight,leak-proofpumpsuctionlinestoprohibitairbeingpumped throughthesystem;and
4. changingfiltersandfluidsatprescribedintervals.
Forcompletemaintenanceprocedures,seetheMaintenanceManual.
Failuretomaintainthehydraulicsystemwillresultindamagetoitshydrauliccomponentswhichwillresultinincreasedwearandprematurefailure.
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Fig.1:Cylinderlocations
1. Cutterheadraisecylinder 2. Gatheringheadraisecylinder 3. Conveyorliftcylinder
4. Stabilizershoecylinder 5. Conveyorswingcylinder 6. Conveyorchaintake-upcylinder
Fig.2:Hydrauliccomponentlocation
Breather
Tankmagnet
Oillevelswitch
Gatheringheadfloatvalve
Conveyorchaintake-upvalve
Reliefvalve,pilotpressure
7. Pilotpressurefilter
Mainpressuregauge
Hydraulicpump
Valvebank
Anti-chatter/maintenancevalve
Dustcoolingsolenoidvalve
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TheMainControlValve(MCV)(Fig.3),typicallylocatedontherightsideofthe machine,consistsofaseriesofdirectionalcontrolvalvesassembledinarow. Typically,thereare(5)fiveworkingsections.TheMCVdirectsfluidflowtoperformaspecificfunctionofworkthattransformshydraulicenergyintomechanicalenergy.Controlmaybeinitiatedmanuallyorelectrically(throughthesolenoidpilotvalve).
Ifthevalvesectionsareseparatedforanyreason,makesurethatallreassembledpartsareintheirproperlocationandthatallmatingsurfacesarefreeof burrsandforeignitems(paint,dirt,etc.).Assemblystudnutsorscrewsshould betightenedtospecifiedtorques.
Duringdisassemblyofcontrolvalves,giveparticularattentiontoidentificationofparts forreassembly.Spoolsareselectivelyfittedtovalvebodiesandmustbereturnedtothe samebodiesfromwhichtheywereremoved.SpoolsareNOTinterchangeablebetween valvebodies.
Donotsalvagespoolsorvalvebodiesforlaterusein“new”combinations.Damagedor impropercomponentsusedduringassemblymayresultininternalleakageorin "sticking"(hangingup)ofthespoolinthevalvebody.Incorrectcomponentcombinationsmayresultinimproperoperationofthevalvesection,possiblycausingunexpected machineoperationthatcouldresultinmachinedamageorinjurytopersonnel.
9. Conveyorswingsection 10. Conveyorraisesection 11. Gatheringheadsection 12. Cutterraise section
Fig.3:Maincontrolvalve 1. Maininletrelief 2. Pressuresupply
Tankreturn 4. “A”portrelief(typical)
5. “B”portrelief(typical)
6. “B”pressuresolenoid(5places)
7. “A”pressuresolenoid(5places) 8. Stabilizershoesection
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