PDF Operation Manual Cat Bucyrus 25M0 Continuous Miner - 5 MB
This operation manual is essential for the safe and effective use of the Cat Bucyrus 25M0 Continuous Miner.
It details all operator controls, safety features, and standard operating procedures.
Adhering to the guidelines within this manual helps to ensure the safety of the crew and the longevity of this high-production machine.
Reference this document for all operational questions and protocols.
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Operation Manual
Bucyrus - Continuous Miner
Model - 25M0
Doc. No.: A6474X332
Bucyrus America, Inc. ________________________________________
2045 West Pike Street Telephone: 724-743-1200
Houston, PA 15342 Fax: 724-743-1201 Internet: www.bucyrus.com
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________________________________________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. Possi-
ble 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 ma-
chine damage.
© BUCYRUS AMERICA, INC.
NOTICE!
Points in the text marked with this symbol draw attention to harm-
ful situations. Possible consequences are: damage to the ma-
chine or damage in the immediate vicinity.
IMPORTANT!
Points in the text marked with this symbol contain useful tips and
information intended to facilitate work for you. They do not warn
about harmful or dangerous situations.
■ Items in lists are marked with bullets.
– Points in sub-lists are marked with a long dash at the start of
the line.
Points in text marked in this way describe individual operations.
Follow these instructions step by step. They will help you carry out
your work faster and more importantly, safer.
______________________________________________________________
A6474X332 VSSV/00 1.5
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___________________________________________ Safety instructions
Installation and start-up
inclined face On inclined faces secure all component parts by chains, e.g. to the
support.
environmental acceptability When working with oils, greases and other chemical substances, ob-
serve the safety regulations applicable to the product.
Dispose of cleaning rags, etc. which have been soiled with oil, grease
or other chemical substances in an environmentally safe manner.
controls When starting up machine, do not operate any controls located inside
the operator’s compartment (optional) from outside the compartment.
starting procedures Follow the starting procedure instructions in the operations manual.
red zone Do not operate any levers, pedals or controls if anyone is in the red
zone. (See Red Zone in Chapter 5 of this manual)
Operation
© BUCYRUS AMERICA, INC.
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 func-
tion properly.
operator’s compartment Clean the operator’s compartment at regular intervals. Ensure that the
(optional) operating symbols are legible in order to avoid any operator errors and
resulting accidents.
Never climb onto, or climb out of the machine while it is in motion.
Do not operate the machine with any part of your body outside of the
operator’s compartment in order to prevent body parts from being
crushed between the machine and outside objects .
traveling Use extreme caution when traveling in close quarters or in congested
or blind-travel areas.
passengers Never carry passengers. Passengers may be thrown off the machine
or crushed between the machine and outside objects.
safety rules Always follow all safety rules of each particular mine when operating
the machine.
problems and malfunctions If problems or malfunctions are encountered while operating the unit, it
must be properly shutdown and the problem corrected immediately.
______________________________________________________________
A6474X332 VSSV/00 2.9
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________________________________ Overview of safety instructions
WARNING!
Warn “ALL CLEAR” before starting the conveyor. Failure to do so
may result in serious injury or death.
IMPORTANT!
The “CONV ON” key must be released before “SHIFT”. If “SHIFT”
is released first, the conveyor motors will shut off.
IMPORTANT!
The “FAN ON” key must be released before “SHIFT”. If “SHIFT” is
released first, the fan motor will shut off.
CAUTION!
Always ensure operator safety while operating the machine.
CAUTION!
Always be alert to hazardous conditions and take corrective ac-
tion as necessary.
IMPORTANT!
Care should be taken not to stall cutters on conveyor during cut-
© BUCYRUS AMERICA, INC.
ting operations. Severe damage to motors and gear boxes could
occur if cutters or conveyor are repeatedly stalled.
IMPORTANT!
Tram is limited in the forward direction while the cutters are run-
ning with the cutter head feedback circuit. As the cutters begin to
cut the material from the face the sump speed will automatically
slow the tram down to prevent over sumping the machine.
IMPORTANT!
Inspection of the bits and bit blocks before the start of each shift
will reduce later problems. Mining with dull, bent or broken bit
blocks increases dust and noise levels, as well as putting exces-
sive strain on both cutter and tram drives.
WARNING!
Failure to maintain the hydraulic system will result in damage to
its hydraulic components which will result in increased wear and
premature failure.
IMPORTANT!
Schematics may vary from one unit to the next. Consult the Bu-
cyrus America, Inc. parts book for the schematic for your ma-
chine.
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 be-
tween valve bodies.
______________________________________________________________
A6474X332 VSSV/00 2.19
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________________________________ Overview of safety instructions
WARNING!
Each stabilizer cylinder is extremely heavy. The next steps will
remove the cylinder from its tractor frame mounting. Be prepared
to support the weight from its tractor frame mounting. Be pre-
pared to support the weight of the cylinder when it becomes free
from the mounting.
IMPORTANT!
To obtain maximum performance, the duocone seals must be in-
stalled accurately to insure uniform loading at the mating faces
and achieve a stable running position. Misalignment or cocking of
seal rings during assembly can produce non-uniform loading and
wobbling of the seals in their housings resulting in leakage due to
scoring and/or pumping of debris past the toric rings. Improper
installation can also result in breakage of the metal seal rings.
NOTICE!
Improper care and installation of duocone seals can result in im-
mediate leakage or reduced service life.
IMPORTANT!
© BUCYRUS AMERICA, INC.
The toric must lie uniformly in the seal with the sealing ring and
parallel to the seat face. Be sure that the toric is not twisted and
that it rests uniformly against the retaining lip or not deeper in one
side of the seat than the other.
IMPORTANT!
Do not get any oil onto the rubber torics!
IMPORTANT!
Even a small piece of lint can hold the faces apart and cause leak-
age!
IMPORTANT!
A mixture of marking compound and spindle oil is good lube for
the gears under light loads for 2-3 revolutions only. Check tooth
patterns all round to make sure the pattern/markings are uniform.
CAUTION!
Be careful not to set fire to any grease or lubricant when heating
bearings!
IMPORTANT!
Observe all applicable fire and safety regulations when heating
bearings!
______________________________________________________________
A6474X332 VSSV/00 2.29
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_______________________________________________________________
Installation
________________________________________________________________
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__________________________________________________________
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___________________________________________________Operation
radio remote control When operated by a radio (Fig. 16), a portable wireless remote with a
unique code feature sends radio commands to a receiver in the switch
console via a whip antenna setup. The small whip antennae intercept
the radio signals which the receiver translates into electrical com-
mands to various electrical circuits to perform the function selected.
These circuits energize solenoids which actuate pilot-valves, switches,
or relays controlling a specific mechanical, hydraulic, or electrical func-
tion.
There are eight selectable frequencies which permits each operator to
activate only his designated miner, allowing several remote-controlled
miners to operate in the same area without getting their radio signals
crossed. In addition, an improperly decoded radio signal will automati-
cally shutdown the miner.
Always refer to the specific radio remote control operation manual sup-
plied with your specific machine for details and options on the radio
remote control.
IMPORTANT!
Refer to the radio remote control operation manual supplied with
your machine for information regarding the operation of your spe-
© BUCYRUS AMERICA, INC.
cific remote control.
Fig. 16: Radio remote control (typical)
Top view
______________________________________________________________
A6474X332 VSSV/00 5.12
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___________________________________________________Operation
System Menu
The control system provides information, diagnostic, and setup screens
that are grouped together in the system menu (Fig. 26). The system
menu is accessed by using the display module and a remote control
handset.
To access and navigate the system menu using the radio remote:
Press the SHIFT and MENU key to access the system menu
screen.
IMPORTANT!
All functions and motors are shut down and disabled when the
system menu is selected.
Press CONV UP or CONV DOWN to move the cursor up and down
the list.
Press SHIFT and MENU to select the highlighted item
© BUCYRUS AMERICA, INC.
To leave the menu and return to remote mode, press SHIFT and
REMOTE.
Fig. 26: System menu, example
______________________________________________________________
A6474X332 VSSV/00 5.22
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___________________________________________________Operation
Starting procedure
WARNING!
Failure to read and understand all operating instructions before
starting the Continuous Miner could result in serious injury or
death to the operator or persons around the machine or cause
damage to the machine.
WARNING!
Read all instructions carefully before attempting to start or
operate machine.
WARNING!
Understand the functions of all controls before starting the
Continuous Miner. Read and follow the instructions on all warn-
ing tags on the machine, observe all regulations and safety pre-
cautions .
WARNING!
Never operate a Continuous Miner which has been damaged or is
not operating properly. Any part of the Continuous Miner which
© BUCYRUS AMERICA, INC.
does not function properly can be a hazard. Report it immediately
to your supervisor or their designee.
WARNING!
Before starting the Continuous Miner, make sure that no one is in
the red zone (Fig. 30 through Fig. 34).
NOTICE!
In extremely cold weather, allow motors and gear cases to idle.
This will warm the hydraulic oils and lubricants. Still oils and
greases could immobilize the machine.
IMPORTANT!
A pump “growl” means not enough oil is reaching the pumps
through the suction lines. Ensure the pump gets primed before
continuing operation. Always check the oil level.
DANGER!
Improper position could result in injury or death to the operator
by crushing him against the rib or roof supports. It may also
cause him to run over the trailing cable or dislodge the roof
supports.
WARNING!
Turning on the water sprays prior to cutting prevents the accumu-
lation of dust and the generation of excessive heat which could
cause an ignition or explosion.
After reading the previous descriptions and locating each control, the
operator is ready to operate the Continuous Miner. An experienced
operator should monitor a new operator’s indoctrination to the starting
procedure.
______________________________________________________________
A6474X332 VSSV/00 5.32
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___________________________________________________Operation
Breaker “ON”/”OFF” in radio remote
The control system allows the main circuit breaker on the miner to be
turned on and off using the radio remote control console. This normally
requires that a battery backup version of the power supply be installed
on the machine.
To turn the breaker off:
Press and hold the “SHIFT” and “C.B. OFF” keys together for two
(2) seconds. After two (2) seconds, the breaker off solenoid will
energize, turning off the machine circuit breaker.
To turn the breaker on:
It is essential that a battery backup version of the control system power
supply be installed for this function to be available. Typically, a hydrau-
lic valve provides the mechanical force for the breaker mechanism. To
allow this valve to be operated after loss of power, a hydraulic accumu-
lator is charged by the pump motor during normal “powered” operation
of the machine. If the hydraulic accumulator is discharged, then it will
© BUCYRUS AMERICA, INC.
not be possible for the breaker to be turned on from the radio remote.
Press and hold the “SHIFT” and “C.B. ON” keys together for two (2)
seconds. After two (2) seconds, the breaker on solenoid will ener-
gize, turning on the machine circuit breaker.
IMPORTANT!
The backup accumulator must maintain a minimum pressure of
500 psi for 12 minutes after the pump has been de-energized.
______________________________________________________________
A6474X332 VSSV/00 5.42
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_______________________________________ Mechanical assemblies
Conveyor tail section
The conveyor tail section (Fig. 43) pivots and has the ability to be
raised and/or lowered. The conveyor pivots on the main frame behind
and just below the cutter head pivot. Two single acting hydraulic cylin-
ders permit the operator to raise the conveyor discharge end to a maxi-
mum height and clearance varying per machine or to lower the dis-
charge end of the conveyor to a specific ground clearance.
A double-acting hydraulic cylinder on the right side of the conveyor
permits the discharge end to swing 45 degrees left or right of the
conveyor centerline. The range in height and swing of the conveyor
with an overhang permits the conveyor to accommodate any haulage
vehicle.
Two AC electric motors drive through the gathering head gear cases
to a foot shaft sprocket to propel the conveyor chain.
Fig. 43: Conveyor tail section
© BUCYRUS AMERICA, INC.
Conveyor
tail section
Gathering head and Continuous loading arms (CLAs)
The gathering head (Fig. 44) loads the material that is mined by the
cutter head assembly onto the conveyor for transport to the rear of the
machine. The gathering head assembly consists of a gathering pan
and two continuous loading arms (CLAs), each driven by a bevel gear
case (or pot). Each CLA has 3 to 6 fingers, or blade fan-type rotating
assemblies. The CLA’s are driven by rotary drive shafts in their respec-
tive gear cases. The CLA’s gather and force the cut material into the
conveyor throat and onto the moving flights.
The AC motors that drive both the conveyor and the gathering head are
located on each end of the gathering head assembly. Through each
motor lies a specially-constructed torque shaft that extends across the
rear of the gathering head frame into a heavy duty input gear case on
that side driving the bevel gear input shaft to it.
The input gear cases contain bevel and helical gears that drive each
main gear case (pot). These in turn drive the CLAs and the foot shaft at
the base of the conveyor. The foot shaft extends across the gathering
pan from the right gear case to the left gear case and has a sturdy 4 or
5 tooth sprocket at its center to drive the conveyor chain.
______________________________________________________________
A6474X332 VSSV/00 5.52
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Hydraulic ____________________________________________________
accumulator A bladder accumulator (Fig. 52) is essentially a fluid pressure stor-
age chamber in which the potential energy of a fluid under pressure
can be stored against a compressible force of a gas to do useful
work. This stored fluid is readily available to perform a given task
when called upon by the requirements of the system in which it is
used.
breather A breather (Fig. 52) permits air to move in and out of the oil tank res-
ervoir to maintain atmospheric pressure.
cylinders Cylinders (Fig. 52) are bored and honed steel tubes enclosing a pis-
ton connected to a rod that extends out the end of the cylinder.
Working surfaces are ground and finely finished with the seals and
gaskets incorporated to prevent leakage. Fig. 50 illustrates the loca-
tion 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 AMERICA, INC.
There are four single-acting cylinders on the miner: the conveyor lift
cylinders (2) and the gathering head raise cylinders (2). Optionally,
there may be conveyor chain take-up cylinders (2), which are also sin-
gle acting.
There are normally five different double-acting cylinders on a miner:
the cutter head raise cylinders (2), the conveyor swing cylinder, and the
stabilizer shoe cylinders (2). There is also an optional second conveyor
swing cylinder for attaching haulage.
Fig. 52: Accumulator and cylinder hydraulic symbols
Cylinder, single acting