PDF Operation Manual Cat Bucyrus 35M3 Continuous Miner - 3 MB
Master the operation of your Cat Bucyrus 35M3 Continuous Miner with this comprehensive manual.
It covers all the essential procedures, safety protocols, and daily checks required for efficient and safe mining operations.
Understanding your machine's functions is key to maximizing productivity and ensuring the longevity of your equipment.
This guide is an indispensable resource for every operator.
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Operation Manual
Bucyrus - Continuous Miner
Model - 35M3
Doc. No.: A6474X309
Bucyrus America, Inc. ________________________________________
4041 Wurno Road Telephone: 540-980-4530
Pulaski, VA 24301 Fax: 540-994-3763 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.
______________________________________________________________
A6474X309 VUSV/0 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. Safety regula-
tions 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 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)
© BUCYRUS AMERICA, INC.
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 func-
tion 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.
______________________________________________________________
A6474X309 VUSV/0 2.9
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________________________________ Overview of safety instructions
NOTICE!
The Continuous Miner has skid type steering. It is capable of turn-
ing 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 warn-
ing may result in very serious injury or death.
IMPORTANT!
The miner can be shutdown at any time in “ETRAM” mode by
pressing the “MACHINE STOP” button on the emergency tram
pendant.
WARNING!
As soon as a tramming function is performed, the stabilizer shoe
© BUCYRUS AMERICA, INC.
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.
CAUTION!
Always ensure operator safety while operating the machine. Be
alert for hazardous conditions and take corrective action as nec-
essary. Failure to be alert and correct hazardous situations may
result in serious injury.
IMPORTANT!
Care should be taken not to stall cutters or conveyor during cut-
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 cutter head be-
gins to cut the material from the face, the sump speed will auto-
matically slow the tram down to prevent over sumping the ma-
chine.
WARNING!
This section is intended to familiarize the user with the major me-
chanical 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.
WARNING!
Failure to maintain the hydraulic system will result in damage to
its hydraulic components which will result in increased wear and
premature failure.
______________________________________________________________
A6474X309 VUSV/0 2.19
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_______________________________________________________________
Storage and transport
________________________________________________________________
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__________________________________________________ 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 re-
ceived 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 America, Inc. service engineers
© BUCYRUS AMERICA, INC.
or by specially trained personnel.
Which tools are required for installation?
tool box No special 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
______________________________________________________________
A6474X309 VUSV/0 4.3
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_______________________________________________________________
Operation
________________________________________________________________
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___________________________________________________Operation
main circuit breaker The main circuit breaker case (Fig. 14) is located at the right hand rear
of the machine above the main case. Incoming cable is connected to
the machine via the cable handler and the victor cable socket.
The case contains a circuit breaker providing 600A overload and
1500A short circuit protection to the machine. The circuit breaker also
functions as an isolation device for the machine.
DANGER!
Power to the machine must always be isolated to the trailing cable
at the section power center before either the victor socket is re-
moved or the main circuit breaker case is opened. Whenever any
work is performed on the continuous miner, all mine, State, and
Federal regulations regarding lockout/tagout of the machine.
Fig. 14: Main circuit breaker
Main circuit Main circuit
breaker case breaker
© BUCYRUS AMERICA, INC.
______________________________________________________________
A6474X309 VUSV/0 5.11
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___________________________________________________Operation
graphics display The graphics display (Fig. 19) is located above the methane monitor on
the right rear bumper 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 mid-
dle 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
Graphics display
© BUCYRUS AMERICA, INC.
______________________________________________________________
A6474X309 VUSV/0 5.21
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___________________________________________________Operation
8. Pre-Start Timers
a. Pump
b. Scrubber
c. Cutters
d. Conveyors
e. Mode change
9. Motor Config
a. Motor full load current settings (viewing only)
1. Pump
2. Scrubber
3. Cutter
4. Conveyor
5. Traction
b. Shear max cutter current
c. Shear min cutter current
d. Motor trip timers
1. Cutter imbalance run-time
2. Cutter imbalance startup
3. Traction undercurrent time
4. Traction illegal current time
© BUCYRUS AMERICA, INC.
10. Traction Config
a. Left hand trim
b. Right hand trim
c. Sump settings
1. Max cutter current
2. Min cutter current
3. Sump speed delta
4. Left hand max sump speed
5. Right hand max sump speed
6. Left hand min sump speed
7. Right hand min sump speed
d. Left tram speeds
1. Speed 1
2. Speed 2
3. Speed 3
e. Right tram speeds
1. Speed 1
2. Speed 2
3. Speed 3
f. Tram start delay
11. Auto Stab Config
a. Auto stab enable
b. Auto stab in coal seam current
c. Auto stab down timer
12. Password Setup
a. Tradesman Password
13. Date/Time Config
14. Clear Fault Log Page
15. Reset Defaults Page
______________________________________________________________
A6474X309 VUSV/0 5.31
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___________________________________________________Operation
Safety precautions for underground operation
In addition to the preceding instructions for operating the Continuous
Miner, observe the following special precautions after the Continuous
Miner is taken underground.
■ Communication is a key element in maintaining safety. Exact in-
structions and warnings should be given to, and thoroughly under-
stood 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 in a permissible condition, fol-
lowing all state and federal laws.
■ 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 imme-
© BUCYRUS AMERICA, INC.
diate 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 water hose and 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 compartment
(optional), facing the intended direction of travel.
■ Position the Continuous Miner in the center of the road way to al-
low maximum safe clearance. Consistently maintain clearance,
which is critical to the safe movement of the Continuous Miner.
______________________________________________________________
A6474X309 VUSV/0 5.41
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___________________________________________________Operation
Scrubber motor
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 re-
sult in a radio switch fault. If this occurs, all buttons must be re-
leased 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!
© BUCYRUS AMERICA, INC.
The “FAN/OFF” button must be released before “SHIFT”. If
“SHIFT” is released first, the fan motor will shut off.
Release the “SHIFT” button.
To stop the scrubber fan motor
Press and hold the “FAN/OFF” button. The fan motor will shut-
down immediately.
Release the “FAN/OFF” button.
______________________________________________________________
A6474X309 VUSV/0 5.51
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___________________________________________________Operation
The next face cut
Having cut bottom clearance for the gathering head blade, the operator
can now make a deep sump at the top such as a full drum diameter as
shown in the first view of Fig. 37. He can commence his down-cut until
his gathering head pan is full. Optimally, all this is being done while
awaiting the next haulage car so that maximum loading rate can be
achieved when the car arrives.
While loading the haulage car, the operator completes the down-cut to
the mine bottom as shown in the second view of Fig. 37.
Depending on the depth of the top sump, a small cusp of coal will be
left behind the drum on the mine bottom. This cusp is removed by
backing the miner out of the face a small distance while the cutter
head is running.
The miner is now in a similar position as that shown in the first view of
Fig. 36 and the operator can proceed with the next cutting cycle.
Using the stabilizer shoe
© BUCYRUS AMERICA, INC.
The stabilizer shoe is located under the rear deck of the main frame
and beneath the conveyor. It is hinged at its front edge and is lowered
by a hydraulic cylinder.
The stabilizer shoe serves two purposes:
■ To elevate the rear of the miner for maintenance work.
■ To provide stability, if necessary, during sumping.
■ To provide a higher down-cut force at the coal face while shearing
down during mining operations.
The advantage of increasing down-cut force at the face while shearing
down is important particularly when cutting hard coal seams. Fig. 37
illustrates the advantage of the stabilizer shoe in the down-cut applica-
tion.
Fig. 37: The next face cut
Miner sumps in at top and begins down cut Miner completes down cut with small cusp remaining
______________________________________________________________
A6474X309 VUSV/0 5.61
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___________________________________________________ Hydraulic
Hydraulic system overview
Hydraulic power for all hydraulically-actuated functions originates
with the pump assembly. This includes power for cylinders, hy-
draulic motors, control valves, and pilot valves.
Fig. 46 gives an overview of hydraulic cylinders located on the 35M3
Continuous Miner. Fig. 47 shows the location of other hydraulic com-
ponents.
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 hydrau-
lic schematic in your Bucyrus America, Inc. parts manual supplied with
your machine.
Operation considerations
In order for a hydraulic system to function correctly, it must be properly
maintained. Maintenance of the hydraulic system includes:
© BUCYRUS AMERICA, INC.
■ 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.