Cat CM235 Continuous Miner Operation and Maintenance Manual A6474X376

A6474X376 February 2012

Operation and Maintenance Manual CM235 Continuous Miner A6474X376 (Introduction - Maintenance)

SAFETY.CAT.COM

__________________________________________________________

This manual is intended to provide GENERAL product information. The illustrations, descriptions and procedures contained in this publication apply only to THIS machine. Caterpillar reserves the right to revise models and designs without prior notice.

This machine 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 Caterpillar and these regulatory agencies, or any repair or replacement of parts contrary to the 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 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.

© CATERPILLAR 2012.

ALL RIGHTS RESERVED

_______________________________________________________________

Table of contents Safety Precautions ............................................................................ 4 General Maintenance Instructions .................................................... 6 Lock Wiring Fasteners....................................................................... 8 Self-locking Screws ........................................................................... 8 Locknuts ............................................................................................ 8 Torque Values ................................................................................... 9 Lubrication and Maintenance Schedule ............................................ 12 Specific Lubrication and Maintenance Procedures ........................... 17 Every Shift................................................................................. 17 Daily .......................................................................................... 20 Weekly....................................................................................... 27 Crawler Chain Adjustment Procedure.................................. 29 Conveyor Chain Tension Adjustment Procedure................. 33 Monthly...................................................................................... 36 Every Three Months.................................................................. 42 Every Six Months ...................................................................... 47 Tail Shim Adjustment Procedure....................................................... 50 Lubricant Specifications .................................................................... 58

________________________________________________________________ A6474X376

REV 1

Safety Instructions _______________________________________________ Safety Precautions

The following safety precautions should be observed whenever operating or performing any maintenance, repair, or adjustment procedure on this machine.

Additional precautions may appear in each section of this book. All precautions listed applicable to this machine, as well as all applicable regulatory agency rules and regulations must be followed at all times.

!

WARNING If the hydraulic overflow is blocked during power fill operations, the hydraulic tank will become pressurized during the power fill procedure and damage to the air reservoirs may result.

!

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.

! 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 by feeling hoses and fittings with bare hands. Pin hole leaks can penetrate the skin.

! 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.

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 drain into the bottle.

IMPORTANT

For motor bearings that require high temperature lithium complex grease (Spec. 10015), a special “button” style lubrication fitting is available to prevent the accidental use of multi-purpose lithium complex grease at these locations.

! NOTICE

Incorrect grease or over greasing of the electric motor may cause serious damage to the motor. Follow the greasing procedure outlined above.

IMPORTANT

For motor bearings that require high temperature lithium complex grease, a special “button” style lubrication fitting is available to prevent the accidental use of multipurpose lithium complex grease at these locations.

IMPORTANT

Incorrect grease or over greasing of the electric motor may cause serious damage to the motor. Follow the greasing procedure outlined in previous instructions.

________________________________________________________________ 4 CM235 Maintenance

_______________________________________________ Safety Instructions !

WARNING If the hydraulic overflow is blocked during power fill operations, the hydraulic tank will become pressurized during the power fill procedure and damage to the air reservoirs may result.

!

WARNING The following steps releases the shims, which will fall free. Watch out for falling shims when loosening the capscrews.

IMPORTANT

This example is for illustration only. Parameters must be determined for each individual application.

______________________________________________________________ A6474X376 REV 1 5

General Maintenance Instructions___________________________________ Introduction

Maintenance at regular intervals increases the operational safety and prolongs the service life of the machine. This manual contains recommendations on machine and component inspections, machine lubrication, lubricant (oil) change procedures, filter maintenance, and adjustment procedures to properly maintain the machine.

Tools

General tools are required for maintenance. If a procedure requires a specialty tool or material, it will be identified in the procedure.

Illustrations and Procedures The maintenance intervals and procedures given in this manual are based on typical machines and typical mine conditions. Mine conditions and machine configuration may require the recommended intervals or maintenance procedure be modified from those given.

The illustrations used in this manual are for a typical machine and may vary from your machine. If repair work is required, always refer to the specific drawing in the parts book supplied with your machine.

Maintenance Notes

Before performing maintenance on this machine, observe the following: 1. In order to avoid individual components not being serviced or being inadequately serviced, a general maintenance plan should be developed.

2. Use only suitable and approved tools for maintenance work.

3. Use only original spare parts when replacing components.

4. All electrical work must be supervised and inspected by a certified electrician.

5. Anyone performing maintenance on this equipment must be trained on machine operation.

6. Shutdown the machine on level ground.

7. Turn circuit breaker to the "OFF" position and disconnect the trailing cable.

Follow all Mine, State, and Federal lockout/tagout procedures.

8. Only work on the miner in an area where the roof is properly supported.

9. 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.

10. Relieve all hydraulic pressures and position the levers and controls, if applicable, in Neutral or Off. 11. After ensuring that all personnel are clear of the machine, test all controls to ensure that the unit will not move.

________________________________________________________________ 6 CM235 Maintenance

__________________________________ General Maintenance Instructions 12. Test the air for methane (if applicable) before and during any maintenance or repair work.

13. 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.

14. Do not perform maintenance in a congested area. This could endanger the maintenance person or others in the vicinity.

15. Whenever a potential problem is uncovered during a periodic maintenance check, it is imperative that it be corrected immediately by a qualified maintenance technician.

16. 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.

______________________________________________________________ A6474X376 REV 1 7

Special Fasteners ________________________________________________ Introduction

Various types of specialty fasteners, self-locking bolts and nuts, lock wiring, Super Bolts, etc., may be in use on the machine. It is important that these fasteners be used in the correct manner to provide the locking qualities required.

Locking Wire Fasteners

When using a single locking wire, insert the wire through the fastener from the inside to the outside of the bolt circle, advancing in a clockwise direction (Fig. 1).

When using wired pairs, insert the wire in the left hand fastener (as viewed from the center of the bolt circle) from the inside to the outside of the bolt circle. Insert the right end of the wire through the right hand fastener (Fig. 1).

Fig. 1: Lock wire fasteners

Self-Locking Screws

1. Self-locking screws are generally used where measured torque is required.

2. Use a hand wrench, not a power wrench, to tighten to get an accurate reading.

3. Performance is reduced with each use. Limit reuse to twice.

4. If assembly requires shimming, establish the shimming requirements using standard fasteners. After shimming requirements are established, replace standard fastener with self-locking and torque as required.

Lock Nuts

1. Lock nuts with nylon or fiber inserts should not be reused.

2. Lock nuts with a spring steel lock ring in the head can be reused.

3. Hand thread the nut to engage the threads before using a power wrench.

4. Bolt or stud threads should extend beyond the nut.

________________________________________________________________ 8 CM235 Maintenance

___________________________________________________ Torque Values Introduction

The following charts list the recommended torque values for common fasteners used on the Continuous Miner. Use these torque values unless the drawing or instructional material states otherwise.

Do not use these tables for any bolt grades except those specifically listed.

Use a calibrated torque wrench for accuracy.

Imperial Bolts

Table 1: Grade 8 bolt torque specifications (calculated at 75% proof load) Bolt size

Recommended torque setting (ft-lbs) (dry)

Recommended torque setting (ft-lbs) (wet)

1/4 5/16

12 25

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

______________________________________________________________ A6474X376 REV 1 9

Torque Values ___________________________________________________

Table 2: Metric bolt torque specifications (calculated at 75% proof load) 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

________________________________________________________________ 10 CM235 Maintenance

____________________________________________Maintenance Schedule Introduction

This section outlines the frequency at which maintenance tasks should be carried out. Depending on operating conditions, more frequent intervals may be required.

Lubricant and Fluid Capacities

The following lubricant specifications and fluid capacities should be observed when adding or changing a lubricant or greasing a component.

Table 3: Lubricants and fluid capacities Location

Specification

Approximate capacity

Hydraulic oil tank

Spec. 100-1

72 gal (273 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 Input Cutter Head Gear Case Reach Cutter Head Gear Case Final Cutter Head Gear Case Motor Lube Hoses

Spec. 100-15 Spec. 100-15 Spec. 100-15 Spec. 100-15 Spec. 100-14

3 gal (11.36 L) 3.7 gal (14.01 L) 6 gal (22.71 L) 3.5 gal (13.25 L) Variable

Notes

1

Spec, sheets, listing both the physical characteristics and vendors and lubricants that are known to meet each specification, are given at the end of this section.

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.

______________________________________________________________ A6474X376 REV 1 11

Maintenance Schedule ____________________________________________ Table 4: Lubrication and maintenance schedule Item

Description

Places

Lubricant

Specification

Every Shift 1

Cutter head lift cylinder pins, upper

2

Lithium based grease

Spec. 100-3

2

Cutter head lift cylinder pins, lower

2

Lithium based grease

Spec. 100-3

3

Conveyor swing cylinder pin, front

1

Lithium based grease

Spec. 100-3

4

Conveyor swing cylinder pin, rear

1

Lithium based grease

Spec. 100-3

5

Cutter head frame pivot pin, right

1

Lithium based grease

Spec. 100-3

6

Cutter head frame pivot pin, left

1

Lithium based grease

Spec. 100-3

7

Cutter head bits

Inspect

8

Scrubber screen

Clean

9

Daily Conveyor roller

1

Lithium based grease

Spec. 100-3

10

Gathering head pivot pin, left

1

Lithium based grease

Spec. 100-3

11

Gathering head pivot pin, right

1

Lithium based grease

Spec. 100-3

12

Crawler idler roller

2

Lithium based grease

Spec. 100-3

13

Conveyor raise cylinder pin, upper

2

Lithium based grease

Spec. 100-3

14

Conveyor swing pivot pins

Lithium based grease

Spec. 100-3

15

Gathering head cylinder pin, upper

2

Lithium based grease

Spec. 100-3

16

Gathering head cylinder pin, lower

2

Lithium based grease

Spec. 100-3

17

Stabilizer shoe pin

2

Lithium based grease

Spec. 100-3

18

Conveyor chain take-up pin

2

Lithium based grease

Spec. 100-3

19

CLA head pot assembly (Check)

2

High demulsibility EP gear oil

Spec. 100-15

20

CLA head transfer case (Check)

2

High demulsibility EP gear oil

Spec. 100-15

21

Tram gear case (Check)

2

High demulsibility EP gear oil

Spec. 100-15

22

Input cutter head gear case (Check)

2

High demulsibility EP gear oil

Spec. 100-15

23

Reach cutter head gear case (Check)

2

High demulsibility EP gear oil

Spec. 100-15

24

Final cutter head gear case (Check)

2

High demulsibility EP gear oil

Spec. 100-15

25

Hydraulic oil level (Check)

1

AW hydraulic oil

Spec. 100-1

26

Weekly Return filter element (Change)

1

27

Pilot pressure filter element (Change)

1

28

Pressure filter element (Change)

1

29

Crawler chain (Inspect)

2

30

Conveyor chain (Inspect)

31

Fasteners (nuts, bolts, screws)

Inspect

32

Electrical cables, conduits, and glands

Inspect

33

Hydraulic/water hoses and connections

Inspect

34

Lighting

Inspect

35

Reflectors and warning tags

Inspect

36

Machine stop switch (Inspect)

37

Scrubber

1

2 Clean

________________________________________________________________ 12 CM235 Maintenance

____________________________________________Maintenance Schedule Table 4 (continued): Lubrication and maintenance Item

Description

Places

Lubricant

Specification

38 39

Monthly CLA head pot assembly (Change) CLA head transfer case (Change)

2 2

High demulsibility EP gear oil High demulsibility EP gear oil

Spec. 100-15 Spec. 100-15

40 41

Input cutter head gear case (Change) Reach cutter head gear case (Change)

2 2

High demulsibility EP gear oil High demulsibility EP gear oil

Spec. 100-15 Spec. 100-15

42 43

Final cutter head gear case (Check) CLAs

2 Inspect

High demulsibility EP gear oil

Spec. 100-15

44 45

Input cutter head gear case Reach cutter head gear case

2 2

Sample Sample

See Note 1 See Note 1

46 47

Final cutter head gear case (Check) CLA head pot assembly

2 2

High demulsibility EP gear oil Sample

Spec. 100-15 See Note 1

48 49 50

CLA head transfer case Tram gear case Crawler idler roller

2 2 2

Sample Sample Sample

See Note 1 See Note 1 See Note 1

51

Main hydraulic tank

1

Sample

See Note 1

52

Every three months Cutter motor bearings

4

Spec. 100-14

53

Gathering head motor bearings

4

54

Pump motor bearings

2

55

Scrubber motor bearings

2

High temperature lithium complex grease High temperature lithium complex grease High temperature lithium complex grease High temperature lithium complex grease

56

Every six months Tram gear case (Change)

2

High demulsibility EP gear oil

Spec. 100-15

57 58 59

Hydraulic oil (Change) Water filter (strainer) (Change) Breathers (Change)

1 1 All

AW hydraulic oil

Spec. 100-1

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.

______________________________________________________________ A6474X376 REV 1 13

Maintenance Schedule ____________________________________________ Fig. 2: Lubrication and maintenance chart 22, 41, 44 3 - Conveyor swing cylinder rear pin 4 - Conveyor swing cylinder front pin 22, 41, 44 - Main cutter head gear case 23, 48, 53, 54, 55 - Hydraulic oil tank 37 - Machine stop switch 47, 52 - Tram gear case

23, 48, 53, 54, 55

47, 52 47, 52

37

4

3

________________________________________________________________ 14 CM235 Maintenance

____________________________________________Maintenance Schedule Fig. 2: Lubrication and maintenance chart, continued 9 - Crawler idler roller 12 - Stabilizer shoe cylinder lower pin 13 - Conveyor raise cylinder upper pin 15 - Conveyor swing pivots 16 - Gathering head cylinder upper pin 18, 38, 45 - CLA head pot assembly 19, 39, 46 - CLA head input case 20 - Tram gear case 21, 40, 43 - Input cutter head gear case 25, 26, 27 - Hydraulic filters 30 - Crawler chain 37 - Pump stop switch 49 - Cutter motor 50 - Gathering head motor 51 - Pump motor

21, 40, 43 49

50 18, 38, 45 19, 39, 46

9

16

30

51

20

12 37 25, 26, 27 13

15

15

______________________________________________________________ A6474X376 REV 1 15

Maintenance Schedule ____________________________________________ Fig. 2: Lubrication and maintenance chart, continued 9 - Crawler idler roller 12 - Stabilizer shoe cylinder lower pin 15 - Conveyor swing pivots 16 - Gathering head cylinder upper pin 18, 38, 45 - CLA head pot assembly 19, 39, 46 - CLA head input case 20 - Tram gear case 21, 40, 43 - Input cutter head gear case 49 - Cutter motor 50 - Gathering head motor 15

15

12

20

16

18, 38, 45

9

19, 39, 46 50

49 21, 40, 43

________________________________________________________________ 16 CM235 Maintenance

__________________________________________Maintenance Instructions Specific lubrication and maintenance procedures Every shift The purpose of this section is to describe the following maintenance procedures, to be performed every shift: 1. Cutter head lift cylinder pins (upper and lower, left and right) lubrication 2. Conveyor swing cylinder pins (front and rear) lubrication 3. Cutter head pivot pin lubrication 4. Cutter head bit inspection 5. Scrubber cleanout Cutter Head Cylinder Pins (upper and lower)

Lubricate the right and left cylinder pins (upper and lower) through the grease fittings located on each cylinder (Fig. 3). Pump approximately 3 cu. in. (50 cu. cm.) into each fitting.

Fig. 3: Cutter head cylinder pins (typical both sides)

Upper cutter head cylinder pin

Lower cutter head cylinder pin grease fitting

______________________________________________________________ A6474X376 REV 1 17

Maintenance Instructions __________________________________________ 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. 4). Pump approximately 3 cu. in. (50 cu. cm.) into each fitting.

Fig. 4: Conveyor swing cylinder pin lubrication Conveyor swing cylinder pin, rear

Cutter Head Pivot Pin (left and right)

Conveyor swing cylinder pin, front

Lubricate left and right cutter head pivot pins through the grease fittings located on the left and right front lubrication blocks (Fig. 5). Pump approximately 3 cu. in. (50 cu. cm) of grease into each fitting.

Fig. 5: Cutter head pivot pins (typical both sides) Cutter head pivot pin lubrication

________________________________________________________________ 18 CM235 Maintenance

__________________________________________Maintenance Instructions Cutter Head Bits

Inspect the cutter head bits to ensure that they will rotate in their holders and for damaged or missing bits (Fig. 6). Replace bits immediately if any are missing or damaged.

Fig. 6: Cutter head bits Bit holder

Scrubber Cleanout

Bit

Cleanout the scrubber every shift.

1. Open the scrubber screen access cover (Fig. 7).

2. Remove the scrubber screen and wash.

3. Remove the demistor cell and wash.

4. Using the washdown hose, spray out the scrubber. Spray forward and out the front of the scrubber.

5. Wash out the demistor sump.

Fig. 7: Scrubber screen access cover Scrubber screen access cover

______________________________________________________________ A6474X376 REV 1 19

Maintenance Instructions __________________________________________ Daily The purpose of this section is to describe the following maintenance procedures, to be performed daily: 1. Conveyor roller lubrication 2. Gathering head pivot pin (right and left) lubrication 3. Crawler idler roller (right and left) lubrication 4. Conveyor raise pivot pin (right and left) lubrication 5. Stabilizer shoe cylinder pin (upper and lower, left and right) lubrication 6. Conveyor raise cylinder in (upper and lower, left and right) lubrication 7. Conveyor swing pivot pin (top and bottom) lubrication 8. Gathering head cylinder pin (upper and lower, left and right) lubrication 9. CLA head pot (right and left) and transfer gear cases (right and left), oil level check 10. Tram gear cases (right and left), oil level check 11. Input cutter head and reach cutter gear cases, oil level check 12. Hydraulic oil level check 13. Final cutter gear case, oil level check Conveyor Roller Lubrication

Lubricate the conveyor roller through the grease fittings located on the shaft (Fig. 8). Pump approximately 3 cu. in. (50 cu. cm.) into each fitting.

Fig. 8: Conveyor roller lubrication Grease fittings (2)

________________________________________________________________ 20 CM235 Maintenance

__________________________________________Maintenance Instructions Gathering Head Pivot Pin (right and left)

Lubricate the left and right upper and lower gathering head cylinder pins through the grease fittings located on the left and right front lubrication blocks (Fig. 9). Pump approximately 3 cu. in. (50 cu. cm.) of grease into each fitting.

Crawler Idler Roller (right and left)

Lubricate the left and right crawler idler rollers (Fig. 9) through the grease fittings located on the outside face of the crawler idler roller.

Conveyor Raise Cylinder Pin (left and right)

Lubricate the upper conveyor raise cylinder pins through the grease fittings located on the right side of the conveyor (Fig. 10). Pump approximately 3 cu. in (50 cu. cm) of grease into each fitting.

Fig. 9: Gathering head pivot pin, conveyor raise pivot, and crawler idler roller (typical both sides)

Gathering head pivot pin lubrication

Crawler idler roller

Fig. 10: Conveyor raise cylinder pin lubrication

Upper conveyor raise cylinder pin grease fittings (2)

______________________________________________________________ A6474X376 REV 1 21

Maintenance Instructions __________________________________________ Conveyor Swing Pivot Pins

Lubricate the conveyor swing pivot pins through the four (4) grease fittings located each side of the conveyor (Fig. 11). Pump approximately 3 cu. in (50 cu. cm) of grease into each fitting Fig. 11: Conveyor swing pivot pins (typical top and bottom) .

Conveyor swing pivot pin lubrication fittings (2) (typical both sides)

Conveyor swing pivot pin lubrication fittings (2) (typical both sides)

Gathering Head Raise Cylinder Pins

Lubricate the upper gathering head raise cylinder pins (Fig. 12) 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. 12: Gathering head raise cylinder pins (typical both sides)

Gathering head raise cylinder pin (upper)

Gathering head raise cylinder pin (lower)

________________________________________________________________ 22 CM235 Maintenance

__________________________________________Maintenance Instructions Stabilizer Shoe Pin (right and left)

Lubricate the lower stabilizer shoe cylinder pins (right and left) through the grease fittings located on the rod end of each cylinder (Fig. 13). Pump approximately 3 cu. in (50 cu. cm) of grease into each fitting.

Fig. 13: Lower stabilizer shoe cylinder pin (typical both sides)

Stabilizer cylinder pivot (right) Stabilizer cylinder pin (right) Stabilizer cylinder pin (left) Stabilizer cylinder pivot (left) Stabilizer shoe pivot

Conveyor Chain Take-up Pin (right and left)

Lubricate the conveyor chain take-up pin (Fig. 14) through the grease fitting located on the pin. Pump approximately 3 cu. in (50 cu. cm) of grease into each fitting.

Fig. 14: Conveyor chain take-up pin (right and left) Conveyor chain take-up pin

______________________________________________________________ A6474X376 REV 1 23

Maintenance Instructions __________________________________________ 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. 15). If oil is needed, add oil through the fill hole until oil comes out of 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. 15). If oil is needed, add oil through the fill hole until oil comes out of the breather.

Fig. 15: CLA head pot assembly and transfer case lubrication Input case Check plug

Pot check plug

Oil fill, Input case

Tram Gear Case (right and left)

Pot fill plug

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. 16). Oil should be visible in each sight glass. If oil level is low, add oil through the fill plug hole.

Fig. 16: Tram gear case oil level (typical both sides)

Oil fill plug

Oil check

________________________________________________________________ 24 CM235 Maintenance

__________________________________________Maintenance Instructions Input Cutter Gear Case Reach 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 input and reach cutter gear cases through the sight glasses located on each side of the cutter head assembly (Fig. 17). If oil level is low, add oil through the fill plugs located on each side of the gathering head.

Fig. 17: Input and reach cutter head gear case oil levels Input sight glass (typical both sides) Input fill plug (one per side)

Reach fill plug (one per side)

Final Cutter Gear Case

Reach sight glass (typical both sides)

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. 18). 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. 18: Final cutter head gear case oil levels Oil fill plug (one per side)

Oil check plug (one per side)

______________________________________________________________ A6474X376 REV 1 25

Maintenance Instructions __________________________________________ Hydraulic Oil Level

Check the hydraulic oil level using the read out on the main page of the graphics display on the operator’s case on the right hand side of the machine (Fig. 19).

If the oil level is low, add oil as follows: Hydraulic oil power fill procedure 1. Open the diversion valve.

2. Check that the hydraulic tank overflow is obstruction free (Fig. 19).

!

WARNING If the hydraulic overflow is blocked during power fill operations, the hydraulic tank will become pressurized during the power fill procedure and damage to the air reservoirs may result.

3. Activate the “CONVEYOR DOWN” function on the remote control to begin power fill.

4. Add oil until oil flow from the overflow.

5. Verify that the oil level is OK on t he main page of the graphics display.

6. Closes the diversion valve.

Fig. 19: Hydraulic oil level

Hydraulic oil level

Hydraulic oil overflow

Hydraulic oil fill hose

________________________________________________________________ 26 CM235 Maintenance

__________________________________________Maintenance Instructions Weekly The purpose of this section is to describe the following maintenance procedures, to be performed weekly: 1. Pressure filters (bypassing and non-bypassing), check and change as required 2. Return filter, check and change as required 3. Crawler chain, inspect 4. Conveyor chain, inspect 5. Inspect/check tightness/condition of all fasteners (nuts, bolts, screws, etc.)

6. Inspect electrical cables, conduits, and glands 7. Inspect hydraulic and water hoses and connections 8. Inspect lighting 9. Inspect reflectors and warning tags 10. Inspect/check the function of each machine stop switch 11. Scrubber cleaning Pressure Filter

Change the pressure filter element (Fig. 20). If the element is extremely dirty, a more frequent change interval may be required.

Pilot Pressure Filter

Change the pilot pressure filter element (Fig. 20). If the element is extremely dirty, a more frequent change interval may be required.

Return Filter

Change the return filter element (Fig. 20). If the element is extremely dirty, a more frequent change interval may be required.

Fig. 20: Hydraulic filter location

Pilot pressure filter

Pressure filter

Return filter

______________________________________________________________ A6474X376 REV 1 27

Maintenance Instructions __________________________________________ Crawler Chain Tension

Check the crawler chains for proper tension.

To check for proper tension: 1. Raise the complete crawler assembly off of the ground and securely block under the machine. The machine must be securely supported off the ground.

2. Chain sag should be 2-1/2 inches (64 mm) to 3-1/2 inches (89 mm) at the center of the crawler (Fig. 21).

Fig. 21: Crawler track tension measurement

Bottom of tractor wear shoe

Conveyor Chain Tension

2 1/2” - 3 1/2” gap (64 - 89 mm)

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. 22). If adjustment is necessary, see the Conveyor chain tension adjustment procedure in this chapter.

Fig. 22: Conveyor chain tension measurement

Chain measurement area

________________________________________________________________ 28 CM235 Maintenance

__________________________________________Maintenance Instructions Crawler Chain Adjustment Introduction

It is critical to maintain proper crawler chain tension. Loose chains can damage the sprocket and tight chains can cause excessive wear on the tram track assembly, including motors and drives. Both conditions reduce crawler chain life.

The crawler chain tension is adjusted using the front idler take-up jacks.

Grease is added to tighten or bled off to loosen the track .

Tool List

Standard tool set Grease gun

Procedure

To adjust the crawler chain tension: 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.

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.

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 Federal and mine lockout/tagout regulations.

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. 21). 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 11, 12, or 13 provides the appropriate sub-procedure to correct improper track tension.

10. Locate the front idler take-up jack grease fitting and attach the grease gun to the fitting.

11. If the tram track tension is too tight, readjust the idler position using the following steps: a. Pump grease into the take-up jack to extend the cylinder and remove pusher plate pressure on the idler shims. b. Remove one or more idler adjustment shims from the idler slide channel.

______________________________________________________________ A6474X376 REV 1 29

Maintenance Instructions __________________________________________ c.

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.

d. 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 3-1/2 inches) from the bottom wear shoes when the tractor frame is blocked off the floor.

12. If the tram track is too loose, readjust the idler position using the following steps: a. 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 3-1/2 inches) from the bottom wear shoes when the tractor frame is blocked off the floor. b. Insert shims (Fig. 23) into the idler slide channel until the space between the tractor frame and the pusher plate is filled. c.

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.

d. Evaluate the resulting track tension and repeat these steps until the track reaches proper tension.

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.

!

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: a. Pump grease into the take-up jack to extend the cylinder and remove the pusher plate pressure on the idler shims. b. Remove all of the idler adjustment shims from the idler slide channel. c.

Open the pressure release valve for the front idler take-up jack and allow the cylinder to contract.

________________________________________________________________ 30 CM235 Maintenance

__________________________________________Maintenance Instructions d. The tram track tension should now be reduced and separation of the tram track will be easier. e. Locate a tram track link near the tram idler. f.

Remove the four Conelok nuts and flat head screws that secure the crawler pins (Fig. 23).

g. Using the hammer and punch, remove the crawler pins to disconnect the link from the track. Remove the disconnected link. h.

Connect the two ends of the tram track and secure the two end links together with the crawler track pin.

i.

Secure the crawler track pin between the two links with the 3/8-16X11/4 flat head socket head screws and 3/8-16 Conelok nuts.

j.

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.

k.

Insert shims into the idler slide channel until the space between the tractor frame and the pusher plate is filled.

l.

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.

m. The idler adjustment shims will keep the idler stationary and the track tensioned. n. Evaluate the resulting track tension and repeat until the track reaches proper tension.

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. Close the front rub rail cover and secure the front rub rail to the tractor frame with hex head capscrews and lock washers.

17. Connect the trailing cable to energize the miner.

18. Raise the tractor frame off the blocking by lowering the stabilizer and gathering head and cutter head assemblies.

19. Carefully remove the support blocking from under the tractor frame.

20. Lower the tractor frame onto the floor by raising the stabilizer and gathering head and cutter head assemblies.

21. Carefully remove the blocking from underneath the raised stabilizer, gathering head, and cutter head assemblies.

______________________________________________________________ A6474X376 REV 1 31

Maintenance Instructions __________________________________________ Fig. 23: Tram track adjustment

Take-up cylinder

Shims Idler assembly

Pad

Track retention pin

Lock pin

________________________________________________________________ 32 CM235 Maintenance

__________________________________________Maintenance Instructions Conveyor Chain Tension

To check the chain tension: 1. Make sure the conveyor chain area is clean and free of any loose material.

2. Position the rear conveyor section in a straight line with the cutting head to maximum possible height.

3. Position yourself to the side of the gathering pan, under protected roof, and start the conveyor. a. There should be a smooth transition or flow of the chain as it comes through and over the foot shaft sprocket. If the arch of the chain is trailing above the sprocket, the chain needs to be tensioned. b. If, when the conveyor is rapidly started and stopped, the chain tends to fold back on itself, the chain needs tensioned. c.

If, when the conveyor is swung to the extreme left to right, there is too much excess chain, the chain may need to be adjusted in that position.

If adjusted in this position, swing the conveyor back straight and recheck adjustment to verify that the chain has not been over-tensioned.

5. With correct tension, there should be no deflection of the flight tips near the tail roller.

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. If the valve adjustment is correct, then 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.

______________________________________________________________ A6474X376 REV 1 33

Maintenance Instructions __________________________________________ Fasteners

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 following fasteners and tighten as required: 1. Cutter head gear case bolts 2. Cutter head motors bolts 3. Center drums bolts 4. End drums bolts 5. Tram cases bolts 6. Tram motors bolts 7. Gathering head CLAs bolts 8. Gathering head pots bolts 9. Gathering head motors bolts

Electrical Cables, Conduits, and Glands

Visually inspect all electrical cables and glands for signs of wear or damage.

Hoses and Fittings

Visually inspect 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 or making repairs: 1. Relieve pressure before disconnecting hoses.

2. Check for leaks with a piece of cardboard. Do not use hands.

3. 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 by 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 the other switch.

________________________________________________________________ 34 CM235 Maintenance

__________________________________________Maintenance Instructions Scrubber Cleaning

Clean the scrubber (Fig. 24) as follows: 1. Lower the gathering head and cutter head assemblies until they touch the floor.

2. Lower the conveyor assembly until it is level with the floor.

3. Disconnect the trailing cable to de-energize the miner.

4. Insert a hose in the scrubber air intake at the front of the miner. Thoroughly flush the scrubber inlet duct.

5. Remove any accumulated debris from inside the duct. Insert the hose into the duct and thoroughly flush it with water.

Fig. 24: Scrubber cleaning

Scrubber intake

______________________________________________________________ A6474X376 REV 1 35

Maintenance Instructions __________________________________________ Monthly The purpose of this section is to describe the following maintenance procedures, to be performed monthly: 1. CLA head pot and transfer gear cases, change the oil 2. Input and reach cutter head gear cases, change the oil 3. Inspect the CLAs 4. Sample the oil in the input and reach cutter head gear cases, the CLA head pot and transfer gear cases, the tram gear cases, and the main hydraulic oil tank CLA Head Pot Assembly

Change the oil in both CLA head pot assemblies (Fig. 25).

1. Level the miner, raise the gathering head pan, and secure in place.

2. Clean dirt and debris from around the drain plug located under the gear case.

3. Remove the drain plug and allow oil to completely drain from the gear case.

4. Clean and reinstall drain plug.

5. Clean dirt and debris from around the check plug and remove the plug.

6. Clean dirt and debris from around the fill plug and remove the plug.

7. 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.

8. Clean and reinstall the check and fill plugs.

CLA Input Case

Change the oil in both CLA head input cases (Fig. 25).

1. Level the miner, raise the gathering head pan, and secure in place.

2. Clean dirt and debris from around the drain plug located under the gear case.

3. Remove the drain plug and allow oil to completely drain from the gear case.

4. Clean and reinstall drain plug.

5. Clean dirt and debris from around the check plug and remove the plug.

6. Clean dirt and debris from around the fill plug and remove the plug.

________________________________________________________________ 36 CM235 Maintenance

__________________________________________Maintenance Instructions 7. 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.

8. Clean and reinstall the check and 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.

If the gear case is scheduled for oil drain and refill, obtain the oil sample prior to the oil change.

Fig. 25: CLA pot assembly and input case Input case Check plug

Pot check plug

Oil fill, Input case

Pot fill plug

______________________________________________________________ A6474X376 REV 1 37

Maintenance Instructions __________________________________________ Input Cutter Head Gear Case Reach Cutter Head Gear Case

Change the oil in both input and reach cutter head gear cases (Fig. 26).

1.

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.

2.

Remove the drain plug and allow oil to completely drain from the gear case.

3.

Clean and reinstall the drain plug.

4.

Clean dirt and debris from around the check plug and remove the plug.

5.

Clean dirt and debris from around the fill plug and remove the plug.

6. Slowly add oil through the fill plug until oil begins to flow from the check plug hole. Allow sufficient time for the oil to travel throughout the gear case when filling.

7. Clean and reinstall the check and fill plugs.

Fig. 26: Input and reach cutter head gear case Input sight glass (typical both sides) Input fill plug (one per side)

Reach fill plug (one per side)

Reach sight glass (typical both sides)

________________________________________________________________ 38 CM235 Maintenance

__________________________________________Maintenance Instructions Final Cutter Head Gear Case Change the oil in both final cutter head gear cases (Fig. 27).

1. Lower the cutter head completely to the ground. Clean dirt and debris from around the drain plug, located under the gear case.

2. Remove the drain plug and allow oil to completely drain from the gear case.

3. Clean and reinstall the drain plug.

4. Clean dirt and debris from around the check plug and remove the plug.

5. Clean dirt and debris from around the fill plug and remove the plug.

6. 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.

7. Clean and reinstall the check and fill plugs.

Fig. 27: Final cutter head gear case Oil fill plug (one per side)

Oil check plug (one per side)

______________________________________________________________ A6474X376 REV 1 39

Maintenance Instructions __________________________________________ CLAs

Inspect the CLAs (Fig. 28) for damage. If a CLA needs replaced, see CLA removal and installation procedure in the Mechanical section of this manual.

Fig. 28: CLAs

CLA

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.29) 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 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 drain into the bottle.

________________________________________________________________ 40 CM235 Maintenance

__________________________________________Maintenance Instructions 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: 1. Input cutter head gear case (left and right) 2. Main cutter head gear case (left and right) 3. Input gathering head gear case (left and right) 4. Main gathering head gear case (left and right) 5. Main hydraulic oil tank

Fig. 29: 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

______________________________________________________________ A6474X376 REV 1 41

Maintenance Instructions __________________________________________ Every three months The purpose of this section is to describe the following maintenance procedures, to be performed every three months: 1. Lubricate the cutter motors 2. Lubricate the gathering head motors 3. Lubricate the pump motor 4. Lubricate the scrubber motor bearings IMPORTANT

For motor bearings that require high temperature lithium complex grease (Spec. 10015), a special “button” style lubrication fitting is available to prevent the accidental use of multi-purpose 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. 30) using the following procedure: 1. Open the cover (Fig. 30) to access the motor.

2. 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 loaded relief fittings, then a. Lubricate both motor bearings until new grease appears out of the relief ports on the exit side of the bearing. b. 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: a. Remove the plug and lubricate both motor bearings until new grease appears out of the relief ports on the exit side of the bearing. b. Operate the motor for five (5) minutes and then inspect for grease leaks in the bearing area.

3. 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.

________________________________________________________________ 42 CM235 Maintenance

__________________________________________Maintenance Instructions Fig. 30: Cutter motor bearing lubrication (typical each side)

Entry plug

Exit plug

______________________________________________________________ A6474X376 REV 1 43

Maintenance Instructions __________________________________________ 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. 29).

To lubricate the motors: 1. Open the cover (Fig. 31) to access the motor.

2. 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 loaded relief fittings, then a. Lubricate both motor bearings until new grease appears out of the relief ports on the exit side of the bearing. b. 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: a. Remove the plug and lubricate both motor bearings until new grease appears out of the relief ports on the exit side of the bearing. b. Operate the motor for five (5) minutes and then inspect for grease leaks in the bearing area.

3. Replace the plugs in the ports.

Fig. 31: Gathering head motor bearing lubrication (typical each side)

Bearing grease fittings located behind cover

________________________________________________________________ 44 CM235 Maintenance

__________________________________________Maintenance Instructions Pump Motor Bearings

Lubricate the pump motor (Fig. 32) with high temperature lithium complex grease (Spec. 100-14) through the two (2) grease fittings located the right side of the machine using the following procedure: 1. Open the cover (Fig. 32) to access the motor.

2. 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 loaded relief fittings, then a. Lubricate both motor bearings until new grease appears out of the relief ports on the exit side of the bearing. b. 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: a. Remove the plug and lubricate both motor bearings until new grease appears out of the relief ports on the exit side of the bearing. b. Operate the motor for five (5) minutes and then inspect for grease leaks in the bearing area.

3. Replace the plugs in the ports.

Fig. 32: Pump motor bearings

Pump motor location Operator’s case (swing open to expose pump motor)

Rub rail (Swing open to allow operator’s case to swing out)

______________________________________________________________ A6474X376 REV 1 45

Maintenance Instructions __________________________________________ IMPORTANT

For motor bearings that require high temperature lithium complex grease, a special “button” style lubrication fitting is available to prevent the accidental use of multipurpose lithium complex grease at these locations.

Scrubber Motor Bearings

Lubricate the scrubber motor bearings (Fig. 33) with high temperature lithium complex grease through the grease fittings located on the scrubber side of the machine. To lubricate the motors: 1. Remove the cover to access the motor.

2. Remove grease plug (s) on exit side of bearing (s).

3. Lubricate bearing using “button” fitting until new grease appears out of open port on exit side of bearing (s).

4. Operate motor (s) for five (5) minutes.

5. Replace grease plug (s) in all port (s).

IMPORTANT

Incorrect grease or over greasing of the electric motor may cause serious damage to the motor. Follow the greasing procedure outlined in previous instructions.

Fig. 33: Scrubber motor bearings

Scrubber motor

________________________________________________________________ 46 CM235 Maintenance

__________________________________________Maintenance Instructions Every six months The purpose of this section is to describe the following maintenance procedures, to be performed every six months: 1. Change the oil in the tram gear cases 2. Change the hydraulic oil 3. Change the water filter 4. Inspect and clean/change all breathers Tram Gear Case

Change the oil in both tram gear cases (Fig. 34).

1. Remove the drain plug and allow oil to completely drain from the gear case.

2. Clean and reinstall the drain plug.

3. Replace the breather, located in the fill tube.

4. Remove the fill plug located on top of the gear case or on the fill tube.

5. 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.

6. Clean and reinstall the fill plug.

Fig. 34: Tram gear case

Oil fill plug

Oil check

______________________________________________________________ A6474X376 REV 1 47

Maintenance Instructions __________________________________________ Hydraulic Oil

Change the oil in the hydraulic oil tank (Fig. 35).

1. Clean all dirt and debris from around the fill cap and the drain plug.

2. Remove the drain plug and allow the oil tank to completely drain.

3. Clean and reinstall the drain plug.

4. Inspect and clean oil overflow, making sure there are no obstructions to overflow.

!

WARNING If the hydraulic overflow is blocked during power fill operations, the hydraulic tank will become pressurized during the power fill procedure and damage to the air reservoirs may result.

5. Fill the tank with oil using the power fill pump until the oil level reaches the full level as indicated on the dipstick. The hydraulic tank capacity is 73 gal (273 L), hydraulic system capacity is 82 gal (310 L). To activate the power fill: a. Open the diversion valve. b. Engage the conveyor down function.

6. After filling, start the machine and engage all cylinders for the full length of travel (full extend and retract) in order to purge the hydraulic system of air.

7. Check the oil level on the graphics display on the operator’s case on the right hand side of the machine. Add additional oil as required until oil level is “OK”.

Fig. 35: Hydraulic oil change

Hydraulic oil level

Hydraulic oil overflow

Hydraulic oil fill hose

________________________________________________________________ 48 CM235 Maintenance

__________________________________________Maintenance Instructions Water Filter (Strainer)

Change the water circuit filter (Fig. 36).

Fig. 36: Water filter Water filter

Gear Case Breathers

Change the breathers on the input and main cutter gear cases, the CLA head pot and transfer gear cases, and the tram gear cases (Fig. 37).

Fig. 37: Gear case breather locations Breather

CLA input case breather plug

CLA pot breather

Breather

______________________________________________________________ A6474X376 REV 1 49

Maintenance Instructions __________________________________________ 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.

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.

5. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine lockout/tagout regulations.

6. Loosen the socket head capscrews that secure the shims between the shim retainer and the conveyor lower pivot plate (Fig. 38).

Fig. 38: Shim removal Socket head capscrews

Shim retainer

Lower pivot plate

Shims

7. Connect the trailing cable to energize the miner.

________________________________________________________________ 50 CM235 Maintenance

__________________________________________Maintenance Instructions !

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 Federal and mine lockout/tagout regulations.

10. Replace the removed shims (Fig. 38) and add the number of shims required to level the conveyor front and tail sections.

11. Tighten the socket head capscrews.

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 (Fig. 39). If the sections are not horizontally aligned, then add or subtract shims as required.

16. Re-insert the blocking between the top of the tractor frame and the bottom of the conveyor following mine standard blocking procedures.

17. Securely retighten the socket head capscrews.

Fig. 39: 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

______________________________________________________________ A6474X376 REV 1 51

Lubricant Specifications___________________________________________ Introduction

The following lubricants specifications are referenced throughout this manual.

Any lubricant used must meet these standards listed. For your convenience, a list of manufacturers and lubricants that have been identified as meeting these standards is given for each specification.

Failure to use lubricants that meet the standard listed may reduce component life and may void any associated warranty.

Table 7: Spec. 100-1: Anti-wear hydraulic oil specification Limit

Type

ISO VG

61/75

68

ASTM Grade

380/345

315

Pour Point (ASTM D-97)

Max. 20° F (-29° C)

-20° F

Flash Point (ASTM D-92)

Min. 415° F (212° C)

400° F

Viscosity SUS @ 100° F 283-347

352

SUS @ 210° F 50-58

56

CST @ 40° C

61.2 - 74.8

CST @ 100° C

8.5 Typ.

Viscosity Index (ASTM D-2270)

Min. 90

96

Oxidation Test (ASTM D-943)

2.0 mg KOH max after 1000 hrs

Rust Prevention Test (ASTM D-665, A & B

Pass

Pass

Foam Test (ASTM D-892-46T)

Pass

Pass

Four Ball Wear Test (ASTM D-2266) (40 KG, 1800 RPM, 130° F, one hour)

Not more than 0.50 mm scar diameter

0.50 mm

400 mg max

294 mg

Copper

200 mg max

131 mg

Iron

100 mg max

3 mg

50 mg max

25 mg

Sludge & Metal Corrosion (ASTM D-943) (conducted at conclusion of 1000 hour oxidation test) Insoluble sludge in oil and water layers plut that adhering to the catalyst coils or the test tub.

Metals in combined oil, water, and sludge (ASTM D-810-59)

Pump Wear Test (ASTM D-2882) (Total Ring and Vane Weight Loss) Hydrolytic Stability Test (ASTM D-2619)

0.1

Copper Specimen Weight Loss

0.05 mg/CM2 max

Acidity of Water Layer

6.0 mg KOH max

0.5

________________________________________________________________ 52 CM235 Maintenance

___________________________________________Lubricant Specifications

Table 8: Spec. 100-1: Anti-wear hydraulic oil approved 1 2 3 4

Supplier Amoco Oil Company Gulf Oil Mobil Oil Corporation Chevron U.S.A.

5 6 7 8 9 10 11 12

Sun Oil Company Unocal 76 Shell Oil Company Century Lubricating Oils, Inc. Atlantic Richfield Company Texaco Lubricants Company Exxon Pennzoil

13

Standard Oil Company Standard Oil Co. of Ohio Boron Oil Company BP Oil Inc. Lubricating Engineers Conoco Inc. Hydrotex Phillips Miners Oil

14 15 16 17 18

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

______________________________________________________________ A6474X376 REV 1 53

Lubricant Specifications___________________________________________ Table 9: Spec. 100-3: Extreme pressure motor bearing grease and hand grease specification Limit NLG1 Grade Number 2

Type 2

Worker Penetration (ASTM D-217)

265-295

280

Dropping Point (ASTM D-566) Bomb Oxidation (ASTM D-942)

Min. 350° F (177° C) Not more than 10 PSI DROP

373° F 2.5

Rust Inhibitors

Required

Yes

Wheel Bearing Test (ASTM D-1263) (6 Hours @ 235° F )

Not more than 5% loss

Water Washout (ASTM D-1264)

Loss not more than 5% @ 100° F Loss not more than 15% @ 175° F

Grease Mobility

Not less than 0.1 gram flow per Second @ 0° F

Timken OK Load (ASTM D-2509)

Not less than 50 lbs.

(50 lbs.)

Four Ball EP Test (ASTM D-2569)

Load wear index not less than 30.0 Weld point not less than 200 kg. Min.

31 200

4.25 4.00

Four Ball Wear Test (ASTM D-2266) Not more than 0.60 mm. SCAR diameter 0.44 (20KG., 1800 RPM, 130° F, One Hour) Table 10: Spec. 100-3: Extreme pressure motor bearing and hand grease approved suppliers

1

Supplier Amoco Oil Company

2 3 4 5 6 7 8

Gulf Oil Mobil Oil Corporation Chevron U.S.A. Sun Oil Company Unocal 76 Shell Oil Company Century - Fuchs

9 10 11 12 13

Texaco Lubricants Company Exxon Pennzoil Lubricating Engineers Conoco Inc.

14

Hydrotex

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 Replex 2, 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

15 16

Phillips Atlantic Richfield Company

Philube EP Grease Litholine H EP-2 Grease

________________________________________________________________ 54 CM235 Maintenance

___________________________________________Lubricant Specifications Table 11: Spec. 100-14: Synthetic lithium complex grease for electric motor bearings Limit

Type

NLG1 Grade

2

Thickener

Lithium soap complex

Base Oil Type

Synthetic polyalphaolefin base oils (POA)

Worked Penetration (60 strokes) (ASTM D-217)

265 - 295

280

Dropping Point (ASTM D-2265)

470° F (243° C) min

509° F (260° C)

Water Washout Resistance Weight 10% or less Loss @ 175° F (79° C) (ASTM D-1264)

6%

Grease Mobility (US Steel Test LT-37)

18 grams/min @ 0° F (-18° C) min

20 grams/min

Four Ball Wear (ASTM D-2266)

0.70 mm Max scar diameter

0.50 mm

Four Ball EP Weld Load (ASTM D2596)

530 lb (240 kg) min

550 lb (250 kg)

Timken OK Load (ASTM D-2509)

55 lb (25 kg) min

65 lb (30 kg)

Rust Corrosion Protection (ASTM D1743)

Pass

Pass

Base Oil Viscosity @ 104° F (40° C)

95 - 120

100

Table 12: Spec. 100-14: Synthetic lithium complex grease for electric motor bearings approved suppliers 1

Supplier Mobil Oil Corp.

Brand name Mobility SHC 100

2 3

Conoco-Phillips Shell

Triton 100 Albida EMS 2

______________________________________________________________ A6474X376 REV 1 55

Lubricant Specifications___________________________________________ Table13: Spec. 100-15: High demulsibility extreme pressure gear oils specification Limit

Type

ISO VG

220

220

A.G.M.A. Grade

5EP

5EP

Viscosity Index (ASTM D-2270)

Min. 95

98

Flash Point (ASTM D-92)

Min. 450° F (232° C)

480° F (250° C)

Pour Point (ASTM D-97)

Max. 15° F (-9° C)

-27° F (-17° C)

Timken Test (ASTM D-2782)

Min. 65 lbs.

70 lbs.

FKOUR Ball EP Test (ASTM D-2783)

Weld load kg. Min. 260 load wear index not less than 51.0

270 57

Oxidation Stability (ASTM D-2893) Viscosity Increase @ 100° C

Not more than 6%

4.6%

FZG Scuffing Test (ASTM D-5182) Failure Load Stage

Not less than 12th stage.

>12

SUS @ 100° F

950-1200

1119

SUS @ 210° F

85-110

95.5

CST @ 40° C

198-242

212

CST @ 100° C

15.24

18.7

DEMULSIBILITY (ASTM D-1401) Min. 30 @ 180° F ml Oil, Water, Emulsion

0 ml. Emulsion Max.

42 ml. Oil 38 ml. Water 0 ml. Emulsion

Copper Corrosion (ASTM D-130)

1 or 1b

1b

Foam Test (ASTM D-892)

Pass

Pass

Rust Test (ASTM D-665)

Pass

Pass

Viscosity (ASTM D-445)

Table 14: Spec. 100-15: High demulsibility extreme pressure gear oils approved suppliers

1

Supplier Conoco Inc.

Brand name GLW Gear Oil 220

________________________________________________________________ 56 CM235 Maintenance