Cat CM445 Continuous Miner Operation and Maintenance Manual - PDF DOWNLOAD

A6474X437 August 2012

Operation and Maintenance Manual CM445 Continuous Miner A6474X437 (Introduction - Operation)

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

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Table of contents Safety Instructions ............................................................................. 4 Red Zones ......................................................................................... 6 General Description........................................................................... 11 Installation ......................................................................................... 12 Storage .............................................................................................. 17 Machine Mounted Controls ............................................................... 19 Gauges .............................................................................................. 23 Remote Operation ............................................................................. 25 Pre-Operational Checks .................................................................... 26 Daily Checks ..................................................................................... 26 Machine Shutdown Functions ........................................................... 27 Start-Up Procedure ........................................................................... 28 Shutdown Procedure ......................................................................... 29 Machine Operation ............................................................................ 30 Hydraulic System .............................................................................. 36 Electrical System ............................................................................... 38 Water System .................................................................................... 39

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REV 0

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, as well as all Federal, State, and Mine safety regulations must be followed at all times.

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DANGER

Do not make any type of temporary repairs to the trailing cable or trailing cable connections. Trailing cables may only be repaired under certain conditions and following specific guidelines.

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DANGER

Only qualified personnel are permitted to make repairs to permissible equipment. The permissibility of any permissible component must be verified after any maintenance or repair work and at regular intervals. Failure to maintain permissible components to OEM standard may result in a fire or explosion. Serious injury or death could occur.

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WARNING Do not attempt to operate this continuous miner until you have been sufficiently trained on this machine and have read and understood this manual and are familiar with all controls and indicators. Operating this machine without the proper training and knowledge may result in serious injury or death to the operator or other personnel.

WARNING Federal law requires that temporary roof supports be in place before approaching the machine to reset a circuit breaker. Under no circumstances should personnel be under unsupported roof. Failure to follow these regulations may result in serious injury or death.

WARNING Only use the Emergency Stop Override to tram the miner away from the rib, releasing the accidentally pushed Machine Stop button. Never use the Emergency Stop Override when a Machine Stop switch has been activated by personnel. Failure to comply with this warning may lead to severe injury or death of personnel.

WARNING The Continuous Miner is radio remote controlled during production operations. Manual operation via machine mounted controls is not permitted for production operations.

Manual operation is for troubleshooting and maintenance under supported roof only.

Operating the Continuous Miner with manual or pendant controls under unsupported roof may result in sever injury or death.

WARNING Before performing maintenance or repair work on this machine, the circuit breaker must be in the “OFF” position and the trailing cable disconnected. Follow all applicable rules and regulations regarding the lockout/tagout procedures. Accidental machine movement or electrical shock may result in serious injury or death to the operator or other personnel.

WARNING Some procedures or test may require the cover of the electrical controller to be removed and some may require the controller to be energized during the procedure. Tall all necessary precautions to prevent electrical shock while working within the controller. An MSHA certified electrician must supervise and inspect all work.

________________________________________________________________ 4 CM445 Continuous Miner

_______________________________________________ Safety Instructions

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WARNING Do not alter, bypass, or remove and emergency or machine stop device. Failure to heed this warning may result in serious injury or death.

WARNING Do not use an emergency or stop device as a means of disconnecting power to the miner. Whenever instructed to disconnect power, it is always meant to turn the main circuit breaker to the “OFF” position and to physically remove the trailing cable and lockout/tagout the machine. Failure to do so may result in serious injury or death.

WARNING Never disconnect a hydraulic hose if the circuit is pressurized or there is a load on the circuit. Pressurized hydraulic fluid or falling loads may result in serious injury or death.

WARNING Do not rely on load holding valves when working under the cutter head or the conveyor.

Always block the cutter head and conveyor in the elevated position. Serious injury or death may occur if the cutter head or conveyor are not mechanically blocked.

WARNING Never work under any assembly or component of this machine that is elevated. Always install enough blocking to support t he machine or component or lower the component to ground level.

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Red Zones ______________________________________________________ Introduction

The radio remote control of miners introduces certain potential safety hazards which the miner operator must watch for and be aware of. While the operator is now free to position himself for convenient visibility of mining operations at the face, he can easily expose himself to the danger of being near mobile heavy equipment.

Most significantly, the operator’s greatest danger is from his Continuous Miner, especially when he is maneuvering it during mining operations. The miner is capable of slewing when turning, especially when the crawlers are split. The discharge conveyor can also swing. In each of these cases, the miner operator is in danger of being hit, or worse yet, run over by his own machine. Equally dangerous is the possibility of the operator being pinned against the rib by his own miner.

Red Zones (Danger Areas)

Some typical situations dangerous to the miner operator are illustrated on the following pages. The danger area, or red zone (Fig. 1) is indicated by alternating red and white diagonal stripes.

This information is for general reference only. All mining methods are dictated by the mine regulations and ventilation and roof control procedures.

Fig. 1: Red zone designation

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______________________________________________________ Red Zones Tramming the miner (Fig. 2) from one place to another, especially maneuvering around intersections. This illustrates that the operator should not place himself between his miner and the rib.

Beginning the first sump (Fig. 2) in a new cut. The miner is against the left rib and the discharge conveyor is swung toward the center of the entry ready for the haulage car. The operator must stay clear of the discharge conveyor and the rear of the miner.

Fig. 2: Red zones

Tramming the miner red zone

Beginning 1st sump red zone

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Red Zones ______________________________________________________ Sumping in the left hand side of the cut (Fig. 3). As the miner penetrates the face, new unsupported roof is being exposed, and the operator now has an additional constraint to his movements. He must also stay clear of the haulage vehicle at the rear of the miner as it approaches the miner and while it is loading.

Repositioning the miner for the right hand cut (Fig. 3). Because the miner is backing out and turning in close quarters, the operator must stay behind the miner to be safe.

Sumping in the right hand cut (Fig. 3). Again, the operator must stay away from the face where the newly-exposed roof is unsupported, as well as staying clear of the haulage vehicle while it approaches and loads.

Fig. 3: Red zones

Sumping on the left hand side red zone

Repositioning miner for right hand cut red zone

Sumping in the right hand cut red zone

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______________________________________________________ Red Zones Crosscut red zones (Fig. 4). Beginning and completing crosscuts requires a lot of maneuvering of the miner and loading the haulage vehicle while at awkward positions. Crosscuts also result in newly-exposed unsupported roof. Respecting a red danger zone is important to operator safety in these conditions.

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

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

Fig. 4: Crosscut red zones

Beginning a right hand crosscut red zone

Right hand crosscut development

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Red Zones ______________________________________________________ Pillaring red zones (Fig. 5) Remote control offers a significant safety advantage in partial or complete removal of the pillars in retreat mining because it places the operator further away from potential collapsing roof.

Much of the area around the miner must be considered a red zone, mostly because of extensive unsupported roof and the need for temporary supports under weakened roof. With remote control, the operator can position himself safely away from the miner while still retaining a good view of the mining cycle.

A red zone around the miner is no longer applicable when working in the opposite right hand pillar, as the operator is now excluded from the entire working area because of failing roof considerations, even with the existence of temporary roof supports

When making an additional end cut into the pillar, creating a fender of coal between the two cuts, additional temporary roof supports are installed.

Because of roof pressures, the fender will tend to slough its ribs in the process of eventually crushing. Hence, the operator must stay away from this fender as well as avoiding the entry and crosscut areas as shown.

Fig. 5: Pillaring red zones

Pillaring in a left hand cut red zone

Pillaring in a end cut red zone

Pillaring in a right hand cut red zone

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______________________________________________ General Description Introduction

The CM445 Continuous Miner is designed for harder cutting applications. The cutter head is powered by two 280 HP (one hour rating) cutting head motors mounted in the cutter head assembly. The motors tie together at a common drive shaft, allowing for the combined power of both motors at the cutter head.

Additionally, there are two 55 HP conveyor/gathering head motors, two 75HP AC traction motors controlled by Variable Frequency Drives (VFDs), two 41 hp tail drive motors and a 75 HP pump motor.

Fig. 6: General Arrangement 9 10 7

1

6 5

8 2 4 3 1.

2.

3.

4.

5.

Cutter head assembly Cutter motor location Gathering head assembly Gather head motor location Hydraulic pump and motor location

6. Traction motor location 7. Traction controller (left side) 8. Gathering head cylinder 9. Conveyor swing cylinder 10. Conveyor assembly

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Installation ______________________________________________________ Introduction

The CM445 Continuous Miner can be shipped either as a complete machine or in component sections, depending on customer preference or transportation weight restrictions. The machine should only be unloaded by experienced personnel. Always refer to the Pre-Operational Checks and Start Up procedure before attempting to unload an assembled machine. If shipped in components, it is recommended that a representative assist in the reassembly.

Machine and Component Weights

When lifting the machine, also verify machine or component weights and use appropriate lifting mechanisms. Note that the weights listed below may vary depending on options and custom design.

Table 1: Component Weights

Description

Approximate Weight

Tractor frame assembly

93,000 lbs (42,185 kg)

Conveyor assembly

17,000 lbs (7,711 kg)

Cutter head assembly

53,500 lbs (24,267 kg)

Gathering head assembly

23,500 lbs (10,659 kg)

Complete machine

187,000 lbs (85,000 kg)

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______________________________________________________ Installation Fig. 7: Assembly lifting points and transport dimensions Frame lifting eye locations

Lifting eye location

Lifting eye location

Lifting eye location (typical both sides)

Bumper lifting eye locations

Lifting eye location

Lifting eye location

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Installation ______________________________________________________ Fig. 7, continued: Assembly lifting points and transport dimensions Conveyor lifting eye locations Lifting eye

Lifting eye

Lifting eye

Lifting eye

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______________________________________________________ Installation Fig. 7, continued: Assembly lifting points and transport dimensions Cutter head lifting eye locations

Lifting points

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Installation ______________________________________________________ Fig. 7, continued: Assembly lifting points and transport dimensions Gathering head lifting eye locations

Lifting point Lifting point

Lifting point

Lifting point

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_________________________________________________________Storage Storage

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

Corrosion Protection

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

Exposure to Sunlight

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

Dirt and Moisture

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

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

Short-term Storage

During short-term storage (approximately 4 weeks) of equipment outdoors, but at temperatures above freezing, electrical components need not be removed.

Such components must be particularly protected against excessive temperatures, dirt, and moisture.

Long-term Storage

If the equipment is to be stored more than six months, the following lubrication and corrosion inhibiting procedures must be followed: 1. If the cylinder rods are exposed, the rods must be coated with a corrosion inhibiting fluid.

2. Completely fill the hydraulic oil tank with oil.

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

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

5. Completely drain the water system and refill with a 50/50 antifreeze/water solution. Pump the antifreeze mix through the system until the antifreeze mix comes out the water sprays. ENSURE THAT THE SYSTEM IS COMPLETELY PURGED AND NO WATER OR AIR POCKETS EXIST. 6. The equipment must be stored in a well ventilated, dry room. Do not store outdoors.

Machine Electrical Components

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

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Storage _________________________________________________________ Traction Drives

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

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

Random Sample Inspection

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

Natural Aging

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

Long-term storage of spare components Hydraulic Components

Miscellaneous Components

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

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

Motors

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

Fan Assembly

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

Plastic Deformation

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

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________________________________________ Machine Mounted Controls Circuit Breakers

Power is supplied to the machine via a trailing cable. Once the trailing cable is connected and energized, power is isolated from the machine by the main circuit breaker and the tram circuit breaker.

As soon as the main circuit breaker is closed, power is supplied to the pump motor, left and right cutter circuits, left and right conveyor/gathering head circuits, and the lighting and control circuits. Closing the tram circuit breaker will supply power to the tram motor circuit.

Fig. 8: Circuit Breaker

2

1

1. Main circuit breaker, main disconnect box Breaker Operation

Breaker 1. Main circuit

2. Tram circuit breaker, controller case Function

Operation

Isolates the entire machine from power supplied via the trailing cable.

Push to the left to turn ON (close the breaker).

Push to the right to turn OFF (open the breaker).

2. Tram

Isolates the tram circuit.

Push to the right to turn ON (close the breaker).

Push to the left to turn OFF (open the breaker).

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WARNING Follow all laws regarding the use of roof supports before approaching a machine (for example, to reset a circuit breaker). Serious injury or death may result from working under unsupported roof.

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Machine Mounted Controls ________________________________________ Control Switches

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There are control switches located on the front of the controller case that will function after the main circuit breaker is on (closed). The continuous miner is normally operated by radio remote. Manual operation via controls on the controller case is not permitted for production operation. Manual operation is for troubleshooting and maintenance under supported roof only.

WARNING Do not attempt to operate the continuous miner until you have been sufficiently trained on the machine and have read and understand this manual and are familiar with all controls and indicators. Operating this machine without the proper training and knowledge may result in serious injury or death to the operator or other personnel.

Fig. 9: Control switches 1

1.

2.

3.

4.

5.

6.

7.

8.

Machine Stop Miner Operation CLA Modes MCB1 MCB2 MCB3 MCB4 MCB5

9. MCB6 10. MCB7 11. MCB8 12. MCB9 13. MCB10 14. MCB11 15. MCB12 16. MCB13

2

3

4 - 11

12 - 19

20

21

17. MCB14 18. MCB15 19. MCB16 20. Conveyor Hour Meter 21. Cutter Head Hour Meter

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________________________________________ Machine Mounted Controls Control Switch Operation Switch

Function

Operation

Machine Stop

Removes power from the control circuit, Push the button to stop all motors. shutting down the machine.

Miner Operation

Determines mode of operation.

MAINTENANCE is a mode of operation that limits the miner to one motor function at a time. This mode is for use during motor vibration analysis. As soon as this mode is selected, a thirty (3) minute timer is activated. At the end of the thirty (30) minutes, the pump motor will shut down. To restart the timer, the MINER switch must be cycled to REMOTE and back to MAINTENANCE. E-TRAM allows the miner to be trammed from the tram pendant.

REMOTE allows the miner to be operated from the radio remote.

GND CHK causes the mine power center to trip thereby shutting down the machine.

CLA Modes

Controls the CLA and conveyor modes of operation.

ARMS & CHAINS turns on CLA arms and conveyor chain.

ARMS ONLY turns on the machine’s CLA arms.

CHAINS ONLY turns on the conveyor chain.

MCB1

15A beaker for the 120VAC+ side of the PUSH in to set/reset. control power circuit.

PULL to open.

MCB2

15A breaker for the 120VAC- side of the control power circuit.

PUSH in to set/reset.

PULL to open.

MCB3

15A breaker for the 120VAC+ side of the area light circuit.

PUSH in to set/reset.

PULL to open.

MCB4

15A breaker for the 120VAC- side of the area light circuit.

PUSH in to set/reset.

PULL to open.

MCB5

25A breaker for the 12VAC+ side of the PUSH in to set/reset. headlight circuit.

PULL to open.

MCB6

25A breaker for the 12VAC- side of the headlight circuit.

PUSH in to set/reset.

PULL to open.

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Machine Mounted Controls ________________________________________ Control Switch Operation, continued Switch MCB7

Function 5A breaker for the 12VAC+ side of the RTD module circuit.

Operation PUSH in to set/reset.

PULL to open.

MCB8

5A breaker for the 12VAC- side of the RTD module circuit.

PUSH in to set/reset.

PULL to open.

MCB9

5A breaker for the 120VAC+ side of the PUSH in to set/reset. contactor circuit.

PULL to open.

MCB10

5A breaker on the 90VDC+ side of the solenoid circuit.

PUSH in to set/reset.

PULL to open.

MCB11

5A breaker on the 0VDC- side of the solenoid circuit.

PUSH in to set/reset.

PULL to open.

MCB12

5A breaker on the 24VDC+ side PLC power circuit.

PUSH in to set/reset.

PULL to open.

MCB13

5A breaker on the 0VDC- side of the PLC power circuit.

PUSH in to set/reset.

PULL to open.

MCB14

5A breaker on the communications circuit.

PUSH in to set/reset.

PULL to open.

MCB15

5A breaker on the communications circuit.

PUSH in to set/reset.

PULL to open.

MCB16

5A breaker on the communications circuit.

PUSH in to set/reset.

PULL to open.

Conveyor Hour Meter

Displays hours of running time for the conveyor motor.

N/A

Cutter Head Hour Meter Displays hours of running time for the cutter head motors.

N/A

Key Switch

TURN counter-clockwise to energize the control circuit.

Left Side Machine Stop

Safety device built into the control circuit; must be on for the machine to operate

There is a machine stop button located on the left rear corner of the machine.

Like the machine stop button on the control case, pressing the left side machine stop button will shutdown the pump, thereby shutting down the machine.

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________________________________________ Machine Mounted Controls Gauges

There are 10 gauges (Fig. 10) located on the right hand side of the machine (above the main case) that are used to monitor hydraulic and water pressure throughout the miner.

Fig. 10: Gauges

1

2

3

4

5

6

7

8

9

10

1. Mine Water Pressure 2. Main Pressure 3. Pilot Pressure 4. Gathering Head Float Pressure 5. Shear Down Pressure 6. Conveyor Chain Take-Up Pressure 7. Stabilizer Shoe Down Pressure 8. Booster Pump Pressure 9. Booster Pump Intake Water Pressure 10. Booster Pump Output Water Pressure

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Machine Mounted Controls ________________________________________ Gauge Functions Gauge

Function

Mine Water Pressure

The first gauge in the row of gauges is MINE WATER PRESSURE. This gauge monitors the pressure of the supply water coming into the water system from the mine. The pressure should be a minimum of 250 psi under dynamic conditions and should not exceed 500 psi. If the pressure exceeds 500 psi, immediately adjust the supply water pressure or shutdown the machine (see Shutdown procedure in this manual).

Main Pressure

The second gauge in the row of gauges is MAIN PRESSURE. This gauge is used to measure the pressure in main flow - primary pressure circuit. See the main flow - primary pressure circuit in the Hydraulic manual for further information.

Pilot Pressure

The third gauge in the row of gauges is PILOT PRESSURE. This gauge is used to monitor the supply pressure for all pilot functions. See the pilot pressure circuit in the Hydraulic manual for further information.

Gathering Head Float Pressure

The fourth gauge in the row of gauges is GH FLOAT PRESSURE. This gauge is used to monitor the pressure in the gathering head circuit during gathering head float operations. See the gathering head raise/hold/ float-lower circuit in the Hydraulic manual for further information.

Shear Down Pressure

The fifth gauge in the row of gauges is SHEAR DOWN PRESSURE. This gauge is used to monitor the pressure of the cutting head cylinder circuit during shear down operations. See the shear down/ maintenance (anti-chatter) valve in the cutter head cylinder circuit in the Hydraulic manual for further information.

Conveyor Chain Take-Up Pressure

The sixth gauge in the row of gauges is CONVEYOR CHAIN TAKE-UP PRESSURE. This gauge is used to monitor the pressure of the automatic conveyor chain tensioner. See the conveyor take-up circuit in the Hydraulic manual for further information.

Stabilizer Shoe Down Pressure

The seventh gauge in the row of gauges is STAB SHOE DOWN PRESSURE. This gauge is used to monitor the pressure of the stabilizer shoe circuit when the stabilizer shoe is being lowered to the floor. See the stabilizer shoe cylinders circuit in the Hydraulic manual for further information.

Booster Pump Pressure

The eighth gauge in the row of gauges is BOOSTER PUMP PRESSURE. This gauge is used to monitor the booster pump pressure. See the booster pump circuit in the water section of the Hydraulic manual for further information.

Booster Pump Intake Water Pressure

The ninth gauge in the row of gauges is BP INTAKE WATER PRESSURE. This gauge monitors the pressure of the water going into the booster pump. See the booster pump circuit in the water section of the Hydraulic manual for further information.

Booster Pump Output Water Pressure

The tenth gauge in the row of gauges is BP OUTPUT WATER PRESSURE. This gauge monitors the pressure of the water coming out of the booster pump. See the booster pump circuit in the water section of the Hydraulic manual for further information.

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________________________________________ Remote Control Operation Radio Remote

The continuous miner is normally radio remote (Fig. 11) controlled during production operations. Remote operation is allowed when the machine is energized and the miner switch is in the remote position. See the Remote Operation manual for further information on the radio remote control of the machine.

Pendant Control

Limited machine functions can be operated from a pendant control (Fig. 11) connected to the machine by an umbilical cable. This control is used in the event that the operator loses radio link with the miner and the miner needs to be moved.

The pendant controller can turn the pump motor on and off, can tram the machine, and can raise and lower the cutting head.

In order to use the pendant, it must be connected to the machine via a pigtail.

After plugging in the umbilical cord, the miner switch must be placed in the ETram position.

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

See the Remote Operation manual for further information on the pendant control of this machine.

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WARNING Follow all applicable laws and regulations regarding the use of temporary roof supports before approaching the machine to connect the umbilical cord. Under no circumstances should personnel be under unsupported roof. Failure to follow these regulations may result in serious injury or death.

Fig. 11: Radio Remote and Pendant Control

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Operation _______________________________________________________ Pre-Operational Checks

The following checks should be completed before the machine is put into service for the first time. Corrections or adjustments should be made by a qualified maintenance person.

1. Verify that all circuit breakers are in their OFF positions.

2. Check all hydraulic and lubricant fluid levels.

3. Verify that the cooling water is connected. Operating the machine without cooling water will seriously reduce the life of the motors.

4. Check and operate all control handles and remote switches to ensure all machine functions are operating correctly. Return all handles/switches to the neutral position.

5. Check, and adjust as necessary, the tension of the conveyor and crawler chains.

Daily Checks

The following checks should be completed at the beginning of every shift. Repairs and adjustments should be made immediately by a qualified maintenance person.

1. Visually inspect all cylinders, gear boxes, tanks, and hydraulic components for leaks and damage.

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

3. Check the full length of the trailing cable for damage. Ensure that the trailing cable is properly suspended across intersections and that the trailing cable clamp at the machine is secure.

4. Clean any foreign material from the conveyor and gathering pan.

5. Check that all covers and guards are in place and are secure.

6. Perform daily maintenance.

7. Check the conveyor and crawler chain tensions.

8. Be certain that all other machines and personnel are clear of the area and start the machine. Check for correct operation of all stop and emergency stop buttons (both on the machine and on the radio remote).

9. After starting the machine, allow the hydraulic system to warm up for five to ten minutes and then verify that the hydraulic system pressure is correct (see the hydraulic schematic in the parts book for your machine).

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____________________________________________ Emergency Shutdown Emergency Shutdown Controls

The are controls located on the machine, the radio remote, and the tram pendant that give the operator the ability to quickly shutdown the miner. All personnel should be aware of the location of shutdown controls and how to use them.

The following controls can be used to shutdown the machine:

Control

Location

Action

Result

Main Circuit Breaker

Main Disconnect Box

Push to the right to Isolates the entire machine from power supplied via the turn OFF (open the trailing cable. breaker).

Machine Stop

Control Case

Push to activate.

Shuts down all motors on the machine.

Machine Left Side E- STOP

Radio Remote Push to activate.

Shuts down all motors on the machine. Note: The stop button is defaulted to function as a machine shutdown (power center trip). Once it is pressed, the remote transmits that message for several seconds before shutting itself down.

Pump Off

Radio Remote Push toggle switch up to activate.

Shuts down all motors on the machine.

Machine Stop

Tram Pendant Push to activate.

Shuts down all motors on the machine.

Key Switch

Machine Right Turn key clockwise Side, Left of Gauge Panel

De-energizes the control circuit.

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Start-Up Procedure _______________________________________________ Introduction

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The following procedures are recommended for starting up the continuous miner. These procedures are for starting the machine during normal operations and assume that the operator has been fully trained and that machine is correctly connected to the trailing cable and that all pre-operational checks, including daily maintenance, have been performed.

WARNING Do not attempt to operate this continuous miner until you have been sufficiently trained on this machine and have read and understood this manual and are familiar with all controls and indicators. Operating this machine without the proper training and knowledge may result in serious injury or death to the operator or other personnel.

Start-Up (Radio Remote)

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

1. Turn the main circuit breaker to the “ON” position.

2. Turn the key switch to the “ON” position.

3. Turn the “TRAM CIRCUIT BREAKER” to the “ON” position.

4. Turn the “MINER” mode of operation selector switch to “REMOTE”.

5. Press the “ON/OFF” button on the transmitter to turn on the transmitter.

6. Press and hold the “SHIFT” button on the transmitter.

7. While holding the “SHIFT” button, press the “PUMP/OFF” button. A prestart warning horn will sound. Hold both buttons in until the pump starts.

8. Release the “PUMP/OFF” key. The pre-start warning horn will stop.

IMPORTANT

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

9. Release the “SHIFT” key.

________________________________________________________________ 28 CM445 Continuous Miner

_____________________________________________ Shutdown Procedure Shutdown Procedure (Radio Remote)

The continuous miner must be properly shutdown before leaving the area or before performing any maintenance or service. Some maintenance or service procedures may require additional steps to insure the safety of the maintenance personnel working on or around the machine and will be listed in the maintenance section of this guide.

1. Back the miner about one foot from the face providing sufficient clearance and shut off the cutter head motors (see Cutter operation in this section).

2. Turn off the water sprays by pressing the “WATER/OFF” button on the transmitter.

3. Make sure that the conveyor is empty and then shut down the conveyor motors. a. Press and hold the “CONV/OFF” button on the transmitter. The conveyor motors should shut down immediately.

4. Tram the miner to an area of well supported roof. Park the machine in its designated parking area out of traffic and on flat, solid ground. If it is not possible to park the machine on flat ground, park the machine at a right angle to the slope.

5. Lower the cutter head to the floor.

6. Lower the conveyor and gathering head.

7. Press and hold the “PUMP/OFF” button on the transmitter. The pump motor should shutdown immediately.

8. Release the “PUMP/OFF” button.

9. Turn the machine circuit breaker to the “OFF” position.

10. Turn the key switch to the “OFF” position.

11. Turn off the main power supply.

12. Turn off the mine water supply.

______________________________________________________________ A6474X437 REV 1 29

Operation _______________________________________________________ Tramming Operation

1. Ensure that the pump motor is running (see Start up procedure in this chapter).

2. Ensure that the stabilizer shoe is away from the mine floor.

3. Raise cutter boom to best possible position to allow clearance from roof, ribs, and floor.

4. Raise gathering head away from the mine floor.

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

6. Ensure adequate clearance at all times while tramming machine. Be award of people, equipment, and cables.

Remote control Tram enable

1. To enable machine tramming, press and release either “TRAM ENABLE” button (the prestart warning horn will sound).

2. Once enabled, any combination of tram buttons (“LEFT TRAM FWD” , “LEFT TRAM REV”, “RIGHT TRAM FWD”, “RIGHT TRAM REV”) can be used to tram the miner. During tramming, the tramming horn will sound (a slightly different sound than the prestart warning horn). As soon as the tram button is released, the tramming horn will stop but the prestart warning horn will continue to sound.

3. Once a tram function button has not been pushed for a pre-set amount of time, the prestart warning horn will stop. Once the prestart warning horn stops, no tram function will work.

4. To re-enable the tram function, press and release either “TRAM ENABLE” button.

Tram direction

1. Press the “TRAM FWD” button to tram both tracks forward..

2. Press the “TRAM REV” button to tram both tracks in reverse.

3. Press the left tram forward button (blue and white button with a black forward arrow located on left side of remote) to tram the left track forward.

4. Press the left tram reverse button (blue and white button with a black reverse arrow located on left side of remote) to tram the left track in reverse.

5. Press the right tram forward button (blue and white button with a black forward arrow located on right side of remote) to tram the right track forward.

6. Press the right tram reverse button (blue and white button with a black reverse arrow located on right side of remote) to tram the right track in reverse.

________________________________________________________________ 30 CM445 Continuous Miner

_______________________________________________________ Operation

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

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

Tram speed control

Tram speed is increased or decreased while tramming using the tram buttons on the radio remote.

______________________________________________________________ A6474X437 REV 0 31

Operation _______________________________________________________ Cutter Operation Starting cutter motors

!

WARNING

1. Ensure that the cutter head is not in contact with anything. Cutter head motors must never be started under a load.

Never start cutter head motors under a load. Starting motors under load may result in motor damage or premature failure.

2. Warn ALL CLEAR before starting the cutter head.

!

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

3. Ensure that the pump motor is running as the cutter motors will not run if the pump motor is not running.

4. Press the “SHIFT” button and wait 1/4 second.

IMPORTANT

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

5. While holding the “SHIFT” button, press the “CUTER/OFF” button.

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

IMPORTANT

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

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

IMPORTANT

The “CUTTER ON” key must be released before “SHIFT”. If “SHIFT” is released first, the cutter motors will shut off.

7. Release the “SHIFT” button.

Stopping cutter motors

To stop the cutter motors 1. Press and hold the “CUTER/OFF” button. The cutter motors should shutdown immediately.

2. Release the “CUTTER/OFF” button.

________________________________________________________________ 32 CM445 Continuous Miner

_______________________________________________________ Operation Conveyor Operation Starting conveyor Motors conveyor forward !

1. Place conveyor boom in desired position.

2. Warn ALL CLEAR before starting the conveyor.

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

3. Ensure that the pump motor is running as the conveyor motors will not start if the pump motor is not running.

4. Press the “SHIFT” button and wait 1/4 second.

IMPORTANT

The “CONV ON” key must be released before “SHIFT”. If “SHIFT” is released first, the conveyor motors will shut off.

5. While holding in “SHIFT”, press “CONV/OFF”. A pre-start warning horn will sound. Continue to hold until the conveyor motor turns on and the conveyor starts to run forward.

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

IMPORTANT

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

7. Release the “SHIFT” button.

Stopping conveyor Motors conveyor forward

To stop the conveyor motors - conveyor forward

Starting conveyor Motors conveyor reverse (momentary only)

1. Place conveyor boom in desired position.

1. Press and hold the “CONV/OFF” button. The conveyor motors should shutdown immediately.

2. Warn ALL CLEAR before starting the conveyor.

3. Ensure that the pump motor is running. The conveyor motors will not start if the pump motor is not running.

4. Press “SHIFT” and wait 1/4 second.

5. While holding in “SHIFT”, press “CONVEYOR OFF” and “REV” buttons.

The pre-start warning horn will sound. Continue to hold until the conveyor motor turns on and the conveyor starts to run in reverse.

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

______________________________________________________________ A6474X437 REV 0 33

Operation _______________________________________________________ Scrubber Fan Operation Starting the scrubber fan

1. Ensure that the pump motor is running. The scrubber motor will not start if the pump motor is not running.

2. Press and hold the [SHIFT] key for 1/4 second. While holding [SHIFT], press FAN ON. The pre-start warning horn will sound. Continue to hold until the scrubber fan motor turns on.

3. Release the FAN OFF key. The pre-start warning horn will stop.

IMPORTANT

The “FAN ON” key must be released before “SHIFT”. If “SHIFT” is released first, the fan motor will shut off.

4. Release the [SHIFT] key.

Stopping the scrubber fan

1. Press and hold the FAN OFF key. The fan motor will shutdown immediately.

2. Release the FAN OFF key.

Lights

1. Press the [SHIFT] and LIGHTS keys together to turn the front lights on.

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

2. Press the [SHIFT] and LIGHTS keys together to turn the lights off.

Fire Suppression (if equipped)

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

When in REMOTE mode, the fire suppression can be activated from the radio remote as follows: 1. Press the fire suppression button. This is a red and white button with a fire extinguisher on the white half of the button. The fire suppression system will activate and, at this time, the fire suppression button can be released.

________________________________________________________________ 34 CM445 Continuous Miner

_______________________________________________________ Operation Conveyor Boom Control

The pump motor must be running in order to operate the conveyor raise, lower, and swing functions.

To position the conveyor: 1. Press the yellow BOOM L button to swing the conveyor tail to the left. The solenoid controlling the left conveyor swing will remain energized until the key is released.

2. Press the yellow BOOM R button to swing the conveyor tail to the left. The solenoid controlling the right conveyor swing will remain energized until the key is released.

3. Press the conveyor down key (half yellow with a black arrow pointing down and half green with REV) button to lower the conveyor boom. The solenoid controlling the conveyor lower function will remain energized until the key is released.

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

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

Stabilizer Shoe Operation

The pump motor must be running in order to raise or lower the stabilizer cylinder.

1. Press STAB/ATRS UP to raise the stabilizer cylinder. The stabilizer cylinder solenoid remains energized until the key is released.

2. Press STAB/ATRS DOWN to lower the stabilizer cylinder. The stabilizer cylinder down solenoid remains on until the key is released.

Shear Up/Down Operation

The pump motor must be running in order to raise or lower the cutter head.

1. Press SHEAR UP to move the cutter head up. The shear up solenoid remains energized until the key is released (unless height limiting is in force).

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

Gathering Head (Pan) Raise/Lower Operation

The pump motor must be running in order to raise or lower the gathering head (pan).

1. Press PAN EXTEND to lift the gathering head. The pan up solenoid remains energized until the key is released.

2. Press PAN RETRACT to “float” the head down.

______________________________________________________________ A6474X437 REV 0 35

Hydraulic System ________________________________________________ Introduction

Hydraulic power for all hydraulically actuated functions originates with the pump assembly. This includes power for the conveyor swing and raise/lower cylinders, the conveyor chain take-up cylinders, the stabilizer shoe cylinders, the cutting head raise/lower cylinders, and the hydraulically actuated dust suppression system.

A 75 HP pump motor drives a three-stage gear pump that delivers hydraulic oil to the hydraulic system. The 156 gallon (592 L) hydraulic oil tank is an integral part of the main frame. Only anti-wear hydraulic oil meeting Specification 100-1 should be used in the hydraulic system.

Load Holding (Load Lock) Valves

The purpose of a load holding (load locking) valve is to prevent the accidental lowering of a hydraulic cylinder, whether suddenly or by gradual bleed off. Both the conveyor raise/lower cylinders and the cutter head raise/lower cylinders incorporate load holding valves.

There is a pilot operated check valve in the load holding valve of each conveyor raise/lower cylinder and a pilot load holding valve attached to each cutter head raised/lower cylinder. Each of these valves prevents its respective cylinder from lowering its load in the absence of a specific pilot pressure. (This pressure is induced only when the lower control of that particular function is engaged.) The load holding valves fro the conveyor and cutter head incorporate a relief function which by-passes the pilot operation whenever the pressure setting is exceeded.

Shear Down (anti-chatter)/ Maintenance valve

The shear down (anti-chatter)/maintenance valve provides back pressure against the cutter head (shear) cylinders in the cutter head lower (shear down) cycle. This back pressure must be overcome before the cutter head will lower, preventing cutter head bounce (chatter).

System Pressure

The machine operator should be familiar with the operating (system) pressure of the machine during normal operations. If the operating pressure is outside of the normal range, it should be reported immediately.

Power Fill Function

The machine is equipped with a power fill function that assists in adding hydraulic oil to the machine’s hydraulic oil tank. The power fill operates from the conveyor lower circuit. The conveyor lower line tees off to a ball valve that is normally closed. With the conveyor in the down position, the ball valve is manually opened. When the conveyor lower function is activated, oil enters the circuit and runs the power fill function. Oil passes through the ball valve to a jet pump, which creates a venturi (vacuum) effect, pulling oil from the clean oil reservoir through a 10 micron filter and a check valve and then to tank.

________________________________________________________________ 36 CM445 Continuous Miner

________________________________________________ Hydraulic System Power Fill Operation

To operate the power fill function: 1. Start the pump motor and fully lower the conveyor.

2. Wipe the suction hose clean and place it in a clean container of hydraulic fluid.

3. Open the ball valve.

4. Engage the conveyor down function.

5. After filling the tank, release the conveyor down function.

6. Close the ball valve.

7. Clean and plug the suction hose to prevent contamination and secure the hose on the machine.

8. Stop the pump motor.

Filters

There are four hydraulic filters on the machine: 1. Pressure filter, bypassing 2. Pilot filter, bypassing 3. Pilot filter, non-bypassing 4. Power fill filter

______________________________________________________________ A6474X437 REV 0 37

Electrical System _________________________________________________ Introduction

The main input power supply for this machine is three-phase 1040VAC power which directly supplies the motor circuits. A control transformer steps the voltage down to 120VAC for the control circuit and 12VAC for the lighting circuit and thermistor module.

Motors

This machine is powered by ten 1040VAC electric motors: 1. One 75 hp pump motor 2. Two 250 hp cutter motors 3. Two 55 hp gathering head/conveyor motors 4. Two 50 hp traction motors 5. One 60 hp scrubber motor 6. Two 41hp tail drive motors

________________________________________________________________ 38 CM445 Continuous Miner

___________________________________________________ Water System Introduction

The minter is equipped with a water system used to cool the electric motors, the control case, the VFD case and for dust control. The mine water is normally connected on the right rear of the machine.

Water supply requirements are: Flow: 25 gpm for cooling Pressure: 250 psi (dynamic) minimum 500 psi maximum The water supply is connected to a ball valve, which must be manually opened before the cooling/dust suppression system can be activated. From the ball valve, water flows through a reverse flushing strainer. Water pressure before and after the filter is monitored by gauges teed into the lines.

Activation

Maintenance

After the ball valve is manually opened, the dust-cooling circuit is operated by remote solenoid control. When the dust-cooling solenoid is energized, the normally closed water valve is opened. Water passes through the solenoid water valve to a pressure manifold and is distributed to the left and right dust cooling circuits.

The following maintenance items should be observed to properly maintain the dust/cooling system: 1. Insure that the water supply meets the requirements listed above. Insufficient water flow and/or pressure will affect cooling capabilities and dust spray operation.

2. Only use water that is clean and as free as possible of corrosive elements.

3. Do not operate the miner without the water supply being connected and activated. Operating the electric motors without proper cooling will seriously reduce motor life.

4. Monitor the water filter and remove and clean as needed to eliminate clogging. This is a by-passing filter; if the filter is clogged, the water will pass unfiltered to the dust/cooling system.

5. Inspect the water spray nozzles on a regular basis. Water should flow from all nozzles when the sprays are operating. Clean as necessary.

______________________________________________________________ A6474X437 REV 0 39

__________________________________________________________

BI001569 A6474X438 August 2012

Operation and Maintenance Manual CM445 Continuous Miner A6474X438 (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 ............................................ 13 Specific Lubrication and Maintenance Procedures ........................... 19 Every Shift ................................................................................. 19 Daily .......................................................................................... 23 Weekly....................................................................................... 31 Crawler Chain Adjustment Procedure .................................. 33 Conveyor Chain Tension Adjustment Procedure ................. 37 Monthly ...................................................................................... 40 Every Three Months .................................................................. 46 Every Six Months ...................................................................... 53 Tail Shim Adjustment Procedure ....................................................... 56 Lubricant Specifications ................................................................... 58

________________________________________________________________ A6474X438

REV 0

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.

!

DANGER

Do not make any type of temporary repairs to the trailing cable or trailing cable connections except as allowed by applicable regulatory agencies. Contact with high voltage power supply will result in severe injury or death from electrocution.

!

DANGER

Only qualified personnel are permitted to make repairs to permissible equipment. The permissibility of any permissible component must be verified after any maintenance or repair work and at regular intervals. Failure to maintain permissible components to OEM standard may result in a fire or explosion. Serious injury or death could occur.

!

!

!

!

!

!

!

WARNING Do not attempt to operate this continuous miner until you have been sufficiently trained on this machine and have read and understood this manual and are familiar with all controls and indicators. Operating this machine without the proper training and knowledge may result in serious injury or death to the operator or other personnel.

WARNING Federal law requires that temporary roof supports be in place before approaching the machine to reset a circuit breaker. Under no circumstances should personnel be under unsupported roof. Failure to follow these regulations may result in serious injury or death.

WARNING Only use the Emergency Stop Override to tram the miner away from the rib, releasing the accidentally pushed Machine Stop button. Never use the Emergency Stop Override when a Machine Stop switch has been activated by personnel. Failure to comply with this warning may lead to severe injury or death of personnel.

WARNING The Continuous Miner is radio remote controlled during production operations. Manual operation via machine mounted controls is not permitted for production operations.

Manual operation is for troubleshooting and maintenance under supported roof only.

Operating the Continuous Miner with manual or pendant controls under unsupported roof may result in sever injury or death.

WARNING Before performing maintenance or repair work on this machine, the circuit breaker must be in the “OFF” position and the trailing cable disconnected. Follow all applicable rules and regulations regarding the lockout/tagout procedures. Accidental machine movement or electrical shock may result in serious injury or death to the operator or other personnel.

WARNING Some procedures or test may require the cover of the electrical controller to be removed and some may require the controller to be energized during the procedure. Tall all necessary precautions to prevent electrical shock while working within the controller. An MSHA certified electrician must supervise and inspect all work.

WARNING Do not alter, bypass, or remove and emergency or machine stop device. Failure to heed this warning may result in serious injury or death.

________________________________________________________________ 4 CM445 Maintenance

_______________________________________________ Safety Instructions

!

!

!

!

WARNING Do not use an emergency or stop device as a means of disconnecting power to the miner. Whenever instructed to disconnect power, it is always meant to turn the main circuit breaker to the “OFF” position and to physically remove the trailing cable and lockout/tagout the machine. Failure to do so may result in serious injury or death.

WARNING Never disconnect a hydraulic hose if the circuit is pressurized or there is a load on the circuit. Pressurized hydraulic fluid or falling loads may result in serious injury or death.

WARNING Do not rely on load holding valves when working under the cutter head or the conveyor.

Always block the cutter head and conveyor in the elevated position. Serious injury or death may occur if the cutter head or conveyor are not mechanically blocked.

WARNING Never work under any assembly or component of this machine that is elevated. Always install enough blocking to support the machine or component or lower the component to ground level.

______________________________________________________________ A6474X438 REV 0 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, the manufacturer recommends that a general maintenance plan 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 CM445 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.

______________________________________________________________ A6474X438 REV 0 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 CM445 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

Grade 8 Imperial Bolts Torque Recommendations (calculated at 75% proof load) Bolt size Dry Lubricated (inches) ft-lbs ft-lbs 1/4 12 6 5/16 25 12 3/8

44

22

7/16

70

35

1/2

107

53

9/16

154

77

5/8 3/4

212 376

106 188

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 3

17794 23507

8897 11753

3-1/4

30286

15143

3-1/2

38266

19133

3-3/4

47545

23773

4

58100

29085

______________________________________________________________ A6474X438 REV 0 9

Torque Values ___________________________________________________ Metric Bolts Metric Bolts Torque Recommendations (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 CM445 Maintenance

______________________________________________________ Installation Fig. 2: Conveyor safety supports

Conveyor safety support (storage location)

Conveyor safety support (installed location)

______________________________________________________________ A6474X438 REV 0 11

Installation ______________________________________________________ Fig. 3: Cutter safety supports

Cutter safety support (storage location)

Cutter safety support (installed location)

________________________________________________________________ 12 CM445 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.

Location

Specification

Approximate capacity

Hydraulic oil tank GH Assembly CLA Primary

Spec. 100-1 Spec. 100-15

156 gals. (592 L) 1 gal (3.79 L)

GH Assembly CLA POT Tram Drive Assembly

Spec. 100-15 Spec. 100-15

2.5 gal (9.46 L) 3 gal (11.36 L)

Drum Drive Assembly, high speed (back) Drum Drive Assembly, low speed (front) Motor Lube Hoses

Spec. 100-15

0.5 gallon (1.89 L)

Spec. 100-15

5 gal (18.93 L)

Spec. 100-14

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.

______________________________________________________________ A6474X438 REV 0 13

Maintenance Schedule ____________________________________________ Table 3: Lubrication and maintenance schedule Item

Description

Places

Lubricant

Specification

Every Shift 1

Cutter head lift cylinder pin, upper

2

Lithium based grease

Spec. 100-3

2

Cutter head lift cylinder pin, 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 pivot pin

2

Lithium based grease

Spec. 100-3

6

Cutter head bits

Inspect

7

Scrubber screen

Clean

8

Daily Conveyor take-up shaft

2

Lithium based grease

Spec. 100-3

9

Gathering head pivot pin

2

Lithium based grease

Spec. 100-3

10

Crawler idler roller

2

Lithium based grease

Spec. 100-3

11

Conveyor raise pivot pin

2

Lithium based grease

Spec. 100-3

12

Stabilizer shoe cylinder pin, upper

2

Lithium based grease

Spec. 100-3

13

Stabilizer shoe cylinder pin, lower

2

Lithium based grease

Spec. 100-3

14

Conveyor raise cylinder pin, upper

2

Lithium based grease

Spec. 100-3

15

Conveyor raise cylinder pin, lower

2

Lithium based grease

Spec. 100-3

16

Conveyor swing pivot pins

8

Lithium based grease

Spec. 100-3

17

Gathering head cylinder pin, upper

2

Lithium based grease

Spec. 100-3

18

Gathering head cylinder pin, lower

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

Main cutter head gear case (Check)

2

High demulsibility EP gear oil

Spec. 100-15

24

Hydraulic oil level (Check)

1

AW hydraulic oil

Spec. 100-1

25

Crawler track

Lubricate

26

Conveyor chain

Lubricate

27

Stab shoe pivot, frame

2

28

Weekly Return filter element (Change)

1

See Parts Book

1

See Parts Book

2

See Parts Book

29 30

Pilot circuit primary filter element (Change) Pressure filter element (Change)

31

Crawler chain

Inspect

32

Conveyor chain

Inspect

33

Fasteners (nuts, bolts, screws)

Inspect

34

Electrical cables, conduits, and glands

Inspect

35

Hydraulic/water hoses and connections

Inspect

36

Lighting

Inspect

37

Reflectors and warning tags

Inspect

38

Machine stop switch (Inspect)

39

Scrubber

Waste oil Waste oil Lithium based grease

Spec. 100-3

2 Clean

________________________________________________________________ 14 CM445 Maintenance

____________________________________________Maintenance Schedule Item

Description

Places

Lubricant

Specification

Monthly 40

CLA head pot assembly (Change)

2

High demulsibility EP gear oil

Spec. 100-15

41 42

CLA head transfer case (Change) Input cutter head gear case (Change)

2 2

High demulsibility EP gear oil High demulsibility EP gear oil

Spec. 100-15 Spec. 100-15

43 44

Main cutter head gear case (Change) CLAs

2 Inspect

High demulsibility EP gear oil

Spec. 100-15

45 46

Input cutter head gear case Main cutter head gear case

2 2

Sample Sample

See Note 1 See Note 1

47 48

CLA head pot assembly CLA head transfer case

2 2

Sample Sample

See Note 1 See Note 1

49 50

Tram gear case Main hydraulic tank

2 1

Sample Sample

See Note 1 See Note 1

51

Every three months Cutter motor

4

Spec. 100-14

52

Gathering head motor

4

53

Pump motor

2

54

Scrubber motor

2

55

Tail drive motor

2

High temperature lithium complex grease 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) Suction strainer, hydraulic oil tank (Change) Breathers

1 2 All

AW hydraulic oil

Spec. 100-1 See Parts Book See Parts Book

60

Water filter (strainer) (Change)

2

See Parts Book

61

Gathering head float valve filter (Change)

1

See Parts Book

Spec. 100-14 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.

______________________________________________________________ A6474X438 REV 0 15

Maintenance Schedule ____________________________________________ Fig. 4: Lubrication and maintenance chart

22, 41, 44 6

3 - Conveyor swing cylinder front pin 4 - Conveyor swing cylinder rear pin 6 - Cutter head bits 22, 41,44 - Main cutter head gear case 24,57,58,59 - Hydraulic oil tank 26, 32 - Conveyor chain 28,29,30 - Hydraulic filters 45 - Input cutter head gear case 49,56 - Tram gear case 54 - Scrubber motor 55 - Tail drive motor 60 - Water filter (strainer) 61 - Gathering head float valve

45

45

61

24, 57, 58, 59 58,59

28,29,30

49, 57

49, 56 60

56

4 26, 32 3

8 ________________________________________________________________ 16 CM445 Maintenance

____________________________________________Maintenance Schedule Fig. 4: Lubrication and maintenance chart, continued 1 - Cutter head lift cylinder pin, upper 2 - Cutter head lift cylinder pin, lower 5 - Cutter head pivot pin 9 - Gathering head pivot pin 11 - Conveyor raise pivot pin 13 - Stabilizer shoe cylinder pin 14 - Conveyor raise cylinder pin 16 - Conveyor swing pivot pins 17 - Gathering head cylinder pin, upper 18 - Gathering head cylinder pin, lower 20,41,48 - CLA head transfer case 22,42,45 - Input cutter head gear case 25,31 - Crawler track 38 - Machine stop 51 - Cutter motor 52 - Gathering head motor 53 - Pump motor 55 -Tail drive motor

22,42,45

51 52 19,40,47

20,41,48

17 1

10

2 9

18

5 11

25,31 21 53

13

38 14 16

16

55

______________________________________________________________ A6474X438 REV 0 17

Maintenance Schedule ____________________________________________ Fig. 4: Lubrication and maintenance chart, continued 35

1 - Cutter head lift cylinder, upper 2 - Cutter head lift cylinder, lower 5 - Cutter head pivot pin 7 - Gathering head cylinder upper pin 9 - Gathering head pivot pin 11 - Conveyor raise pivot pin 12 - Stabilizer shoe cylinder pin, upper 13 - Stabilizer shoe cylinder pin, lower 15 - Conveyor raise cylinder pin 16 - Conveyor swing pivot pins 17 - Gathering head cylinder pin, upper 18 - Gathering head cylinder pin, lower 19, 40,47 - CLA head pot assembly 20, 41, 48 - CLA head transfer case 21 - Tram gear case 22, 42, 45 - Input cutter head gear case 25, 31 - Crawler track 27 - Stab shoe pivot pin 15 38 - Machine stop switch 39 - Scrubber 12 50 - Main hydraulic tank 52 - Gathering head motor 55 - Tail drive motor 27

16

16

38 13 21

25,31 39 11 7

5

17

9

1

2 10

19,40,47

18 20,41,48

50 52 22,42,45

________________________________________________________________ 18 CM445 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 Cutter Head Cylinder Pins (upper and lower)

Lubricate the upper and lower cutter head cylinder pins (right and left). The upper pins are lubricated through the grease fittings located on each pin (Fig. 5). The lower cylinder pins are lubricated through a lubrication block mounted on each side of the machine (Fig. 5). Pump approximately 50 cubic cm (3 cubic inches) into each fitting.

Fig. 5: Cutter head cylinder pins (typical both sides)

Lower cutter head cylinder pin grease fitting

Upper cutter head cylinder pin

______________________________________________________________ A6474X438 REV 0 19

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. 6). Pump approximately 50 cubic cm (3 cubic inches) into each fitting.

Fig. 6: 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. 7). Pump approximately 3 cu. in. (50 cu. cm) of grease into each fitting.

Fig. 7: Cutter head pivot pins (typical both sides) Cutter head pivot pin lubrication

________________________________________________________________ 20 CM445 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. 8). Replace bits immediately if any are missing or damaged.

Fig. 8: Cutter head bits Bit holder

Bit

______________________________________________________________ A6474X438 REV 0 21

Maintenance Instructions __________________________________________ Scrubber screen

Wash down the scrubber screen (Fig. 9) every shift.

Fig. 9: Scrubber screen

Scrubber screen

Washdown hose connection

________________________________________________________________ 22 CM445 Maintenance

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

Lubricate the tail roller through the two (2) grease fittings located on the shaft (Fig. 10). Pump approximately 3 cu. in. (50 cu. cm.) of grease into each fitting.

Fig. 10: Tail roller lubrication

Grease fittings (2)

______________________________________________________________ A6474X438 REV 0 23

Maintenance Instructions __________________________________________ Gathering Head Pivot Pin (right and left)

Lubricate the left and right gathering head pivot pins through the grease fittings located on the left and right front lubrication blocks (Fig. 11). 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. 11) through the grease fittings located on the outside face of the crawler idler roller.

Conveyor Raise Pivot (right and left)

Lubricate the conveyor raise pivot through the grease fitting located on the right and left front lubrications blocks (Fig. 11). Pump approximately 3 cu. in (50 cu. cm) of grease into each fitting.

Fig. 11: Gathering head pivot pin, conveyor raise pivot, and crawler idler roller (typical both sides) Conveyor pivot pin lubrication

Gathering head pivot pin lubrication

Crawler idler roller

________________________________________________________________ 24 CM445 Maintenance

__________________________________________ Maintenance Instructions Upper Stabilizer Shoe Cylinder Pin (right and left)

Lubricate the upper stabilizer shoe cylinder pins (right and left) through the two grease fittings located on the lubrication block on the left side of the machine (Fig. 12). Pump approximately 3 cu. in (50 cu. cm) of grease into each fitting.

Lower Conveyor Raise Cylinder Pin (right and left)

Lubricate the lower conveyor raise cylinder pins (right and left) through the two grease fittings located on the lubrication block on the left side of the machine (Fig. 12). Pump approximately 3 cu. in (50 cu. cm) of grease into each fitting.

Stabilizer Shoe Pivot Pin (right and left)

Lubricate the stabilizer shoe pivot pins (right and left) through the two grease fittings located on the lubrication block on the left side of the machine (Fig. 13).

Pump approximately 3 cu. In (50 cu. Cm) of grease into each fitting.

Fig. 12: Lubrication block - stabilizer shoe and conveyor lift pin lubrication manifold Stab shoe pivot pin lube

Lower Stabilizer Shoe Cylinder Pin (right and left)

Stab shoe cylinder pin lube

Conveyor cylinder pin lube

Lubricate the lower stabilizer shoe cylinder pins (right and left) through the grease fittings located on the rod end of each cylinder (Fig. 10). Pump approximately 3 cu. in (50 cu. cm) of grease into each fitting.

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

Lower stabilizer shoe cylinder pin

______________________________________________________________ A6474X438 REV 0 25

Maintenance Instructions __________________________________________ Upper 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. 14). Pump approximately 3 cu. in (50 cu. cm) of grease into each fitting.

Fig. 14: Upper conveyor raise cylinder pin lubrication

Upper conveyor raise cylinder pin grease fittings (2)

Conveyor Swing Pivot Pins

Lubricate the conveyor swing pivot pins through the four (4) grease fittings located each side of the conveyor (Fig. 15). Pump approximately 3 cu. in (50 cu. cm) of grease into each fitting.

Fig. 15: Conveyor swing pivot pin Conveyor swing pivot pin lubrication fittings (2) (typical both sides)

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

________________________________________________________________ 26 CM445 Maintenance

__________________________________________ Maintenance Instructions Gathering Head Raise Cylinder Pins

Lubricate the upper gathering head raise cylinder pins (Fig. 16) 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. 16: Gathering head raise cylinder pins (typical both sides)

Gathering head raise cylinder pin (upper)

Gathering head raise cylinder pin (lower)

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. 17). If oil is needed, add oil through the fill hole until oil comes out the breather.

CLA Head Transfer Case (right and left)

Level the miner and place the gathering head on grade before checking or adding lubricant. Check the oil level in the hydraulic transfer case (Fig. 17). If oil is needed, add oil through the fill hole until oil comes out the breather.

Fig. 17: CLA head pot assembly and transfer case lubrication Oil check, pot assembly

Oil fill, transfer case

Oil fill, pot assembly

Oil check, transfer case

______________________________________________________________ A6474X438 REV 0 27

Maintenance Instructions __________________________________________ Tram Gear Case (right and left)

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. 18). Oil should be visible in each sight glass. If oil level is low, add oil through either the fill pipe (accessed from the top of the machine) or the fill plug hole (accessed from the side of the machine).

Check that the breather is clean and free of debris.

Fig. 18: Tram gear case oil level (typical both sides) Oil fill plug

Breather (behind cover)

Oil check

________________________________________________________________ 28 CM445 Maintenance

__________________________________________ Maintenance Instructions Input Cutter Gear Case

Ensure fill areas are clean and free of debris. With the gathering head lowered to ground level and the cutter head boom level with ground, check the oil level in both of the input cutter gear cases by removing the check plug located on each side of the cutter head assembly (Fig. 19). Oil should flow from check plug hole when plug (s) is removed. If oil level is low, add oil through the fill plugs located on each side of the gathering head.

Fig. 19: Input cutter gear case oil level (typical) Oil fill plug (one per side)

Oil check plug (one per side)

Main Cutter Gear Case

Ensure fill areas are clean and free of debris. 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. 20). 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. 20: Main cutter head gear case oil level (typical) Oil fill plug (one per side)

Oil check plug

(one per side) ______________________________________________________________ A6474X438 REV 0 29

Maintenance Instructions __________________________________________ Hydraulic Oil Level

With all of the machine cylinders in the fully collapsed position, check the hydraulic oil level (Fig. 21). Remove dipstick from tank and wipe clean. Insert dipstick back into tank and remove. The oil should be level with the full line indicated on dipstick. If oil level is low, add oil until full level is met.

Fig. 21: Hydraulic oil tanks Hydraulic oil tank

Hydraulic oil tank

Dip stick location

________________________________________________________________ 30 CM445 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. Return filter, check and change as required 4. Water filter, check and change as required 5. Crawler chain, inspect 6. Conveyor chain, inspect 7. Inspect/check tightness/condition of all fasteners (nuts, bolts, screws, etc.)

8. Inspect electrical cables, conduits, and glands 9. Inspect hydraulic and water hoses and connections 10. Inspect lighting 11. Inspect reflectors and warning tags 12. Inspect/check the function of each machine stop switch Pressure Filter

Change the pressure filter elements (Fig. 22). If the element is extremely dirty, a more frequent change interval may be required.

Pilot Pressure Filters

Change the pilot pressure filter elements (bypassing and non-bypassing) (Fig. 22). If the elements are extremely dirty, a more frequent change interval may be required.

Return Filter

Change the return filter element (Fig. 22). If the element is extremely dirty, a more frequent change interval may be required.

Fig. 22: Hydraulic filter location Pilot pressure filter (non-bypassing)

Pressure filter

Pilot pressure filter (bypassing)

Return filter

______________________________________________________________ A6474X438 REV 0 31

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. 23).

Fig. 23: Crawler track tension measurement

Bottom of tractor wear shoe

2 1/2” - 3 1/2” gap (64 - 89 mm)

Top of tram track

________________________________________________________________ 32 CM445 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.

______________________________________________________________ A6474X438 REV 0 33

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. 24) into the idler slide channel until the space between the tractor frame and the pusher plate is filled. c.

Open the pressure release valve (Fig. 24) 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.

________________________________________________________________ 34 CM445 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. 24).

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.

______________________________________________________________ A6474X438 REV 0 35

Maintenance Instructions __________________________________________ Fig. 24: Tram track adjustment

Take-up cylinder

Shims

Idler assembly

Pad

Lock bolt Cleat Conelok nut

________________________________________________________________ 36 CM445 Maintenance

__________________________________________ Maintenance Instructions Conveyor Chain Tension

There are two different types of chain commonly used on the machine: Cincinnati chain (standard) or Joy chain (optional). To check the chain tension: Cincinnati chain: 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.

Joy chain: 1. With the machine locked and tagged out, place a hand on each end of a chain flight near the end of the conveyor. the ends should be not more than 50 mm (2 inches) from center or 100 mm (4 inches) top to bottom. If the deflection is more than 100 mm (4 inches), the chain is too loose and needs tensioned. If the deflection is less than 50 mm (2 inches), the chain is too tight and needs loosened.

Conveyor chain tension adjustment The conveyor chain is tensioned with a hydraulic take-up cylinder. If the chain tension is not being maintained, then: 1. The conveyor chain take-up valve may need to be adjusted. See the Conveyor chain take-up valve adjustment procedure (Pilot/auxiliary pump circuit relief valve adjustments) in this section. If the valve adjustment is correct, then 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.

______________________________________________________________ A6474X438 REV 0 37

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.

________________________________________________________________ 38 CM445 Maintenance

__________________________________________ Maintenance Instructions Scrubber cleaning

To clean out the scrubber (Fig. 25): 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. 25: Scrubber cleaning

Scrubber intake

______________________________________________________________ A6474X438 REV 0 39

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 main cutter head gear cases, change the oil 3. Inspect the CLAs 4. Sample the oil in the input and main 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. 26).

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 Head Transfer Case

Change the oil in both CLA head transfer cases (Fig. 26).

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.

________________________________________________________________ 40 CM445 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. 26: CLA pot assembly and input transfer case Oil check, pot assembly

Oil fill, transfer case

Oil fill, pot assembly

Oil check, transfer case

______________________________________________________________ A6474X438 REV 0 41

Maintenance Instructions __________________________________________ Input Cutter Head Gear Case Change the oil in both input cutter head gear cases (Fig. 27).

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. 27: Input cutter head gear case (typical) Oil fill plug (one per side)

Oil check plug (one per side)

________________________________________________________________ 42 CM445 Maintenance

__________________________________________ Maintenance Instructions Main Cutter Head Gear Case Change the oil in both main cutter head gear cases (Fig. 28).

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. 28: Main cutter head gear case Oil fill plug (one per side)

Oil check plug (one per side)

______________________________________________________________ A6474X438 REV 0 43

Maintenance Instructions __________________________________________ CLAs

Inspect the CLAs (Fig. 29) for damage. If a CLA needs replaced, see CLA removal and installation procedure in the Mechanical section of this manual.

Fig. 29: 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.30) 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.

________________________________________________________________ 44 CM445 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. 30: 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

______________________________________________________________ A6474X438 REV 0 45

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 IMPORTANT

For motor bearings that require high temperature lithium complex grease (Spec. 10015), the manufacturer provides a special “button” style lubrication fitting 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. 31) using the following procedure: 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.

! NOTICE

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

________________________________________________________________ 46 CM445 Maintenance

__________________________________________ Maintenance Instructions Fig. 31: Cutter motor bearing lubrication (typical each side)

Motor located behind cover

Button type grease fitting

Cutter motor lubrication (2)

Spring loaded grease relief fitting

______________________________________________________________ A6474X438 REV 0 47

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. 32).

To lubricate the motors: 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.

________________________________________________________________ 48 CM445 Maintenance

__________________________________________ Maintenance Instructions Fig. 32: Gathering head motor bearing lubrication (typical each side)

Gathering head motor lubrication

Motor located behind cover

Button type grease fitting

Spring loaded grease relief fitting

______________________________________________________________ A6474X438 REV 0 49

Maintenance Instructions __________________________________________ Pump Motor Bearings

Lubricate the pump motor (Fig. 33) 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. 33) 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. 33: Pump motor bearings

Pump motor lubrication fitting (2)

Motor located behind cover

________________________________________________________________ 50 CM445 Maintenance

Maintenance Instructions __________________________________________ Scrubber motor bearings

IMPORTANT

Lubricate the scrubber motor bearings (Fig. 34) with high temperature lithium complex grease (Spec. 100-14) as follows:

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

1. Remove the cover to access the motor.

2. Inspect the grease fittings on the exit side of the front and rear motor bearing.

3. If the exit side motor bearing ports are equipped with spring loaded relief fittings: a. Lubricate both motor bearings using the button type fittings until new grease appears out of the relief port on the exit side of the bearing. b. Operate the motor for five minutes. c.

Inspect for any grease leakage in the area around the bearing.

Fig. 34: Scrubber motor

Spring loaded grease relief fitting

Scrubber motor

________________________________________________________________ 51 CM445 Maintenance

__________________________________________ Maintenance Instructions Tail drive motor bearings

Lubricate the left and right tail drive motor bearings with high temperature lithium complex grease through the two grease fittings located on each motor (Fig. 35).

1. Remove the cover to access the motor.

2. Inspect the grease fittings on the exit side of the front and rear motor bearing.

3. If the exit side motor bearing ports are equipped with spring loaded relief fittings: a. Lubricate both motor bearings using the button type fittings until new grease appears out of the relief port on the exit side of the bearing. b. Operate the motor for five minutes. c.

Inspect for any grease leakage in the area around the bearing.

Fig. 35: Tail drive motor

Spring loaded grease

Tail drive motor (both sides)

______________________________________________________________ A6474X438 REV 0 52

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 hydraulic oil tank suction strainer 4. Inspect and clean/change all breathers Tram Gear Case

Change the oil in both tram gear cases (Fig. 36).

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. 36: Tram gear case Oil fill plug

Oil check

________________________________________________________________ 53 CM445 Maintenance

__________________________________________ Maintenance Instructions Hydraulic Oil, Suction Strainer, and Breather

Change the oil in the hydraulic oil tank (Fig. 37).

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. Remove and replace the suction strainer.

4. Clean and reinstall the drain plug.

5. Replace both breathers.

6. Add oil to the tank until the oil level is correct on the dipstick.

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

8. Recheck the oil level on the dipstick. Add more oil as needed.

Fig. 37: Hydraulic oil tank Hydraulic oil tank

Hydraulic oil tank

Dip stick location

______________________________________________________________ A6474X438 REV 0 54

Maintenance Instructions __________________________________________ Gear case breathers

Change the breathers on the main and input cutter gear cases, the CLA head pot and transfer gear cases (Fig. 38), and the tram gear cases. Reference drawings in the parts book for your machine for breather locations.

Fig. 38: Gear case breather locations

Main cutter gear case breather Input cutter gear case breather

Main gathering head gear case breather (located behind plate)

________________________________________________________________ 55 CM445 Maintenance

__________________________________________ 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. 39).

Fig. 39: Shim removal Socket head capscrews

Shim retainer

Lower pivot plate

Shims

7. Connect the trailing cable to energize the miner.

______________________________________________________________ A6474X438 REV 0 56

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. 40) 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. 40). 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. 40: 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

________________________________________________________________ 57 CM445 Maintenance

___________________________________________ 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.

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

______________________________________________________________ A6474X438 REV 0 58

Lubricant Specifications ___________________________________________ Spec. 100-1: Anti-wear hydraulic oil approved suppliers 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

________________________________________________________________ 59 CM445 Maintenance

___________________________________________ Lubricant Specifications 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) 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

______________________________________________________________ A6474X438 REV 0 60

Lubricant Specifications ___________________________________________ 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

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

________________________________________________________________ 61 CM445 Maintenance

___________________________________________ Lubricant Specifications 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)

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

1

Supplier Conoco Inc.

Brand name GLW Gear Oil 220

______________________________________________________________ A6474X438 REV 0 62

BI001572 A6474X439 August 2012

Operation and Maintenance Manual CM445 Continuous Miner A6474X439 (Hydraulic)

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

Table of contents Safety Instructions ............................................................................. 4 Introduction ........................................................................................ 6 Cylinder locations .............................................................................. 7 Component locations......................................................................... 8 Main control valve ............................................................................. 10 Hydraulic schematics ........................................................................ 11 Hydraulic pump ......................................................................... 11 Main flow/primary pressure ....................................................... 12 Pilot pressure ............................................................................ 13 Cutter head ............................................................................... 14 Conveyor raise/lower ................................................................ 17 Conveyor swing ......................................................................... 19 Gathering head ......................................................................... 21 Stabilizer shoe ........................................................................... 24 Booster pump/high speed cutter raise ...................................... 26 Conveyor chain take-up ............................................................ 27 Reduced MCV pilot pressure/radio function MCV .................... 28 Dust-scrubber sprays ................................................................ 29 Water schematics .............................................................................. 30 Water supply circuit ................................................................... 31 Water component location ........................................................ 33 Scrubber backflush circuit ......................................................... 34 Dust cooling water supply circuit ............................................... 35 Right hand chassis spray cooling circuit ................................... 36 Left hand chassis spray cooling circuit ..................................... 37 Left hand cutter head spray cooling circuit ............................... 38 Right hand cutter head spray cooling circuit ............................. 39 Scrubber assembly ................................................................... 40 Adjustment procedures ..................................................................... 41 Troubleshooting................................................................................. 47

________________________________________________________________ A6474X439

REV 0

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.

!

DANGER

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

!

DANGER

The area under and around the raised cutter head is dangerous. Securely block the head before performing maintenance on or below it. Failure to block the raised cutter head could result in serious injury or even death.

!

DANGER

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

!

DANGER

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

!

DANGER

Do not adjust the main relief over 3,000 psi (207 bar). Destruction of the valve bank and the main pump could result.

!

DANGER

Always be alert for any unintended machine movement.

!

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

!

WARNING

!

WARNING

!

WARNING Use extreme caution when performing test procedures and making adjustments. Unless noted in the procedures, all controls are to be in the neutral position.

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

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

!

WARNING Two people are required to adjust pressure settings. One person will make the adjustments while the second person must remain at the machine stop at all times during the adjustment procedure. Failure to do so may result in serious injury or death.

!

WARNING Always allow cylinder functions to bottom out (stop moving) before adjusting any pressure. Pressure adjustments will only be accurate when the cylinder is in this condition.

!

WARNING Keep body parts clear of machine while in raised position or serious injury could result.

________________________________________________________________ 4 CM445 Hydraulics

______________________________________________ Safety instructions !

WARNING Never disconnect a hydraulic hose if the circuit is pressurized or there is a load on the circuit. If a hose is disconnected while the cylinder is supporting a load, the load will fall.

IMPORTANT

Never rely on the load holding valve as a means of supporting the cutter or conveyor boom while making repairs. Severe injury or death could result.

IMPORTANT

Before making any further adjustments, verify that the hydraulic oil is at operating temperature.

IMPORTANT

The main relief is set higher than the port reliefs and will only relieve if a spike occurs in the system or if the port relief does not function properly. This provides protection of the main pump section.

IMPORTANT

Always use the proper tools when adjusting valve cartridges.

IMPORTANT

Do not start any motors - CLA, cutter head, pump, or traction motors - until all pressures are set. Start the pump motor as directed.

IMPORTANT

The two inch locking ball valve between the pump and main control valve must be locked open in normal operation.

IMPORTANT

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

______________________________________________________________ A6474X439 REV 0 5

Hydraulic _______________________________________________________ Introduction

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

Fig. 1 gives an overview of hydraulic cylinders located on the CM445 Continuous Miner. Fig. 2 shows the location of other hydraulic components.

Schematics

This section gives general descriptions of the hydraulic components used on the miner along with typical schematics for hydraulic functions. The schematics in this section are general; always refer to the hydraulic schematic in your parts manual supplied with your machine.

Hydraulic maintenance

In order for a hydraulic system to function correctly, it must be properly maintained. Maintenance of the hydraulic system includes: 1. maintaining atmospheric pressure in the tank by keeping the breather clean and free of obstructions; 2. maintaining a sufficient oil level in the tank; 3. maintaining tight, leak-proof pump suction lines to prohibit air being pumped through the system; and 4. changing filters and fluids at prescribed intervals.

For complete maintenance procedures, see the Maintenance Manual.

!

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

________________________________________________________________ 6 CM445 Hydraulics

_______________________________________________________ Hydraulic Fig. 1: Cylinder locations

1

1

2

7

2 1

3

4

4

3

3

4

5 5 6

1. Cutter head raise cylinder 2. Gathering head raise cylinder 3. Conveyor lift cylinder

6

6

4. Stabilizer shoe cylinder 5. Conveyor swing cylinder 6. Conveyor chain take-up cylinder

______________________________________________________________ A6474X439 REV 0 7

Hydraulic _______________________________________________________ Fig. 2: Hydraulic component location

1,2 3 4

19

5,6,7

20 19

8,9,10

18

11 12,13 14,15

16,17

1.

2.

3.

4.

5.

6.

7.

PC flow control valve Gathering head float valve Pilot operated control valve Hydraulic pump Relief valve Pilot pressure filter Return filter

8. Valve bank 9. Anti-chatter/maintenance valve 10. Check valve 11. Pressure gauges 12. Conveyor chain take-up valve 13. 2-way pressure ball valve 14. 3-way direction valve

15. Relief valve 16. Solenoid valve 17. 2-unit solenoid manifold 18. Oil level switch 19. Breather 20. Tank magnet

________________________________________________________________ 8 CM445 Hydraulics

_______________________________________________________ Hydraulic Main control valve

The Main Control Valve (MCV) (Fig. 3), typically located on the right side of the machine, consists of a series of directional control valves assembled in a row.

Typically, there are six (6) working sections. The MCV directs fluid flow to perform a specific function of work that transforms hydraulic energy into mechanical energy. Control may be initiated manually or electrically (through the solenoid pilot valve).

If the valve sections are separated for any reason, make sure that all reassembled parts are in their proper location and that all mating surfaces are free of burrs and foreign items (paint, dirt, etc.). Assembly stud nuts or screws should be tightened to specified torques.

IMPORTANT

!

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

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

______________________________________________________________ A6474X439 REV 0 9

Hydraulic _______________________________________________________ Fig. 3: Main control valve 8

9

10

11

12

13

2

5

3

6 1

7 4

1.

2.

3.

4.

9. Conveyor raise section 10. Conveyor swing section 11. Gathering head section 12. Stabilizer section 13. Booster pump/high speed cutter raise section ________________________________________________________________

10

Main relief cartridge Pilot port connection Main outlet section “A” port relief (typical)

5.

6.

7.

8.

“B” port relief (typical) “B” pressure solenoid (6 places) “A” pressure solenoid (6 places) Cutter raise section

CM445 Hydraulics

_______________________________________________________ Hydraulic Hydraulic pump assembly

Hydraulic power for all of the hydraulically actuated functions originates with the pump assembly (Fig. 4). Always be sure the shut-off valve (if equipped) is turned to open and the locking device is replaced before starting the machine.

Hydraulic pump on circuit

This pump utilizes three working sections: one main flow, one auxiliary and one pilot flow. Oil is supplied from the oil reservoir through a suction line to the pump inlet ports. A quick disconnect allows oil sampling before the flow enters the pump. The main and auxiliary flow lines move through bypass filters set at 50 psi each before entering the main control valve, which is monitored by a pressure gauge. After leaving the pump, the pilot flow continues on to the conveyor take-up circuit, which is monitored by a pressure gauge, and flows through a relief valve set a 500 psi before returning to the tank. The pilot flow also flows through a non-bypassing filter before entering the gathering head circuit, the scrubber spray solenoid manifold and the main control valve.

IMPORTANT

The two inch locking ball valve must be locked open in normal operation.

Fig. 4: Hydraulic pump circuit

Pressure Return Suction

______________________________________________________________ A6474X439 REV 0 11

Hydraulic _______________________________________________________ Main and auxiliary flow Primary and auxiliary pressure circuits

The main flow-primary pressure circuit is powered by the hydraulic pump.

From the pump, oil enters a 10 micron by-passing pressure filter and continues to the main control valve, whose relief is set at 3,000 psi (204 bar). The main control valve operates all cylinder functions.

The auxiliary pressure circuit is powered by the hydraulic pump. Oil from both the primary and auxiliary circuits exits the main control valve and passes to the oil reservoir. The auxiliary pressure circuit is powered by hydraulic pump gear section A2. The A2 gear section is rated at 90 Lpm at a pressure of 138 bar (23.7 gpm at 2,000 psi). This open center circuit supplies oil to the mid-inlet section of the main control valve. The mid-inlet section feeds the booster pump/high speed cutter head raise control valve. From the pump, oil enters a 10 micron by-passing pressure filter and continues to the mid-inlet section of the main control valve, whose relief is set at 2,300 psi (156 bar.

Oil from both the primary and auxiliary circuits exits the main control valve and passes through a tank return manifold to a 10 micron by-passing return filter before entering the oil reservoir. Once in the reservoir, the oil is forced to flow through and around baffle plates for cooling and de-aerating before re-entering the suction line. Also, there are floor magnets located in the reservoir to trap ferrous metal particles.

Fig. 5: Main and auxiliary flow (pump running)

Pressure Return Suction

________________________________________________________________ 12 CM445 Hydraulics

_______________________________________________________ Hydraulic Pilot pressure circuit

The pilot hydraulic section is a closed-center system powered by the hydraulic pump. It supplies oil flow to the following: 1. hydraulic tension conveyor chain take-up 2. gathering head float circuit, and 3. solenoid valves, which control the scrubber sprays, and all main control valve functions.

From the pump, oil flows through a 10 micron bypass filter, a relief valve set at 500 psi (34 bar) and a 3 micron non-bypassing filter before being distributed to the conveyor take-up, gathering head, and main control valve. Pilot pressure oil also flows on to the solenoid valves and the gathering head float circuit.

Fig. 6: Pilot pressure circuit (pump running)

Pressure Return Suction

______________________________________________________________ A6474X439 REV 0 13

Hydraulic _______________________________________________________ !

DANGER

The area under and around the raised cutter head is dangerous. Securely block the head before performing maintenance on or below it. Failure to block the raised cutter head could result in serious injury or even death.

Cutter head cylinder

Oil is supplied from the hydraulic pump through a 10-micron bypassing pressure filter to the cutter head working section of the main control valve. By manual or remote solenoid control, the valve spool allows oil to enter the cutter head cylinder circuit.

Circuit operation - raise

Reference Fig. 7: To manually raise the cutter head (extend cylinders), pull the valve’s handle. Remote operation is achieved by energizing the cutter head raise solenoid (CHU). Oil goes to port “P2” and continues to the extend port of the cylinders, free flowing through the check valve of the load holding cartridge to extend the cylinders. The cutter head raise circuit is protected by a port relief that is set at 3,000 psi (207 bar).

Circuit operation - lower

Reference Fig. 8: To manually lower the cutter head (retract cylinders), push the valve’s handle. Remote operation is achieved by energizing the cutter head lower (CHD) solenoid. Oil goes to the retract port of the cylinders and also pilots open the load holding cartridge, allowing oil to exit through the extend ports on the cylinders. The extend port oil continues to the anti-chatter/maintenance valve block, where it passes through a counterbalance valve, which is set to relieve at 1,200 psi (83 bar), then through the main control valve and into the oil tank. The cutter head lower circuit is protected by a port relief that is set at 2,800 psi (193 bar).

!

DANGER

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

!

DANGER

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

!

WARNING

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

________________________________________________________________ 14 CM445 Hydraulics

_______________________________________________________ Hydraulic Fig. 7: Cutter head raise circuit

Pressure Return Suction

______________________________________________________________ A6474X439 REV 0 15

Hydraulic _______________________________________________________ Fig. 8: Cutter head lower circuit

Pressure Return Suction

________________________________________________________________ 16 CM445 Hydraulics

_______________________________________________________ Hydraulic conveyor raise/lower circuit

Oil is supplied by the hydraulic pump through a 10-micron bypassing pressure filter to the conveyor raise/lower working section of the main valve control. By manual or remote solenoid control, the valve spool allows oil to enter the conveyor raise/lower cylinder circuit

Circuit operation - raise (extend)

Reference Fig. 9: To manually raise the conveyor (extend the cylinders), pull the valve’s handle. Remote operation is achieved by energizing the conveyor raise (CU) solenoid. Oil free flows through pilot operated check valves to the extend port of the cylinders. The conveyor raise circuit is protected by a port relief that is set at 1,800 psi (124 bar).

Circuit operation - lower (retract)

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

Oil tank fill

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

Fig. 9: Conveyor raise

Pressure Return Suction

______________________________________________________________ A6474X439 REV 0 17

Hydraulic _______________________________________________________ Fig. 10: Conveyor lower

Pressure Return Suction

________________________________________________________________ 18 CM445 Hydraulics

_______________________________________________________ Hydraulic Conveyor swing cylinder circuit

Oil is supplied by hydraulic pump to the conveyor swing working section on the main control valve. By manual or remote solenoid control, the spool allows oil to enter the swing circuit. The range on the cylinder will allow the conveyor tail to move 45 degrees off the centerline of machine in both directions.

Circuit operation right (extend)

Reference Fig. 11: To manually move the conveyor to the right (extend the cylinder), pull the valve’s handle. Remote operation is achieved by energizing the conveyor swing left (CSL) solenoid. Oil free flows to the extend port of the cylinder. The conveyor swing right circuit is protected by a port relief that is set at 1,800 psi (25 bar).

Circuit operation left (retract)

Reference Fig. 12: To manually move the conveyor to the left (retract the cylinder, push the valve’s handle. Remote operation is achieved by energizing the conveyor swing right (CSR) solenoid. Oil free flows to the retract port of the cylinder. The conveyor swing left circuit is protected by a port relief that is set at 1,800 psi (125 bar).

Fig. 11: Conveyor swing cylinder circuit - left

Pressure Return Suction

______________________________________________________________ A6474X439 REV 0 19

Hydraulic _______________________________________________________ Fig. 12: Conveyor swing cylinder circuit - right

Pressure Return Suction

________________________________________________________________ 20 CM445 Hydraulics

_______________________________________________________ Hydraulic Gathering head raise/ hold/float/lower circuit

Circuit operation Raise (extend)

Circuit operation Lower (retract)

Oil is supplied by the hydraulic pump to the gathering head working section of the main control valve. By manual or remote solenoid control, the valve spool allows oil to enter the gathering head raise circuit.

Reference Fig. 13: To manually raise the gathering head pan (extend the cylinder), pull the valve’s handle. Remote operation is achieved by energizing the gathering head up solenoid (GHU). Oil free flows through the check valve in counterbalance valve designated “VR” in the gathering head float valve block and is directed to both cylinder extend ports. At any time while raising the gathering head, the operator can stop the gathering head pan by centering the handle on the valve (or de-energizing the solenoid) and the pan will hold in position. The gathering head raise circuit is protected by a port relief that is set at 1,700 psi (117 bar).

Reference Fig. 14: To put the gathering head pan in the lower mode, push the valve’s handle. Remote operation is achieved by energizing the gathering head down (GHD) solenoid. This vents the port labeled “V” on the gathering head float valve block to tank and allows control of the gathering head lower via the valves in the block. The counterbalance valve “VR” is set to relieve at 1,200 psi to allow the gathering head to drift down at a controlled rate of speed. This valve is adjustable and the rate of retract speed for the cylinders can be increased by decreasing the pressure setting of the valve.

Conversely, the retract speed for the cylinders can be decreased by increasing the pressure setting of the valve. When in the float condition, the cylinders carry some of the gathering head pan weight to prevent the gathering head leading edge from digging into the soft bottom of the mine and moves the machine’s center of gravity forward when mining. The gathering head lower circuit is protected by a port relief that is set at 1,700 psi (117 bar).

The counterbalance valve that is designated “CR” is set to relieve at 1,800 psi (124 bar). This setting will relieve pressure directly to the tank in the event of a forced movement of the gathering head.

The pilot pressure supply for the gathering head float comes from the hydraulic pump through a 3 micron non by-pass filter to the gathering head float valve.

The pilot pump provides make up oil for the gathering head cylinders. When the pan goes over uneven terrain, it may raise quickly and extend the gathering head cylinders at a rapid rate. This temporary condition can create high demand for pilot oil supply. In extreme cases, the pilot pressure may decrease to the point where the main control valve may not have sufficient pilot pressure to shift when the solenoids are engaged. It is, therefore, possible to experience a momentary loss of radio control of the machine.

To minimize the chance of the occurrence, a restrictor orifice is installed in the pilot supply for the valve block. This orifice is protected from contamination by an upstream filter. A downstream check valve keeps system pressure from entering the pilot pressure lines. An adjustable needle valve allows for the bleeding off of pressure for maintenance. This needle valve is to remain closed except for performing maintenance. A gauge is incorporated into the valve block for maintenance and troubleshooting.

______________________________________________________________ A6474X439 REV 0 21

Hydraulic _______________________________________________________ Fig. 13: Gathering head raise circuit

Pressure Return Suction

________________________________________________________________ 22 CM445 Hydraulics

_______________________________________________________ Hydraulic Fig. 14: Gathering head lower circuit

Pressure Return Suction

______________________________________________________________ A6474X439 REV 0 23

Hydraulic _______________________________________________________ Stabilizer shoe cylinders

Oil is supplied by the hydraulic pump to the stabilizer shoe working section of the main control valve. By manual or remote solenoid control, the valve spool allows oil to enter the stabilizer shoe circuit.

Circuit operation - raise (retract)

Reference Fig. 15: To manually raise the stabilizer shoe (retract the cylinder), pull the valve’s handle. Oil also pilots open the load holding cartridge, allowing oil to exit the extend port of the cylinders. The stabilizer raise circuit is protected by a port relief that is set at 1,400 psi (100 bar).

Circuit operation - lower (extend)

Reference Fig. 16: To manually lower the stabilizer shoe (extend the cylinders), push the valve’s handle. The stabilizer lower circuit is protected by a port relief that is set at 2,500 psi (160 bar).

The stab shoe soft touch block is identical in design to the cutter head antichatter/maintenance valve but its functional operation is slightly different. The stab shoe soft touch valve block has two primary functions: 1. It provides back pressure against the stabilizer cylinder pistons when lowering the stabilizer. This prevents the machine from raising off the ground when the stab shoe down function is selected for an extended period of time (either manually or via remote solenoid control).

2. It allows for bypassing of the counterbalance valve to eliminate the back pressure against the stabilizer cylinder pistons. This provides the maximum pressure differential between the two sides of the stabilizer cylinders.

The stab shoe soft touch valve block is supplied on machines that may be equipped with an optional “auto stab down” feature that energizes the stabilizer lower solenoid (SSD) for a pre-determined time period under certain machine conditions.

Fig. 15: Stabilizer shoe circuit - raise (retract)

Pressure Return Suction

________________________________________________________________ 24 CM445 Hydraulics

_______________________________________________________ Hydraulic Fig. 16: Stabilizer shoe circuit - lower (extend)

Pressure Return Suction

______________________________________________________________ A6474X439 REV 0 25

Hydraulic _______________________________________________________ Booster pump/high speed cutter head raise

Oil is supplied by the hydraulic pump to a 10 micron bypassing filter set at 50 psi before continuing on to the booster pump/high speed cutter head raise working section of the main control valve. By manual or remote solenoid control, the valve spool allows oil to enter the booster pump/high speed cutter head raise circuit.

Circuit operation - start

Reference Fig. 17: To manually start the booster pump, push the valve’s handle. Oil is directed to the booster pump hydraulic motor creating increased water pressure for the dust spray/scrubber and scrubber back flush circuits. The booster pump/high speed cutter head raise circuit is protected by a port relief that is set at 2,300 psi (160 bar).

Fig. 17: Booster pump/high speed cutter head raise circuit - start

Pressure Return Suction

________________________________________________________________ 26 CM445 Hydraulics

_______________________________________________________ Hydraulic Conveyor chain take-up circuit (optional)

Reference Fig. 18: The pilot-auxiliary hydraulic pressure circuit is powered by the hydraulic pump. From the pump, oil provides hydraulic power to the hydraulic tension conveyor chain take-up and to the three pilot pressure circuits.

The oil continues to the conveyor chain take-up valve where it passes thru a free flow check valve cartridge out to (2) two conveyor chain take-up cylinder assemblies. The conveyor chain take-up valve consist of a check valve to hold pressure in the circuit, a pressure reducing/relieving cartridge to reduce the pilot pressure to 200 psi for conveyor chain tension and relieves pressure build up above 200 psi. A needle valve cartridge relieves pressure from the circuit for maintenance.

!

DANGER

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

Fig. 18: Conveyor chain take-up circuit

Pressure Return Suction

______________________________________________________________ A6474X439 REV 0 27

Hydraulic _______________________________________________________ Reduced MCV pilot pressure circuit - radio function main control valve

Reference Fig. 19: The pilot pressure circuit is powered by the hydraulic pump.

From the pump, the pilot pressure oil passes through a 3 micron NONbypassing filter. The pilot pressure is controlled by a pressure relief valve that is normally set to 500 psi (34 bar). When the non by-passing 3 micron filter element starts clogging with trapped particles, the radio system/solenoid functions will slow down, indicating that it is time to change the filter element. For filter element maintenance and changing schedules, see the Maintenance manual.

Oil continues to the pilot port of the main control valve. The reduced pressure is required to prevent damage to the main control valve. This supplies oil pressure, which allows the small solenoid pilot valve to shift the spools in the working sections of the main control valve.

Fig. 19: Reduced MCV pilot pressure circuit - radio function main control valve circuit

Pressure Return Suction

________________________________________________________________ 28 CM445 Hydraulics

_______________________________________________________ Hydraulic Dust-scrubber sprays hydraulic circuit

Reference Fig. 20: The pilot-auxiliary hydraulic pressure circuit is powered by the hydraulic pump. From the pump, oil passes through a 3 micron nonbypassing filter and is controlled by a pressure relief valve that is normally set to 500 psi (34 bar). The oil continues to a solenoid manifold which has a normally closed cartridges. One cartridge is for the dust spray/scrubber system and the other is for the scrubber backflush function.

When the D/S coil is energized, it shifts the spool allowing oil to travel to pilot operated normally closed water valve, shifting its spool to allow water to pass through it to the dust spray/scrubber water circuit. When the BF coil is energized, it shifts the spool, allowing oil to travel to pilot operated normally closed water valve, shifting its spool to allow water pressure to pass through it to the backflush scrubber circuit.

In both cases, when the solenoid cell is de-energized, the spool in the hydraulic pilot valve shifts back to its neutral position, venting the hydraulic pilot pressure on the water control valve. This venting allows the water control valves to return to their normally closed positions.

Fig. 20: Dust-scrubber sprays hydraulic circuit Pump running

Pump running, pilot operated water valve on

Pressure Return Suction

______________________________________________________________ A6474X439 REV 0 29

Water___________________________________________________________ Introduction

A water supply to the continuous miner is required for the following purposes: 1. cooling water for all motors, transformers, etc.

2. spray water for dust suppression and air cleaning via the scrubber system The water supplied by the mine must meet the following requirements: 1. minimum flow rate of 25 gpm for cooling 2. total flow rate: based on customer dust plan 3. minimum pressure of 250 psi (dynamic), 500 psi maximum

Schematics

The water system circuits described below are for a typical CM445 miner. The circuit for your machine may vary depending on your dust plan and unique requirements. Always refer to the schematic in the parts book for your machine.

________________________________________________________________ 30 CM445 Hydraulics

__________________________________________________________ Water Water supply circuit

Mine water is supplied to the miner from a connection located on the right side of the miner (typical). The water supply to the miner is controlled through a 2 position, manually-operated ball valve. Immediately after are connections for two optional wash down hoses, one on the left hand side of the miner and one on the right side. The mine water then passes through a strainer that is equipped with an automatic back-flush feature.

From the strainer, the water is directed to the inlet of a booster pump. The booster pump is driven by a hydraulic motor that is controlled by the booster pump/high speed cutter head raise working section of the main control valve (see the hydraulics section of this manual for further details). There is a valve piped in parallel with the booster pump which allows mine water to continue to the remainder of the miner when the booster pump is not running. When the booster pump is running the check valve is closed because the water pressure on the outlet side of the pump is greater than the pressure on the suction side.

The high pressure side of the booster pump is equipped with a relief valve that is set at 125 psi (8.6 bar).

From the booster pump, the water is directed to the water distribution manifold where it supplies the dust spray/cooling and scrubber back flush control valves.

The supply to the water distribution manifold from the booster pump is monitored with a flow switch and a pressure switch to provide protection to the booster pump and other critical components on the machine. Please refer to the electrical control section of this manual for further information.

Gauges measure the pressure of the mine water, booster pump inlet water and booster pump outby water.

______________________________________________________________ A6474X439 REV 0 31

Water___________________________________________________________ Fig. 21: Water supply circuit

________________________________________________________________ 32 CM445 Hydraulics

__________________________________________________________ Water Fig. 22: Dust-cooling component locations 1

1

1

2 2 3

3

4 4

5,6

7,8,9

10 17,18,19

1.

2.

3.

4.

5.

6.

7.

8.

9.

11

12,13

12,13

16

14

15

12

10. 0-600 psi pressure gauge (3) 11. Reverse flushing strainer 12. Ball valve 13. Washdown hose connection 14. Atmospheric relief 15. Scrubber box 16. Water transducer enclosure 17. 2-unit pressure manifold 18. NC 2-way pilot operated valve 19. 4-unit pressure manifold ______________________________________________________________ A6474X439

Cutter head front spray manifold Cutter head side spray manifold Cutter motor spray manifold Gathering head spray manifold RH chassis front spray manifold RH chassis side spray manifold Water booster pump assembly Check valve Relief valve REV 0

33

Water___________________________________________________________ Scrubber back flush circuit

The scrubber back flush circuit (Fig 23) utilizes water supplied from the water distribution manifold and is operated by remote solenoid control (see Electrical section in this chapter). When the scrubber back flush solenoid coil (B/F) is energized, it shifts a spool, allowing hydraulic oil to flow to the hydraulic pilot operated, normally closed water valve. The hydraulic oil shifts the spool, allowing water to pass though it to the scrubber back flush nozzle. For the hydraulic portion of this circuit, see the Hydraulic section of this chapter.

Fig. 23: Scrubber back flush circuit

________________________________________________________________ 34 CM445 Hydraulics

__________________________________________________________ Water Dust-cooling water supply circuit

The dust-cooling water circuit (Fig. 24) utilizes water supplied from the water distribution manifold and is operated by remote solenoid control (see Electrical section in this chapter). When the dust-cooling solenoid (D/S) is energized, it shifts a spool, allowing hydraulic oil to travel to the hydraulic pilot operated normally closed water valve. The hydraulic oil shifts the spool, allowing water to pass through it to the secondary dust-cooling pressure manifold. The secondary dust-cooling pressure manifold distributes water to the five unique dustcooling circuits: 1.

2.

3.

4.

5.

Right Hand Chassis Spray Cooling Circuit Left Hand Chassis Spray Cooling Circuit Left Hand Cutter Head Spray Cooling Circuit Right Hand Cutter Head Spray Cooling Circuit Scrubber Assembly Spray Cooling Circuit

For the hydraulic portion of this circuit, see the Hydraulic section of this manual.

The dust-cooling water circuit is protected by a relief valve that is set at 350 psi (24 bar).

Fig. 24: Dust-cooling water supply circuit

______________________________________________________________ A6474X439 REV 0 35

Water___________________________________________________________ Right hand chassis spray cooling circuit

From the secondary dust-cooling pressure manifold, water is supplied to the right hand chassis spray cooling circuit (Fig. 25) where it supplies spray/cooling water to the following components: control case, RH tram motor, pump motor, right hand chassis sprays, RH and LH CLA motors, RH and LH gathering head sprays and the throat sprays.

Fig. 25: Right hand chassis spray cooling circuit

________________________________________________________________ 36 CM445 Hydraulics

__________________________________________________________ Water Left hand chassis spray cooling circuit

From the secondary dust-cooling pressure manifold, water is supplied to the left hand chassis spray cooling circuit (Fig. 26) where it supplies spray/cooling water to the following components: LH tram motor, transformer, LH cutter head motor spray manifold, center cutter head spray bar manifold.

Fig. 26: Left hand chassis spray cooling circuit

______________________________________________________________ A6474X439 REV 0 37

Water___________________________________________________________ Left hand cutter head spray cooling circuit

From the secondary dust-cooling pressure manifold, water is supplied to the left hand cutter head spray cooling circuit (Fig. 27) where it supplies spray/cooling water to the following components: LH cutter head motor, LH cutter head side spray manifold and LH cutter head spray bar manifold.

Fig. 27: Left hand cutter head spray cooling circuit

________________________________________________________________ 38 CM445 Hydraulics

__________________________________________________________ Water Right hand cutter head spray cooling circuit

From the secondary dust-cooling pressure manifold, water is supplied to the right hand cutter head spray cooling circuit (Fig. 28) where it supplies spray/ cooling water to the following components: RH cutter head motor, RH cutter head side spray manifold and RH cutter head spray bar manifold.

Fig. 28: Right hand cutter head spray cooling circuit

______________________________________________________________ A6474X439 REV 0 39

Water___________________________________________________________ Scrubber assembly spray cooling circuit

From the secondary dust-cooling pressure manifold, water is supplied to the scrubber assembly spray cooling circuit (Fig. 29) where it supplies spray/cooling water to the following components: scrubber motor, screen spray nozzle and fan inlet suppression/spray outlet nozzles. There is a pressure reducing valve located between the scrubber motor and the nozzles to allow the nozzle flow to be optimized.

Fig. 29: Scrubber assembly spray cooling circuit

________________________________________________________________ 40 CM445 Hydraulics

___________________________________________ Adjustment procedures Introduction

1. Always refer to the hydraulic schematic in the parts book supplied with your miner.

2. Most relief valves are set to factory specifications and should require no further adjustment.

3. Generally speaking, when adjusting relief valves, turning the adjusting screw in (clockwise) will increase the pressure setting.

4. If the valve pressure setting is unknown, always adjust the valve fully counterclockwise prior to initiating any action that will create flow and prove the potential for pressure.

!

WARNING Use extreme caution when performing test procedures and making adjustments.

Unless noted in the procedures, all controls are to be in the neutral position.

Gauges

The miner is equipped with seven (7) hydraulic pressure gauges to aid in setting relief pressures. The gauges measure the following pressures: 1. mine water pressure 2. main pressure (all functions of the MCV) 3. pilot pressure 4. gathering head float/relief pressure 5. anti-chatter/maintenance (shear down) pressure 6. conveyor chain take-up pressure 7. stabilizer shoe down pressure

Setting relief valves

Setting relief valve pressure is necessary when a relief valve is replaced with a new unit or when an existing relief valve needs to be adjusted. To properly adjust a relief valve, the circuit must be “dead-headed”.

Setting hydraulic pressures

The adjustment procedure should start with the pilot pressure circuit. This system will build pressure as soon as the pump is started. The main relief valve on the main control valve (MCV) and high speed cutter head raise control valve, as well as the pilot pressure relief and brake cooling circuit pressure reducing valve, should all be adjusted to their lowest setting prior to initial start up and adjustment. Reference circuit descriptions, abbreviations, and terms in the Hydraulic Components section of this chapter.

______________________________________________________________ A6474X439 REV 0 41

Adjustment procedures ___________________________________________ IMPORTANT

Do not start any motors - CLA, cutter head, pump, or traction motors - until all pressures are set. Start the pump motor as directed.

Load holding valve adjustment IMPORTANT

The load holding valve is factory preset and should not be field adjusted.

Never rely on the load holding valve as a means of supporting the cutter or conveyor boom while making repairs. Severe injury or death could result.

Adjustment procedure should start with the pilot/auxiliary pressure circuit, which will build pressure as soon as the pump is started.

Pilot/auxiliary pump circuit relief valve adjustments !

The following procedure is for start up of new and rebuilt machines:

WARNING Two people are required to adjust pressure settings. One person will make the adjustments while the second person must remain at the machine stop at all times during the adjustment procedure. Failure to do so may result in serious injury or death.

1. Pilot pressure circuit: Loosen the nut on the relief valve cartridge and turn the screw out (counter-clockwise) using an Allen wrench to prevent over pressuring the gauge on this circuit. Remove the hose and cap or plug the outlet port of the relief valve. Take care to prevent dirt from entering the system.

2. Conveyor chain take-up circuit: Open the needle valve by turning the knob counter-clockwise, opening flow to tank.

3. Start the pump motor (see startup procedure in this manual) and adjust the pilot pressure relief valve. a. Turn the cartridge in until the pressure reading is 500 psi (34 bar). b. While holding the cartridge in place, tighten the nut to lock the spool in place. Double check the pressure reading to ensure that the cartridge was not turned while tightening the nut.

Before making any further adjustments, verify that the hydraulic oil is at operating

IMPORTANT temperature.

4. Adjust the conveyor chain take-up pressure reducing valve (optional). a. Close the needle valve by turning the knob clockwise, opening flow to the take-up cylinders. The pressure reading should be 200 psi (14 bar). b. If adjustment is required, remove the hex socket head plug to adjust the inner spool. Using an Allen wrench, turn the screw in (clockwise) to increase pressure or out (counter-clockwise) to decrease pressure. c.

Replace the hex socket head plug.

5. Re-adjust the pilot pressure 2 relief valve, if necessary, to 500 psi (34 bar).

________________________________________________________________ 42 CM445 Hydraulics

Adjustment procedures ___________________________________________ Pilot relief valve replacement

Set the pilot relief to 500 psi (34 bar), per step 3 of the Pilot/auxiliary pump circuit relief valve adjustments procedure, making sure that the conveyor chain take-up knob is closed (turn clockwise to close).

Conveyor chain take-up valve replacement:

Set the pilot relief to 200 psi (14 bar), per step 4 of the Pilot/auxiliary pump circuit relief valve adjustments procedure, making sure the conveyor chain takeup needle valve is closed (turn clockwise to close).

Main control valve working port relief adjustment

Each valve bank section, with the exception of the gathering head, has two (2) working port reliefs (Fig 30). When the handle is pulled (spool in), oil is directed to the work port and relief closest to the handle; this is “A” port. When the handle is pushed in (spool out), oil is directed to the work port and relief farthest from the handle; this is ‘B” port.

Fig. 30: Main control valve Port reliefs

!

“A” port relief

“B” port relief

WARNING Always allow cylinder functions to bottom out (stop moving) before adjusting any pressure. Pressure adjustments will only be accurate when the cylinder is in this condition.

IMPORTANT The main relief is set higher than the port reliefs and will only relieve if a spike occurs in

the system or if the port relief does not function properly. This provides protection of the main pump section.

!

DANGER

Do not adjust the main relief over 3,000 psi (207 bar). Destruction of the valve bank and the main pump could result.

!

DANGER

Always be alert for any unintended machine movement.

IMPORTANT Reference the Hydraulic section in this chapter for individual circuit information. Al-

ways refer to the hydraulic schematic in your parts manual for your miner.

Always allow cylinder Two people functions are required to bottom to adjust out (stop pressure moving) settings. before adjusting One person anywill pressure. make the Pressure adjustWARNING ! ! WARNING ments adjustments while the will second only be person accurate must when remain the at cylinder the machine is in this stop condition. at all times during the adjustment procedure. Failure to do so may result in serious injury or death.

________________________________________________________________ 43 CM445 Hydraulics

___________________________________________ Adjustment procedures Main control valve adjustment

To properly adjust any relief valve, the hydraulic system must be “dead headed”. Dead heading is achieved by actuating a cylinder function and allowing it to travel to its full stroke position (either extended or retracted). To set the main system relief, it is recommended that the stabilizer shoe cylinder be extended until it is dead headed. Since the stabilizer section of the main control valve is equipped with a port relief in the extend circuit, the port relief must be temporarily adjusted to a pressure setting higher than the main relief. This procedure is described in detail below.

1. During the adjustment procedure, pump output pressure and flow will be relieved past either the main relief or the stabilizer extend port relief which will cause rapid heating of the hydraulic oil. Preparation should be made to perform the adjustment procedure efficiently and in a relatively short period off time. It may be necessary to wait several minutes between adjustment periods.

2. It is critical that the stabilizer extend port relief valve be adjusted back to its proper setting after the main relief is adjusted.

Main relief adjustment

1. Remove the protective cap on the rear port relief of the stabilizer working section and loosen the nut on the adjusting screw. Turn the adjusting screw in all the way.

2. Loosen the nut on the main relief cartridge. Turn the main relief adjusting screw two turns clockwise.

3. Start the pump (see Startup procedure in this chapter) and activate the stabilizer shoe down function. This will raise the back portion of the machine off the ground.

4. With the stabilizer shoe down function bottomed out, turn the main relief cartridge adjusting screw in (clockwise) until a pressure of 3,000 psi (207 bar) is obtained.

!

WARNING Keep body parts clear of machine while in raised position or serious injury could result.

5

With the stabilizer shoe function in the neutral position, hold the main relief cartridge screw in place and tighten the nut to lock the screw in place.

Check the pressure setting to verify that the screw was not moved while tightening the nut.

6. Adjust the stabilizer shoe down port relief (see Port relief adjustment procedure in this chapter).

7. Replace the protective cap.

______________________________________________________________ A6474X439 REV 0 44

Adjustment procedures ___________________________________________ Port relief valve adjustment

If the correct pressure reading is not obtained as noted in Items 1 through 5 below, the port relief (Fig 31) for that function must be adjusted. The port reliefs shown are typical for each section of the valve. The adjustment procedure for each port relief is the same and is: 1. Remove the protective cap on the port relief and loosen the nut on the adjusting screw.

2. Turn the port relief screw in (clockwise) to increase pressure and out (counter-clockwise) to decrease pressure.

3. Once the correct pressure reading is obtained, return the function to the neutral position, hold the screw in place, and tighten the lock nut. Check the pressure reading to ensure that the screw did not turn while the lock nut was being tightened.

Fig. 31: Main control valve - port reliefs “A” port relief

“B” port relief

Cutter raise Conveyor raise Conveyor swing Gathering head Stabilizer Booster pump/HS raise

________________________________________________________________ 45 CM445 Hydraulics

___________________________________________ Adjustment procedures Pressure readings 1. Cutter head

1. Activate the cutter head raise circuit to fully raise the cutter head. The main control pressure gauge should read 2,800 psi (193 bar).

2. Activate the cutter head lower circuit to fully lower the cutter head and raise the front of the machine off the ground. The main control pressure gauge should read 2,800 psi (193 bar).

2. Conveyor raise/lower

1. Activate the conveyor raise circuit to fully raise the conveyor. The main control valve pressure gauge should read 1,800 psi (124 bar).

2. Activate the conveyor lower circuit to fully lower the conveyor. The main control valve pressure gauge should read 1,400 psi (96 bar).

Note: Be sure that the ball valve is closed on the tank oil fill part of this circuit.

3. Conveyor swing

1. Activate the conveyor swing left circuit to fully swing the conveyor to the left.

The main control valve pressure gauge should read 1,800 psi (124 bar).

2. Activate the conveyor swing right circuit to fully swing the conveyor to the right. The main control valve pressure gauge should read 1,800 psi (124 bar).

4. Gathering head

1. Activate the gathering head raise circuit to fully raise the gathering head.

The main control valve pressure gauge should read 1,700 psi (117 bar).

2. If 1,700 psi (117 bar) is not obtainable, check that the relief in the gathering head float valve that is stamped “CR” is set to 1,800 psi (124 bar) (see Gathering head raise/hold/float-lower circuit in the Hydraulic section of this chapter).

5. Stabilizer shoe

1. Activate the stabilizer shoe raise circuit to fully raise the stabilizer shoe.

The main control valve pressure gauge should read 1,400 psi (97 bar).

2. Activate the stabilizer shoe lower circuit allow to fully lower the stabilizer shoe. The main control valve pressure gauge should read 2,500 psi (172 bar).

5. Booster pump/ High speed cutter raise

1. Activate the booster pump circuit to increase water pressure to the dust spray/scrubber and scrubber back flush circuits. The main control valve pressure gauge should read 2,300 psi (160 bar).

______________________________________________________________ A6474X439 REV 0 46

Troubleshooting _________________________________________________ Introduction

!

The following section lists possible problems encountered when servicing the Continuous Miner and can aid in locating and correcting these problems. This section covers basic components, with each listed in a trouble-cause-remedy format.

WARNING Some procedures must be carried out with the cover of the electrical controller removed and some procedures require the controller to be energized during the tests. It is extremely important that you take all necessary precautions to prevent accidental electrical shock while working within the controller. An certified electrician must supervise and inspect all work performed.

Hydraulic troubleshooting procedures

For maintenance procedures and tests that DO NOT require the controller to be energized, precautions include: 1. Before removing the controller covers, remove power from the system by disconnecting the trailing cable.

2. Use insulated gloves and tools where possible.

3. All connections must be tight and care must be taken to prevent bolts, nuts, washers and other small metal fasteners from being dropped or lost inside the controller. These lost fasteners could cause electrical shorts inside the controller.

For procedures that DO require that the controller be energized while the cover is off: 1. At no time should you reach inside the controller while it is energized. If it becomes necessary to make adjustments or to replace parts inside the controller, the “POWER OFF” button must be pushed.

2. Use insulated gloves and tools where possible.

3. All connections must be tight and care must be taken to prevent bolts, nuts, washers and other small metal fasteners from being dropped or lost inside the controller. These lost fasteners could cause electrical shorts inside the controller.

________________________________________________________________ 47 CM445 Hydraulics

_________________________________________________ Troubleshooting Typical hydraulic problems

The most common causes for improper function are: 1. contaminated oil or poor oil quality; 2. low or insufficient oil in the system; 3. using the wrong type of oil or wrong viscosity grade; 4. air in the hydraulic system; 5. internal or external leakage of the hydraulic system; 6. improper mechanical adjustments, such as reliefs; 7. mechanical or structural damage leading to component failure; and 8. components by-passing (internal leaking or inability to hold pressure) which leads to erosion of bushings, valve spools, and other costly, critical components.

The construction and operating characteristics of each of these components should be clearly understood before attempting to troubleshoot the machine.

Please familiarize yourself with the operational descriptions of the hydraulic circuits given in the Hydraulics section of this chapter.

Each component in the system has a maximum rated speed, flow, torque, or pressure. The correct operating pressures of a system must be known and must always be checked and set with a pressure gauge.

______________________________________________________________ A6474X439 REV 0 48

Troubleshooting _________________________________________________ The ability to recognize trouble indicators in a specific system is usually acquired with experience. the gaining of this experience can be greatly enhanced by developing a logical sequence for determining the cause of a hydraulic problem and implementing the proper remedy. Refer to the general troubleshooting charts in this section that illustrate the logical sequence for shutdown, troubleshooting, and restarting the machine. The charts cover: 1.

general safety procedure for shutting down the machine;

2.

troubleshooting excessive noise;

3.

troubleshooting excessive heat;

4.

troubleshooting incorrect flow;

5.

troubleshooting incorrect pressure;

6.

troubleshooting faulty movement/operation; and

7.

general restart checklist and procedure

This general information is intended to enhance the understanding of basic hydraulic principles which will lead to the development of a logical troubleshooting procedure. Specific troubleshooting checklists for each hydraulic circuit are given directly after the very important “Contaminants in hydraulic systems” section.

Contamination

Cleanliness must be a high priority when servicing the hydraulic system. Ensure that bulk oils are at acceptable cleanliness levels.

Areas where customers have made improvements in the past include: 1.

implementing ISO Cleanliness Code standards for bulk hydraulic oils;

2.

evaluating bulk oil shipments for cleanliness by conducting particle counts and maintain records;

3.

minimizing drum usage by utilizing tote tanks and five gallon pails;

4.

utilizing plastic versus steel storage tanks, if possible;

5.

installing desiccant breathers on all bulk tanks;

6.

using sealed plastic containers for adding oil to small sumps;

7.

locating bulk tanks near equipment and pump directly to reservoirs;

________________________________________________________________ 49 CM445 Hydraulics

_________________________________________________ Troubleshooting Cutter head raise failure troubleshooting

1. Check pilot supply pressure at remote control valves.

2. Check pilot pressure at the raise pilot cylinder on the cutter head directional control valve when the remote control valve is in the Raise position.

3

Check the directional control valve for proper operation.

4. Check to see that piping has not been crossed, especially if the problem occurs after maintenance or repair work.

5. Check that the "in-line" counterbalance holding valve is piloted and shifting to direct retract port cylinder oil flow back to tank.

6. Check to see that there is no mechanical bind.

7. Check cylinders for bypassing.

8. Check for pilot pressure on the cutter head cylinder’s holding valves. Also check that the valves are shifting to send oil back to the tank. (Note: cylinder removal will be required to safely achieve this)

Cutter head lower failure troubleshooting

1. Check pilot supply pressure at remote control valves.

2. Check pilot pressure at the Lower pilot cylinder on the cutter head directional control valve when the remote control valve is in the Lower position.

3. Check the direction control valve for proper operation.

4. Check to see that piping has not been crossed, especially if the problem occurs after maintenance or repair work.

5. Check to see that there is no mechanical bind or hydraulic block.

6. Check flow control valve cartridge.

7. Check cylinders for bypassing.

8. Check for pilot pressure on the cutter head cylinder's holding valves. Also check that the valves are shifting to send (extend port) oil back to the tank.

Note: cylinder removal will be required to safely achieve this.

______________________________________________________________ A6474X439 REV 0 50

Troubleshooting _________________________________________________ 8.

utilizing filter carts to maintain oil cleanliness standards;

9.

properly training personnel on the importance of clean oil and best practices for storage and handling; and

10.

monitoring the program closely and looking for continuous improvement.

Eliminate contamination source through “clean” maintenance practices best achieved by maintenance and troubleshooting given below:

Multi-function failure

1.

always clean the area around the component that is to be removed and inspected;

2.

store components in a plastic bag after inspection and prior to replacement on machine;

3.

cap off all open hoses/fittings;

4.

never touch a filter with bare hands when installing it back onto the machine; and

5.

pay close attention to the filler/breather cap and replace it when damaged or in the recommended time frame.

If more than one function fails to operate on the machine, check the output of the pumps. Since this is an “open center” circuit, the normal pressure (with all directional control valves in the center position) should be less than 100 psi.

This pressure reading illustrates the necessary pressure to circulate the oil through the system. If the pressure reading under these conditions is significantly greater than 100 psi, it is likely that one of the control valves is trying to direct oil to one (or more) of the circuits on the machine.

The next step in troubleshooting a multi-function failure is to check the pilot pressure on the main control valve manifold. This pressure should be between 400 500 psi. If the pilot pressure is significantly below 350 psi, start with the General Troubleshooting Flow Chart IV - Incorrect Pressure. Another step to resolve multifunction failure is to have an electrician check for power to the solenoid circuits.

Check for correct pump rotation if electrical work has been performed (such as trailing cable replacement).

________________________________________________________________ 51 CM445 Hydraulics

_________________________________________________ Troubleshooting

Gathering head raise failure

1. Check the directional control valve for proper operation.

2. Check to see that piping has not been crossed, especially if the problem occurs after maintenance or repair work.

3. Check to see that there is no mechanical bind.

4. Check cylinders for bypassing.

5. Check needle valve on pilot circuit to verify that it is not open or leaking off.

6. Check in-line counterbalance valve for proper operation or blockage.

Gathering head float failure

1. Check the control valve for proper operation.

2. Check to see that piping has not been crossed, especially if the problem occurs after maintenance or repair work.

3. Check to see that there is no mechanical bind.

4. Check cylinders for bypassing (they will leak out the top).

5. Check needle valve on pilot circuit to verify that it is not open or leaking off.

6. Check counterbalance valve for proper operation (see the schematic in the parts book supplied with your machine for the proper setting).

1. Check the directional control valve for proper operation.

Conveyor raise failure

2. Check to see that piping has not been crossed, especially if the problem occurs after maintenance or repair work.

3. Be sure that the built-in atmospheric-vented reliefs on the cylinders are not dumping oil.

4. Check to see that there is no mechanical bind.

5. Verify that cylinders are not bypassing.

______________________________________________________________ A6474X439 REV 0 52

Troubleshooting _________________________________________________ Conveyor lower failure

1. Check the directional control valve for proper operation.

2. Check to see that piping has not been crossed, especially if the problem occurs after maintenance or repair work.

3. Verify that pilot pressure is being applied to open the piloted built-in checks.

4. Verify that cylinders are not bypassing.

Conveyor swing failure

1. Check the directional control valve for proper operation.

2. Check for any mechanical bind or any obstruction blocking movement, either to the cylinder itself, the main pivot area, or to some point along or under the discharge conveyor itself. Also check to ensure that the pivot bushings have not frozen up from lack of lubrication.

3. Verify that the cylinder is not bypassing.

Stabilizer raise failure

1. Check the directional control valve for proper operation.

2. Check to see that piping has not been crossed, especially if the problem occurs after maintenance or repair work.

3. Check the lubrication network for bound bushings.

4. Check for any mechanical bind or any obstruction blocking movement.

5. Check cylinder for bypassing.

Stabilizer lower failure

1. Check the control valve for proper operation.

2. Check to see that piping has not been crossed, especially if the problem occurs after maintenance or repair work.

3. Check the lubrication network for bound bushings.

4. Check for any mechanical bind or any obstruction blocking movement.

5. Check cylinder for bypassing.

High speed cutter head raise failure

1. Check pilot supply pressure at remote control valves.

2. Check pilot pressure at the raise pilot cylinder on the cutter head directional control valve when the remote control valve is in the Raise position.

3

Check the directional control valve for proper operation.

4. Check to see that piping has not been crossed, especially if the problem occurs after maintenance or repair work.

5. Check that the "in-line" counterbalance holding valve is piloted and shifting to direct retract port cylinder oil flow back to tank.

6. Check to see that there is no mechanical bind.

7. Check cylinders for bypassing.

8. Check for pilot pressure on the cutter head cylinder’s holding valves. Also check that the valves are shifting to send oil back to the tank. (Note: cylinder removal will be required to safely achieve this)

________________________________________________________________ 53 CM445 Hydraulics

_________________________________________________ Troubleshooting Table 1: Flow chart I for troubleshooting excessive noise

Pump Noisy Cause

Motor Noisy Remedy

Cause

Relief/Counterbalance Valve Noisy Remedy

Cause

Remedy

Cavitation

A

Coupling misaligned

C

Setting too low or too close to another valve setting

D

Air in fluid

B

Motor or coupling worn or damaged

E

Worn poppet and seat

E

Coupling misaligned

C

Pump worn or damaged

E

Remedies A. Any or all of the following: 1.

2.

3.

4.

5.

6.

7.

8.

replace dirty filters wash strainers in solvent compatible with system fluid clean clogged inlet line clean reservoir breather vent change system fluid change to proper pump drive motor speed check fluid temperature check fluid level

B. Any or all of the following: 1. tighten leaky inlet connections 2. fill reservoir to proper levels: with few exceptions, all return lines should be below fluid level in the reservoir 3. bleed air from system 4. replace pump shaft seal; also replace shaft if worn at seal journal 5. replace pump C. All of the following: 1. align unit, ensure that mounting hardware is correct and tight 2. check condition of seals, bearings, and coupling D. 1. install and/or adjust pressure gauge E. 1. overhaul or replace defective parts

______________________________________________________________ A6474X439 REV 0 54

Troubleshooting _________________________________________________ Table 2: Flow chart II for troubleshooting excessive heat Pump Heated

Motor Heated Cause

Fluid Heated

Cause

Remedy

Cause

Remedy

See Fluid Heated

System pressure too high

D

Cause

Remedy

Fluid heated

See Fluid Heated

Cavitation

A

Relief or unloading valve set too high

D

Valve setting incorrect

D

Unloading valve set too high

D

Air in fluid

B

Excessive load

C

Worn or damaged valve

E

Fluid dirty or low supply

F

Relief or unloading valve set too high

D

Worn or damaged motor

E

Incorrect fluid viscosity

F

Excessive load

C

Faulty fluid cooling system

G

Worn or damaged pump

E

Worn pump, valve motor, cylinder, or other component

E

Fluid heated

Remedy

Relief Valve Heated

See Fluid Heated

Fluid heated

Remedies A. Any or all of the following: 1.

2.

3.

4.

5.

6.

replace dirty filters clean clogged inlet line clean reservoir breather vent change system fluid change to proper pump drive motor speed overhaul or replace supercharge pump

F. 1. change filters 2. check system fluid viscosity; change if necessary 3. fill reservoir to proper level G. 1. clean cooler and/or strainer 2. replace cooler control valve 3. repair or replace cooler

B. Any or all of the following: 1. tighten leaky inlet connections 2. fill reservoir to proper levels: with few exceptions, all return lines should be below fluid level in the reservoir 3. bleed air from system 4. replace pump shaft seal; also replace shaft if worn at seal journal C. All of the following: 1. align unit 2. check condition of seals, bearings, and coupling 3. locate and correct mechanical binding 4. check for workload in excess of circuit design D. 1. install and/or adjust pressure gauge; keep at least 125 psi difference between valve settings E. 1. overhaul or replace defective parts

________________________________________________________________ 55 CM445 Hydraulics

_________________________________________________ Troubleshooting Table 3: Flow chart III for troubleshooting incorrect flow No Flow Cause

Low Flow Remedy

Excessive Flow

Cause

Remedy

Cause

Remedy

Pump not receiving fluid

A

Flow control set too low

D

Flow control set too high

D

Pump drive motor not operating

E

Relief or unloading valve set too low

D

RPM of pump drive motor incorrect

H

Pump to drive coupling sheared

C

Flow by-passing thru partially open valve

E of F

Improper size pump used for replacement

H

Pump drive motor turning in wrong direction

G

External leak in system

B

Directional control set in wrong position

F

RPM of pump drive motor incorrect

H

Entire flow passing over relief valve

D

Worn pump, valve, motor, cylinder, or other component

E

Damaged pump

C

Pilot filter clogged

A

Improperly assembled pump

E

Pilot filter clogged

A

Remedies A. Any or all of the following: 1.

2.

3.

4.

5.

replace dirty filters clean clogged inlet line clean reservoir breather vent fill reservoir to proper level overhaul or replace supercharge pump

F. Any or all of the following 1. check position of manually operated controls 2. check electrical circuit on solenoid operated controls 3. repair or replace pilot pressure pump G. 1. reverse rotation

B. Any or all of the following: H. 1. replace with correct unit 1. tighten leaky inlet connections 2. bleed air from system C. All of the following: 1. check for damaged pump or pump drive 2. replace and align coupling D. 1. adjust setting on valve E. 1. overhaul or replace part

______________________________________________________________ A6474X439 REV 0 56

Troubleshooting _________________________________________________ Table 4: Flow chart IV for troubleshooting incorrect pressure No Pressure

Low Pressure

Erratic Pressure

Cause

Remedy

Cause

Remedy

No flow

See Table 3

Pressure relief path exists

See Table 5

Pressure reducing valve set too low

Cause

Excessive Pressure

Remedy

Cause

Remedy

Air in fluid

B

Pressure reducing, relief, or unloading valve misadjusted

D

D

Worn relief valve

E

Pressure recuing, relief, or unloading valve worn or damaged

E

Pressure reducing valve damaged

E

Contamination in fluid

A

Damaged pump, motor, or cylinder

E

Accumulator defective or has lost charge

C

Worn pump, motor, or cylinder

E

Remedies A. 1. replace dirty filters and system fluid B. 1. tighten leaky connections 2. fill reservoir to proper level and bleed air from system C. 1. gas valve for leakage 2. charge to correct pressure 3. overhaul if defective D. 1. adjust valve E. 1. overhaul or replace part

________________________________________________________________ 57 CM445 Hydraulics

_________________________________________________ Troubleshooting Table 5: Flow chart V for troubleshooting faulty operation No Movement Cause No flow or pressure

Slow Movement

Remedy

Cause

See Table Low flow 3

Erratic Movement Remedy

Excessive Speed or Movement

Remedy

Cause

Cause

Remedy

See Table 5

Erratic pressure

See Table Excessive flow 4

See Table 5

Air in fluid

See Table Feedback 1 transducer malfunctioning

E

Limit or sequence device (mechanical, electrical, or hydraulic) inoperative or misadjusted

E

Fluid viscosity too high

A

Mechanical bind

B

Insufficient control pressure for valves

See Table 4

No lubrication of machine ways or linkage

G

Misadjusted or malfunctioning valve amplifier

C

No command signal to valve or amplifier

F

No lubrication of machine ways or linkage

G

Erratic command signal

F

Overriding work load

H

Inoperative or misadjusted valve amplifier

C

Misadjusted or malfunctioning valve amplifier

C

Misadjusted or malfunctioning valve amplifier

C

Inoperative solenoid or proportional valve

E

Sticking valve

D

Malfunctioning feedback transducer

E

Worn or damaged cylinder or motor

E

Worn or damaged cylinder or motor

E

Sticking valve

D

Pilot filter clogged

See Table 3

Worn or damaged cylinder or motor

E

Remedies A. 1. check fluid temperature 2. check system fluid viscosity; change if necessary B. 1. locate bind and repair C. 1. adjust, repair, or replace part D. 1. clean and adjust or replace part 2. check condition of system fluid and filters E. 1. overhaul or replace part F. 1. repair command console or interconnecting wires G. 1. lubricate H. 1. adjust, repair, or replace counterbalance valve

______________________________________________________________ A6474X439 REV 0 58

Troubleshooting _________________________________________________ Table 6: Restarting checklist Has the cause of the failure been remedied?

No

Carry out further investigation.

Yes

Clean or flush the system as required.

Yes Can dirt have entered the system by the unit failure or during replaceNo Is the unit the correct one?

No

Modify or replace with correct unit.

No

Remedy installation.

No

Remedy installation.

Yes

Is the unit adjusted to a safe condition for start up?

Yes Are all hydraulic connections correct?

Yes Are all electrical connections correct?

Yes Is the unit adjustable?

Yes

No

Adjust to a safe condition.

No Have the cases of pumps and motors been filled?

No

Fill case.

Yes

Bleed or prime as necessary.

No

Remove safety interlocks.

No

Sound alarm or inform personnel.

Yes Will the system require bleeding or priming?

No Have all safety interlocks been removed Yes Are all personnel aware the machine is restarting?

Yes Start machine (see Startup procedure in this chapter).

________________________________________________________________ 59 CM445 Hydraulics

_________________________________________________ Troubleshooting Water system including circuits Table 7: Water system troubleshooting including circuits Trouble, symptom or cause

Probable cause

recommended water volume (gpm) can- 1. not be maintained

Dynamic water pressure (psi) is not being supplied to the recommended psi.

Test, check and/or remedy 1.

Change setting to the recommended psi.

2.

Change hose to the recommended diameter size.

3.

Check the water supply itself to see if there is an issue & fix.

1.

Remove the filter and clean it thoroughly; flush the system as necessary.

2.

Change water filter frequently.

1.

Remove the nozzles and clean thoroughly; flush the system as necessary.

2.

Change water filter frequently.

Air in the system.

1.

Check for leaks.

Pressure too high.

2.

Adjust the pressure.

Hydraulic pilot operated water valve stuck open.

1.

Clean or replace.

2.

Faulty solenoid.

2.

Replace.

3.

Radio transmitter toggle switch faulty.

3.

Replace toggle switch.

no water pressure on the 1. pressure gauge 2.

Water filter plugged.

1.

Replace or clean.

Main water ball valve “OFF”.

2.

Close valve.

3.

No incoming water.

3.

Fix water supply issue.

Contaminated water supply

1.

Clean or filter the incoming water supply to the miner.

Incorrect pressure reducing valve setting.

1.

Adjust psi.

2.

Check water volume gpm.

3.

Remove strainer and clean.

4.

Backflush pump, remove nozzle and clean.

5.

Adjust psi.

2.

Water supply hose is not the minimum diameter

3.

Incoming supply of water has a problem.

damaged or clogged filter, contaminates 1. in the water system

plugged water nozzles are restricting the 1. flow of water or pressure fluctuates

pressure fluctuates and there is extreme 1. noise in the system 2. water function will not shut “OFF” with 1. radio transmitter

water filter stopping up 1. frequently jet pump not removing water from sump 1.

2.

Dirt in the system.

Dirt in the system.

Pressure reducing valve internal strainer dirty.

3.

Jet pump nozzle plugged with dirt.

4.

Suction hose from sump to jet pump plugged with sludge or hose has a loose connection.

5.

Incorrect hose size from jet pump to manifold.

6.

Remove restriction or tighten hose connection.

6.

Manifold plugged.

7.

Check for correct hose size.

8.

Clean.

______________________________________________________________ A6474X439 REV 0 60

BI001573 A6474X440 August 2012

Operation and Maintenance Manual CM445 Continuous Miner A6474X440 (Electrical)

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 you’re the 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 Instructions ............................................................................. 4 Introduction ........................................................................................ 6 Electrical Component Locator ........................................................... 7 Electrical Block Diagram ................................................................... 8 Specifications .................................................................................... 9 Circuits .............................................................................................. 10 Power ........................................................................................ 10 Control and Lighting .................................................................. 12 Emergency Stop ........................................................................ 14 Power Center Trip ..................................................................... 15 Methane/Water Monitor............................................................. 16 Earth Leakage Monitor .............................................................. 17 Oil Level .................................................................................... 18 Pump ......................................................................................... 19 Cutter......................................................................................... 22 Conveyor ................................................................................... 25 Scrubber Fan ............................................................................ 28 Tail Drive ................................................................................... 30 Tram .......................................................................................... 34 Tram Pendant ........................................................................... 37 Hydraulic Control ....................................................................... 38 Controller Case ................................................................................. 39 Right Wall .................................................................................. 40 Left Wall .................................................................................... 41 Rear Wall .................................................................................. 42 Swing Panel .............................................................................. 43

________________________________________________________________ A6474X440

REV 0

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, as well as all applicable regulatory agency rules and regulations must be followed at all times.

!

DANGER

Do not make any type of temporary repairs to the trailing cable or trailing cable connections. Trailing cables may only be repaired under certain conditions and following specific guidelines.

!

DANGER

Only qualified personnel are permitted to make repairs to permissible equipment. The permissibility of any permissible component must be verified after any maintenance or repair work and at regular intervals. Failure to maintain permissible components to OEM standard may result in a fire or explosion. Serious injury or death could occur.

!

!

!

!

!

!

!

WARNING Do not attempt to operate this continuous miner until you have been sufficiently trained on this machine and have read and understood this manual and are familiar with all controls and indicators. Operating this machine without the proper training and knowledge may result in serious injury or death to the operator or other personnel.

WARNING Federal law requires that temporary roof supports be in place before approaching the machine to reset a circuit breaker. Under no circumstances should personnel be under unsupported roof. Failure to follow these regulations may result in serious injury or death.

WARNING Only use the Emergency Stop Override to tram the miner away from the rib, releasing the accidentally pushed Machine Stop button. Never use the Emergency Stop Override when a Machine Stop switch has been activated by personnel. Failure to comply with this warning may lead to severe injury or death of personnel.

WARNING The Continuous Miner is radio remote controlled during production operations. Manual operation via machine mounted controls is not permitted for production operations.

Manual operation is for troubleshooting and maintenance under supported roof only.

Operating the Continuous Miner with manual or pendant controls under unsupported roof may result in sever injury or death.

WARNING Before performing maintenance or repair work on this machine, the circuit breaker must be in the “OFF” position and the trailing cable disconnected. Follow all applicable rules and regulations regarding the lockout/tagout procedures. Accidental machine movement or electrical shock may result in serious injury or death to the operator or other personnel.

WARNING Some procedures or test may require the cover of the electrical controller to be removed and some may require the controller to be energized during the procedure. Tall all necessary precautions to prevent electrical shock while working within the controller. An MSHA certified electrician must supervise and inspect all work.

WARNING Do not alter, bypass, or remove and emergency or machine stop device. Failure to heed this warning may result in serious injury or death.

________________________________________________________________ 4 CM445 Electrical

_______________________________________________ Safety Instructions

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WARNING Do not use an emergency or stop device as a means of disconnecting power to the miner. Whenever instructed to disconnect power, it is always meant to turn the main circuit breaker to the “OFF” position and to physically remove the trailing cable and lockout/tagout the machine. Failure to do so may result in serious injury or death.

WARNING Never disconnect a hydraulic hose if the circuit is pressurized or there is a load on the circuit. Pressurized hydraulic fluid or falling loads may result in serious injury or death.

WARNING Do not rely on load holding valves when working under the cutter head or the conveyor.

Always block the cutter head and conveyor in the elevated position. Serious injury or death may occur if the cutter head or conveyor are not mechanically blocked.

WARNING Never work under any assembly or component of this machine that is elevated. Always install enough blocking to support t he machine or component or lower the component to ground level.

______________________________________________________________ A6474X440 REV 0 5

Introduction _____________________________________________________ Introduction

The purpose of this manual is to give an overview the electrical circuits of the CM445 Continuous Miner. This manual is only intended to familiarize the user with the electrical system. All electrical maintenance must be performed by a qualified person.

Electrical Overview

1040VAC, 3-phase power is supplied to the machine via a trailing cable. During normal mining operations, the machine is operated by a radio remote. If required, and under certain circumstances, the control system allows limited functions to be operated from controls located on the machine or from an tram pendant.

Control System Overview

The control system consists of a machine controller, a power supply, input/ output modules, the radio remote, a text display, and an optional graphics display.

The control system monitors machine operating parameters and has the ability to prevent motors from starting or to shut down motors based upon preset parameter values. It will also issue faults, warnings, and alarms based on these parameters. Note: For more information on the control system, see the Graphics Display and Control System manuals in this book.

VFD Overview

The variable frequency drive (VFD) system used 3-phase, 1040 VAC motors for tramming. The motors respond to changes in frequency from the control system to tram the machine at infinitely variable speeds.

________________________________________________________________ 6 CM445 Electrical

_____________________________________________________ Introduction Fig. 1: Electrical component locator

1

10

9 7

8

6

2 3

4

5

2 1.

2.

3.

4.

5.

Tram case Text display Controller case Programming port Main breaker case

6. Tram motor (2) 7. Pump motor 8. CLA junction box 9. Gathering head motor (2) 10. Cuter motor (2) 11. Tail drive motor (2)

______________________________________________________________ A6474X440 REV 0 7

Introduction _____________________________________________________ Fig. 2: Electrical block diagram 13 32

19

21

11

8

11

6

20

3

1

12 35

17

18

9

10

34

34

36

37

14

25 16

15

12 31 33

5

4

7

30 29

24 23

28

22

11

20

27

2

13

11

26

1. Left cutter motor 2. Right cutter motor 3. Left CLA motor 4. Right CLA motor 5. Pump motor 6. Left tram motor 7. Right tram motor 8. Scrubber motor 9. Methane sensor 10. Inclinometer 11. Headlight 12. Reverse light 13. Area light

14. Cutter motor junction box 15. CLA motor junction box 16. Solenoid junction box 17. Hydraulic oil switch 18. Methane junction box 19. Left emergency stop 20. Antenna 21. Incoming water box 22. Main breaker case 23. Key switch 24. USB-stick pratley junction box 25. Rear methane sensor 26. Emergency tram pendant

27. Radio remote 28. Diode hytronic junction box 29. Graphics display 30. LED array 31. VFD Pratley junction box 32. Pump/tram pre-start alarm 33. VFD junction box 34. Tail drive motor 35. Inclinometer pratley junction box 36. Methane power supply 37. Methane controller box

________________________________________________________________ 8 CM445 Electrical

______________________________________________________ Installation Specifications

Specifications for the CM445 are as follows: Nominal Line Power ......................................... 1040VAC, 50 hz Control Transformer ......................................... 1040 VAC to 120VAC and 12VAC Pump Motor Power ........................................... 75 hp/56 KW Left Cutter Motor Power ................................... 250 hp/186 KW Right Cutter Motor Power ................................. 250 hp/186 KW Left Gathering Head/Conveyor Motor Power ... 55 hp/41 KW Right Gathering Head/Conveyor Motor Power. 55 hp/41 KW Left Traction Motor Power ................................ 50 hp/37 KW Right Traction Motor Power.............................. 50 hp/37 KW Left Tail Drive Motor Power .............................. 41 hp/30.5 KW Right Tail Drive Motor Power ........................... 41hp/30.5 KW

______________________________________________________________ A6474X440 REV 0 9

Electrical Circuits ________________________________________________ Power Circuit

All machine motors operate on 1040VAC power which is supplied to the machine via the trailing cable. The trailing cable is energized when connected to the power center and the four power center trip contactors are closed.

The machine is protected by a 600 amp main circuit breaker, CB1, set to instantaneously trip at 1500 amps. Once CB1 is closed, the machine is energized.

Power is active in the lighting and control circuits, as well as the pump, cutter, fan, tail drive and conveyor motor circuits. The pump is further protected by overloads located on each phase of the incoming power to the motor.

The tram circuit is protected by a 400 amp circuit breaker, CB3, instantaneously set to trip at 300 amps. When CB3 is closed, power is active in the tram circuit.

Each motor has a contactor that opens and closes in response to an ON/OFF command. No motor can be started until the pump motor is started (contactor P is closed).

!

WARNING The schematics in this manual are typical and are for reference only. Do not use these schematics to troubleshoot or perform maintenance on the machine. Always refer to the schematic in the parts book for your machine.

________________________________________________________________ 10 CM445 Electrical

________________________________________________ Electrical Circuits Fig. 2: Power circuit

______________________________________________________________ A6474X440 REV 0 11

Electrical Circuits ________________________________________________ Control and Lighting Circuits

The control and lighting circuits are supplied by transformer, T1. The 1040VAC incoming power is stepped down through the transformer to 120VAC and 12VAC circuits.

120VAC

The 120VAC circuit supplies power to control system, including the PLC, the battery backup, and the displays, as well as the area lights. It is also the power source for the emergency tram module, the VFD system, and the ground fault monitoring system.

Individual 120VAC circuits are protected by circuit breakers as follows: 1. The main 120VAC supply lines are protected by two 15A circuit breakers, MCB1 and MCB2.

2. Area lights are protected by two 15A circuit breakers, MCB3 and MCB4.

3. The LCD display is protected by four 5A circuit breakers, MCB13, MCB14, MCB17 and MCB18.

4. The text display is protected by two 5A circuit breakers, MCB15 and MCB16.

5. The solenoids are protected by a 5A circuit breaker, MCB10.

6. The 120VAC feed into the PLC is protected by two 5A circuit breakers, MCB11 and MCB12.

7. The contactors are protected by a 5A circuit breaker, MCB9.

12VAC

The 12VAC circuit supplies power to the headlights, reverse lights and the thermistor module.

The individual 12VAC circuits are protected by circuit breakers as follows: 1. The headlights are protected two 25A circuit breakers, MCB5 and MCB6.

2. The thermistor module is protected by two 5A circuit breakers, MCB7 and MCB8.

3. The reverse lights (optional) are protected by two 15A circuit breakers, MCB19 and MCB20.

Headlights

When the headlight switch on the radio remote is activated, the control system sends a digital output (A9-R) to energize the headlight relay, L, which signals the normally open contacts, L, in lines 703 and 704 to close, turning on the headlights.

Reverse Lights (optional)

When the reverse light switch on the radio remote is activated, the control system sends a digital output (A9-T) to energize the reverse light relay, RL, which signals the normally open contacts, RL, in lines 723 and 724 to close, turning on the reverse lights.

Area Lights

The area lights are turned on upon machine startup.

________________________________________________________________ 12 CM445 Electrical

________________________________________________ Electrical Circuits Fig. 3: Lighting Circuits

______________________________________________________________ A6474X440 REV 0 13

Electrical Circuits ________________________________________________ Emergency Stop Circuit

Power to the motor control circuits is isolated by an emergency stop relay, ESR. Relay ESR is controlled by two machine stop switches, one located on the right side of the machine on the front of the control case and the other on the left rear corner of the machine. Pressing either switch interrupts power to the motor relay, stopping all machine functions.

Fig. 4: Emergency Stop Circuit

________________________________________________________________ 14 CM445 Electrical

________________________________________________ Electrical Circuits Power Center Trip Relay Control Circuit

The power supply module contains a special relay for controlling the external pilot relay (outby machine stop relay). The processor module can send a control message to the power supply at any time to drive the pilot relay output and trip the main power supply to the machine.

Fig. 5: Power Center Trip Relay Control Circuit

______________________________________________________________ A6474X440 REV 0 15

Electrical Circuits ________________________________________________ Methane/Water Monitor Circuit

The methane/water monitor has a dual purpose in that it monitors both methane levels and water pressure and flow. If the methane concentration exceeds the preset value, the cutter motors will shut down (or, if not running, will not be able to be started). If the water pressure drops below a preset value, the pump motor will shut down.

Fig. 6: Methane/Water Monitor Circuit

________________________________________________________________ 16 CM445 Electrical

________________________________________________ Electrical Circuits Earth Leakage Circuit

There are two earth leakage relay monitors: EL120 and EL1100.

EL120 is the earth leakage monitor for the 120VAC lighting and control circuit.

When the current exceeds .1 A, earth leakage relay EL120 will open the EL120 contactor located in line 107, removing power from the area lights and processor module power supply. And input signal is sent to the processor at A8-CC (line 107) and a fault message will be displayed.

EL1100 is the earth leakage detector on the tram circuit. When the current exceeds .1 A, earth leakage relay EL1100 will open the EL1100 contactor located in line 108, interrupting input to the pump relay, P. This will open the pump contactor, shutting down the machine. An input signal is sent to the processor at A8-AA (line 108) and a fault message will be displayed.

Test switches, located on EL120 and EL1100 on the front of the controller swing panel, are used to test the earth relay monitors.

Fig. 7: Earth Leakage Circuit

______________________________________________________________ A6474X440 REV 0 17

Electrical Circuits ________________________________________________ Oil Level Circuit

The hydraulic oil float switch is located within the hydraulic oil tank and has two settings: an alarm level and a shut down level. When the oil in the tank reaches the alarm level, an audible alarm will sound. When the oil reaches the shut down level, the pump motor will shut down.

Fig. 8: Oil Level Circuit

________________________________________________________________ 18 CM445 Electrical

________________________________________________ Electrical Circuits Pump Control Circuit

When the main circuit breaker, CB1, and all emergency stop relays, ESR, are closed, the operator can start the pump. When the pump start button is pushed, the control system sends a signal from location A9-B to the pump relay, P, to close the pump contacts, P. A thermistor module monitors the pump RTD at inputs A16-M and A16-N. The values are transmitted to the Input/Output system communication port of the control system over an A5/A2 molded cable. The current transducers, located on each leg of the incoming pump power supply, send a signal to the control system at inputs A8-S, A8-T, AND A8-U. If the values received from the thermistor module or the current transducer exceed preset values, the control system will de-energize the relay, P, opening contacts P and shutting down the pump motor.

______________________________________________________________ A6474X440 REV 0 19

Electrical Circuits ________________________________________________ Fig. 9: Pump Control Circuit

Neutral AC

________________________________________________________________ 20 CM445 Electrical

________________________________________________ Electrical Circuits Pump Power Circuit

When the normally open pump contactor, P, is energized, the contactor closes.

The pump contactor supplies 1040VAC power to the pump motor through lines 5T1, 5T2, and 5T3. The pump is protected by a current transducer, CT5, that monitors the current draw of the pump during operation. The transducer provides current overload protection while the machine is running. The pump is also equipped with an RTD to provide thermal overload protection. If the control system reads an overload condition, contactor P is opened and the pump is shut down.

Note: There are three pump thermal overloads, CT7A, CT7B, and CT7C, located on each leg of incoming pump power. These thermal overloads protect the pump motor during emergency tramming operations with the remote tram.

Fig. 10: Pump Power Circuit

Ground AC Pilot

______________________________________________________________ A6474X440 REV 0 21

Electrical Circuits ________________________________________________ Cutter Control Circuit

When the main circuit breaker, CB1, and all emergency stop relays, ESR, are closed, and the pump motor is running, the operator can start the cutter motors.

The control system issues a command at A9-D and A9-F to energize the left and right cutter motor relays, A and B, closing contacts A and B and starting the cutter motors.

A thermistor module monitors the cutter motor RTDs at inputs A16-C, A16-D, A16-E, and A16-F. The values are transmitted to the Input/Output system communication port of the control system over an A5/A2 molded cable. The current transducers, located on each leg of the incoming cutter motor power supply, send a signal to the control system at inputs A8-C, A8-D, and A8-E for the left cutter motor and at inputs A8-F, A8-H, and A8-J for the right cutter motor. If the values received from the thermistor module or the current transducers exceed preset values, the control system will de-energize the relays, A and B, opening contacts A and B, and shutting down the left and right cutter motors.

Fig. 11: Cutter Control Circuit

Neutral AC

________________________________________________________________ 22 CM445 Electrical

________________________________________________ Electrical Circuits Cutter Power Circuit

When the pump motor is running and circuit breaker, CB1, is closed, the cutter motor contactors, A and B, are energized and close. 1040VAC power is supplied to the left cutter motor through lines 1T1, 1T2, and 1T3 and to the right cutter motor through lines 2T1, 2T2, and 2T3. The left cutter motor is protected by current transducer CT1 and the right cutter motor by current transducer CT2. The transducers provide current overload protection while the cutter motors are running. Each motor is also equipped with an RTD to provide thermal overload protection. If the control system reads an overload condition during operation, contactors A and B are opened and the motors are shut down.

Fig. 12: Cutter Power Circuit

Ground AC Pilot

______________________________________________________________ A6474X440 REV 0 23

Electrical Circuits ________________________________________________ Conveyor Forward Control Circuit

When the pump motor is running, the operator can start the gathering head/ conveyor motors in either forward or reverse direction. When started in the forward direction, the control system issues a command at A9-J to energize the left and right conveyor forward motor relay, CF, closing contact CF and starting the conveyor motors.

A thermistor module monitors the conveyor motor RTDs at inputs A16-H, A16-J, A16-K, and A16-L. The values are transmitted to the Input/Output system communication port of the control system over an A5/A2 molded cable. The current transducers, located on each leg of the incoming cutter motor power supply, send a signal to the control system at inputs A8-K, A8-L, and A8-M for the left conveyor motor and at inputs A8-N, A8-P, and A8-R for the right conveyor motor. If the values received from the thermistor module or the current transducers exceed preset values, the control system will de-energize the relay, CF, opening contact CF, and shutting down the left and right conveyor motors.

Fig. 13: Conveyor Forward Control Circuit

Neutral AC

________________________________________________________________ 24 CM445 Electrical

________________________________________________ Electrical Circuits Conveyor Forward Power Circuit

When the pump motor is running, the conveyor motors can be started. When the control circuit energizes the forward contactor, CF, the contactor closes.

1040VAC power is supplied to the left conveyor motor through lines 3T1, 3T2, and 3T3 and to the right motor through lines 4T1, 4T2, and 4T3.

Each leg of power going into the left and right conveyor motors is monitored by a current transducer: CT3 on the left motor and CT4 on the right. The transducers provide current overload current protection while the motors are running.

Each motor is also equipped with an RTD to provide thermal overload protection. If the control system detects an overload condition, it will open contactor CF, shutting down the conveyor motors.

Fig. 14: Conveyor Forward Power Circuit

Ground AC Pilot

______________________________________________________________ A6474X440 REV 0 25

Electrical Circuits ________________________________________________ Conveyor Reverse Control Circuit

When the pump motor is running, the operator can start the gathering head/ conveyor motors in either forward or reverse direction. When started in the reverse direction, the control system issues a command at A9-L to energize the left and right conveyor reverse motor relay, CR, closing contact CR and starting the conveyor motors.

A thermistor module monitors the conveyor motor RTDs at inputs A16-H, A16-J, A16-K, and A16-L. The values are transmitted to the Input/Output system communication port of the control system over an A5/A2 molded cable. The current transducers, located on each leg of the incoming cutter motor power supply, send a signal to the control system at inputs A8-K, A8-L, and A8-M for the left conveyor motor and at inputs A8-N, A8-P, and A8-R for the right conveyor motor. If the values received from the thermistor module or the current transducers exceed preset values, the control system will de-energize the relay, CR, opening contact CF, and shutting down the left and right conveyor motors.

Fig. 15: Conveyor Reverse Control Circuit

Neutral AC

________________________________________________________________ 26 CM445 Electrical

________________________________________________ Electrical Circuits Conveyor Reverse Power Circuit

When the pump motor is running, the conveyor motors can be started. When the control circuit energizes the reverse contactor, CR, the contactor closes.

1040VAC power is supplied to the left conveyor motor through lines 3T1, 3T2, and 3T3 and to the right motor through lines 4T1, 4T2, and 4T3.

Each leg of power going into the left and right conveyor motors is monitored by a current transducer: CT3 on the left motor and CT4 on the right. The transducers provide current overload current protection while the motors are running.

Each motor is also equipped with an RTD to provide thermal overload protection. If the control system detects an overload condition, it will open contactor CR, shutting down the conveyor motors.

Fig. 16: Conveyor Reverse Power Circuit

Ground AC Pilot

______________________________________________________________ A6474X440 REV 0 27

Electrical Circuits ________________________________________________ Scrubber Fan Control Circuit

When the pump motor is running, the operator can start the fan motor. When started in the reverse direction, the control system issues a command at A9-N to energize the fan motor relay, F, closing contact F and starting the fan motor.

A thermistor module monitors the fan motor RTDs at inputs A16-P and A16-R. The values are transmitted to the Input/Output system communication port of the control system over an A5/A2 molded cable. The current transducers, located on each leg of the incoming fan motor power supply, send a signal to the control system at inputs A8-V, A8-W, and A8-X for the fan motor. If the values received from the thermistor module or the current transducers exceed preset values, the control system will de-energize the relay, F, shutting down the fan motor.

Fig. 17: Scrubber Fan Control Circuit

Neutral AC

________________________________________________________________ 28 CM445 Electrical

________________________________________________ Electrical Circuits Scrubber Fan Power Circuit

When the pump motor is running, the fan motor can be started. When the control circuit energizes the reverse contactor, F, the contactor closes. 1040VAC power is supplied to the fan motor through lines 7T1, 7T2, and 7T3.

Each leg of power going into the fan motor is monitored by current transducer: CT6. The transducer provides current overload current protection while the motor is running. The motor is also equipped with an RTD to provide thermal overload protection. If the control system detects an overload condition, it will open contactor F, shutting down the fan motor.

Fig. 18: Scrubber Fan Power Circuit

Ground AC Pilot

______________________________________________________________ A6474X440 REV 0 29

Electrical Circuits ________________________________________________ Tail Drive Forward Control Circuit

When the pump motor is running, the operator can start the left and right tail drive motors in either forward or reverse direction. When started in the forward direction, the I/O module issues a command at B9-B to energize the left and right tail drive forward motor relay, TF, closing contact TF and starting the tail drive motors.

A thermistor module monitors the conveyor motor RTDs at inputs A16-Y, A16-Z, A16-AA, and A16-BB. The values are transmitted to the Input/Output system communication port of the I/O module over an A5/A2 molded cable. The current transducers, located on each leg of the incoming tail drive motor power supply, send a signal to the I/O module at inputs B8-C, B8-D, and B8-E for the left tail drive motor and at inputs B8-F, B8-H, and B8-J for the left for the right tail drive motor. If the values received from the thermistor module or the current transducers exceed preset values, the control system will de-energize the relay, TF, opening contact TF, and shutting down the left and right tail drive motors.

Fig. 19: Tail Drive Forward Control Circuit

Neutral AC

________________________________________________________________ 30 CM445 Electrical

________________________________________________ Electrical Circuits Tail Drive Forward Power Circuit

When the pump motor is running, the tail drive motors can be started. When the control circuit energizes the forward contactor, TF, the contactor closes.

1040VAC power is supplied to the left conveyor motor through lines 7T1, 7T2, and 7T3 and to the right motor through lines 8T1, 8T2, and 8T3.

Each leg of power going into the left and right conveyor motors is monitored by a current transducer: CT7 on the left motor and CT8 on the right. The transducers provide current overload current protection while the motors are running.

Each motor is also equipped with an RTD to provide thermal overload protection. If the control system detects an overload condition, it will open contactor TF, shutting down the conveyor motors.

Fig. 20: Tail Drive Forward Power Circuit

Ground AC Pilot

______________________________________________________________ A6474X440 REV 0 31

Electrical Circuits ________________________________________________ Tail Drive Reverse Control Circuit

When the pump motor is running, the operator can start the left and right tail drive motors in either forward or reverse direction. When started in the reverse direction, the control system issues a command at B9-D to energize the left and right tail drive reverse motor relay, TR, closing contact TR and starting the tail drive motors.

A thermistor module monitors the conveyor motor RTDs at inputs A16-Y, A16-Z, A16-AA, and A16-BB. The values are transmitted to the Input/Output system communication port of the I/O module over an A5/A2 molded cable. The current transducers, located on each leg of the incoming tail drive motor power supply, send a signal to the I/O module at inputs B8-C, B8-D, and B8-E for the left tail drive motor and at inputs B8-F, B8-H, and B8-J for the left for the right tail drive motor. If the values received from the thermistor module or the current transducers exceed preset values, the control system will de-energize the relay, TR, opening contact TR, and shutting down the left and right tail drive motors.

Fig. 21: Tail Drive Reverse Control Circuit

Neutral AC

________________________________________________________________ 32 CM445 Electrical

________________________________________________ Electrical Circuits Tail Drive Reverse Power Circuit

When the pump motor is running, the tail drive motors can be started. When the control circuit energizes the reverse contactor, TR, the contactor closes.

1040VAC power is supplied to the left conveyor motor through lines 7T1, 7T2, and 7T3 and to the right motor through lines 8T1, 8T2, and 8T3.

Each leg of power going into the left and right conveyor motors is monitored by a current transducer: CT7 on the left motor and CT8 on the right. The transducers provide current overload current protection while the motors are running.

Each motor is also equipped with an RTD to provide thermal overload protection. If the control system detects an overload condition, it will open contactor TR, shutting down the conveyor motors.

Fig. 22: Tail Drive Reverse Power Circuit

Ground AC Pilot

______________________________________________________________ A6474X440 REV 0 33

Electrical Circuits ________________________________________________ Tram Control Circuit

The tram control circuit uses two three-phase, 1040VAC tram motors that respond to change in frequency from the controls to tram in forward or reverse at varying speeds.

The machine control system provides tram control through CAN communication. The drives are equipped with software that has built in protection for the drive itself, allows communication with the control system, and displays information on the graphics display.

________________________________________________________________ 34 CM445 Electrical

________________________________________________ Electrical Circuits Fig. 23: Tram Control Circuit

______________________________________________________________ A6474X440 REV 0 35

Electrical Circuits ________________________________________________ Tram Power Circuit

When the pump motor is running and the traction breaker, CB3, is closed, the control system can operate the traction system. 1040VAC power is fed to the VFD components, located in the tram case enclosure and out to the left and right tram motors. Power is supplied to the left tram motor through lines YT1, YT2, and YT3 and to the right tram motor through lines XT1, XT2, and XT3.

Fig. 24: Tram Power Circuit AC DC

________________________________________________________________ 36 CM445 Electrical

________________________________________________ Electrical Circuits Tram Pendant Circuit

In the event that the machine cannot be trammed using the remote control, an emergency tram pendant, connected to the machine through and umbilical cord, can be used to start the pump and perform limited tramming operations. The control system allows tramming, stabilizer raise, and cutter raise and lower.

There are pump and tram motor thermal overloads built into the tram pendant circuit that will shut down the pump.

Fig. 25: Tram Pendant Circuit

______________________________________________________________ A6474X440 REV 0 37

Electrical Circuits ________________________________________________ Hydraulic Control Circuit

The hydraulic functions are controlled through a solenoid module. When the operator engages a hydraulic function on the radio remote, the solenoid shifts, directing pilot oil to shift the main hydraulic valve.

Fig. 26: Hydraulic Control Circuit

________________________________________________________________ 38 CM445 Electrical

__________________________________________________ Controller Case Introduction

The controller case is typically located on the right rear side of the machine and houses the major electrical control components. These components are mounted on the right, left, and rear walls, as well as on the front and back of a swing panel.

Fig. 27: Controller case

______________________________________________________________ A6474X440 REV 0 39

Controller Case __________________________________________________ Controller - Right Wall

The following components are mounted on the controller right wall: CT10 - Pump thermal overload relay current transducer CB3 - 400 amp tram circuit breaker set to instantaneously trip at 300 amps.

Fig. 28: Controller - right wall

CT10

CB3

________________________________________________________________ 40 CM445 Electrical

__________________________________________________ Controller Case Controller - Left Wall

The following components are mounted on the controller left wall: CF - Forward contactor for the gathering head motors (left and right) CR - Reverse contactor for the gathering head motors (left and right) P - Pump motor contactor CT3 - Left gathering head motor current transducer CT4 - Right gathering head motor current transducer CT5 - Pump motor current transducer Fig. 29: Controller - left wall CF

CT3

CR

CT4

P

CT5

______________________________________________________________ A6474X440 REV 0 41

Controller Case __________________________________________________ Controller - Rear Wall

The following components are mounted on the controller rear wall: A - Contactor for the left cutter motor B - Contactor for the right cutter motor F - Contactor for the scrubber fan motor CT6 - Scrubber fan motor current transducer CT1 - Left cutter motor current transducer CT2 - Right cutter motor current transducer T1 - 1040VAC to 120VAC/12VAC transformer Fig. 30: Controller - rear wall F

T1

CT6

A

B

CT1

CT2

________________________________________________________________ 42 CM445 Electrical

__________________________________________________ Controller Case Controller - Swing Panel (front)

The following components are mounted on the front of the controller swing panel: ESR - an 18A contactor in the emergency stop circuit. When this contactor is opened, all machine functions capable of producing a machine movement will shutdown.

MMR - an 18A relay in the methane monitoring circuit and interlocks with cutter contactors A and B. When “MMR” opens, the cutter contacts will open, stopping the cutters when the methane monitoring system determines there is high methane concentrations.

EL1100 - The earth leakage monitor is an AC residual ground fault monitor (1000 VAC, grounded supply) that monitors the 1000V circuit on the machine as well as the residual current flowing to earth.

EL120 - The earth leakage monitor is an AC residual ground fault monitor (120 VAC, grounded supply) that monitors the 120V circuit on the machine as well as the residual current flowing to earth.

L - 32A contactor for the front lights.

RL - 32A contactor for the reverse lights.

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

PLM2 - power line modem for the optional outby communications system. It is the control component of the outby communication system.

Ethernet switch - part of the optional outby communication system that sends information from the power line modem to the OBELIX processor.

OPS - power supply for the outby communication system.

ISBT - intrinsically safe relay for the tram pendant.

ISBIB - intrinsically safe relay for the boom inclinometer.

BRM - Bridge rectifier used to convert the AC input from the methane system circuit to a DC output used to pull in the methane monitor relay, MMR. BRE - Bridge rectifier used to convert the AC input from the emergency stop push button circuit to a DC output used to pull in the emergency stop relay, ESR. PCT - Power center trip relay. Used to open the pilot core of the trailing cable and trip the power center.

.

______________________________________________________________ A6474X440 REV 0 43

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

Spare circuit breakers - There are six (6) miniature circuit breakers located on the front of the swing panel. Four of these circuit breakers, two (2) 15A and two (2) 2.5A, are spares MCB19 and MCB20 - 5A miniature circuit breakers that serve as supplementary protection on the reverse lighting circuit.

Fig. 31: Controller - front wall ISBT

ETR

ISBIB

Ethernet switch

OPS

Spare Breakers (2) (15A)

MCB19

MCB20

Spare Breakers (2) (2.5A)

BRM BRE

PLM2

EL120

EL1100

L

RL

ESR

MMR

PTOL

PCT

________________________________________________________________ 44 CM445 Electrical

__________________________________________________ Controller Case Controller - Swing Panel (back)

The following components are mounted on the back of the controller swing panel: Power Supply - The power supply module converts a 110VAC input to 24VDC output for the control system.

Machine Controller - The machine controller is the central processor that stores the control system software.

I/O Module - The I/O module is a relay module that receives both digital and analog inputs and communicates them to the central processor.

Solenoid Module - The solenoid module communicates commands from the central processor to the machine solenoids.

Thermistor Module - The thermistor module communicates the RTD/ thermistor inputs (various temperature readings on the machine) to the central processor.

MMPS - power supply for the methane and water monitoring system.

Fig. 32: Controller - swing panel (rear)

Power supply

Machine controller

I/O Module

Thermistor module

Solenoid module

MMPS (location)

______________________________________________________________ A6474X440 REV 0 45

__________________________________________________________

BI001574 A6474X441 August 2012

Operation and Maintenance Manual CM445 Continuous Miner A6474X441 (Mechanical - Cutter)

SAFETY.CAT.COM

__________________________________________________________

This manual is intended to provide GENERAL product information for the CM445 Continuous Miner. 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 Continuous Miner was manufactured under the guidelines, procedures and requirements of the appropriate government regulatory agencies.

At the completion of the manufacturing process, this unit was issued the appropriate approval numbers and nameplates indicating it met the technical requirements of these regulatory agencies. Any change to the design or structure of this unit, without the consent of 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 Instructions ............................................................................. 4 Torque Values ................................................................................... 7 Component Weights .......................................................................... 9 Safety supports ................................................................................. 9 Cutter motor torque shaft .................................................................. 10 Cutter head (shear) cylinder .............................................................. 13 Cutter head (boom) assembly ........................................................... 18 Cutter motor clutch ............................................................................ 23 Cutter motor ...................................................................................... 26 Cutter drum, end (left or right) ........................................................... 30 Cutter drum, center ........................................................................... 34 Gear case .......................................................................................... 38

________________________________________________________________ A6474X441

REV 0

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.

!

DANGER

Do not make any type of temporary repairs to the trailing cable or trailing cable connections except as allowed by applicable regulatory agencies. Contact with high voltage power supply will result in severe injury or death from electrocution.

!

DANGER

Only qualified personnel are permitted to make repairs to permissible equipment. The permissibility of any permissible component must be verified after any maintenance or repair work and at regular intervals. Failure to maintain permissible components to OEM standard may result in a fire or explosion. Serious injury or death could occur.

!

!

!

!

!

!

!

WARNING Do not attempt to operate this continuous miner until you have been sufficiently trained on this machine and have read and understood this manual and are familiar with all controls and indicators. Operating this machine without the proper training and knowledge may result in serious injury or death to the operator or other personnel.

WARNING Federal law requires that temporary roof supports be in place before approaching the machine to reset a circuit breaker. Under no circumstances should personnel be under unsupported roof. Failure to follow these regulations may result in serious injury or death.

WARNING Only use the Emergency Stop Override to tram the miner away from the rib, releasing the accidentally pushed Machine Stop button. Never use the Emergency Stop Override when a Machine Stop switch has been activated by personnel. Failure to comply with this warning may lead to severe injury or death of personnel.

WARNING The Continuous Miner is radio remote controlled during production operations. Manual operation via machine mounted controls is not permitted for production operations.

Manual operation is for troubleshooting and maintenance under supported roof only.

Operating the Continuous Miner with manual or pendant controls under unsupported roof may result in sever injury or death.

WARNING Before performing maintenance or repair work on this machine, the circuit breaker must be in the “OFF” position and the trailing cable disconnected. Follow all applicable rules and regulations regarding the lockout/tagout procedures. Accidental machine movement or electrical shock may result in serious injury or death to the operator or other personnel.

WARNING Some procedures or test may require the cover of the electrical controller to be removed and some may require the controller to be energized during the procedure. Tall all necessary precautions to prevent electrical shock while working within the controller. An MSHA certified electrician must supervise and inspect all work.

WARNING Do not alter, bypass, or remove and emergency or machine stop device. Failure to heed this warning may result in serious injury or death.

________________________________________________________________ 4 CM445 Continuous Miner

_______________________________________________ Safety Instructions

!

!

!

!

WARNING Do not use an emergency or stop device as a means of disconnecting power to the miner. Whenever instructed to disconnect power, it is always meant to turn the main circuit breaker to the “OFF” position and to physically remove the trailing cable and lockout/tagout the machine. Failure to do so may result in serious injury or death.

WARNING Never disconnect a hydraulic hose if the circuit is pressurized or there is a load on the circuit. Pressurized hydraulic fluid or falling loads may result in serious injury or death.

WARNING Do not rely on load holding valves when working under the conveyor. Always block the cutter head and conveyor in the elevated position. Serious injury or death may occur if the cutter head or conveyor are not mechanically blocked.

WARNING Never work under any assembly or component of this machine that is elevated. Always install enough blocking to support the machine or component or lower the component to ground level.

!

WARNING You could be seriously injured or killed by falling loads. Observe the safe working load limits of all lifting and blocking devices and keep a safe distance from suspended loads.

!

WARNING Failure to follow all applicable lockout/tagout procedures may result in machine damage or serious injury or death of personnel.

______________________________________________________________ A6474X441 REV 0 5

Safety Instructions _______________________________________________ Introduction

The following general guidelines, in addition to specific procedural instructions, should be followed whenever performing maintenance on this machine.

The procedures for the removal and installation of components are for a typical machine and conditions. Tools available, work conditions, or other factors may require procedures to vary from those given.

Tools

It is the responsibility of the mine operator or the employee to provide the necessary tools required for routine maintenance. If a procedure requires a specialty tool or material, it will be identified in the procedure.

Illustrations

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.

Before Maintenance

Before performing maintenance on this machine, observe the following: 1. Shutdown the machine on level ground.

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

Follow all applicable lockout/tagout procedures.

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

4. 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.

Important Notes

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

2. Use only original spare parts when replacing components.

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

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

5. Always refer to the appropriate engineering drawing when replacing components.

________________________________________________________________ 6 CM445 Continuous Miner

___________________________________________________ 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

Grade 8 Imperial Bolts Torque Recommendations (calculated at 75% proof load) Bolt size Dry Lubricated (inches) ft-lbs ft-lbs 1/4 12 6 5/16 25 12 3/8

44

22

7/16

70

35

1/2

107

53

9/16

154

77

5/8 3/4

212 376

106 188

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 3

17794 23507

8897 11753

3-1/4

30286

15143

3-1/2

38266

19133

3-3/4

47545

23773

4

58100

29085

______________________________________________________________ A6474X441 REV 0 7

Torque Values ___________________________________________________ Metric Bolts Metric Bolts Torque Recommendations (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

________________________________________________________________ 8 CM445 Continuous Miner

______________________________________________ Component Weights Component Weights

Following are the approximate weights of the major components of the cutter head assembly. Be certain that adequate lifting and blocking is available whenever a component is being removed or installed as serious injury or death can result from falling loads. Never work under a component that is not adequately and correctly supported.

Component

Approximate Weight

Cutter head (shear) cylinder Cutter head (boom) assembly Cutter motor Cutter drum, end (left or right) Cutter drum, center (half) Cutter drum, center (whole) Cutter head gear case

625 lbs (283 kg) 46,500 lbs (21,092 kg) 2,300 lbs (1,043 kg) 1,277 lbs (579 kg) 1,036 lbs (470 kg) 2,072 lbs (940 kg) 5,100 lbs (2,313 kg)

Fig. 1: Cutter safety supports

Cutter safety support (storage location)

Cutter safety support (installed location)

______________________________________________________________ A6474X441 REV 0 9

Cutter Motor Torque Shaft _________________________________________ Introduction

The following procedure is for the removal and installation of the cutter motor torque shaft.

Tool Set

Basic Tool Set Slide Hammer Blocking

Safety

When removing or installing a cutter motor torque shaft, observe the following safety precautions:

!

!

Cutter Head Safety Support Lifting Device

WARNING Do not rely on load holding valves when working under the cutter head. Always block the cutter head in the elevated position. Serious injury or death may occur if the cutter head is not mechanically blocked.

WARNING Never work under any assembly or component of this machine that is elevated. Always install enough blocking to support the machine or component or lower the component to ground level.

!

WARNING You could be seriously injured or killed by falling loads. Observe the safe working load limits of all lifting and blocking devices and keep a safe distance from suspended loads.

!

WARNING Failure to follow all applicable lockout/tagout procedures may result in machine damage or serious injury or death of personnel.

!

WARNING Never disconnect a hydraulic hose if the circuit is pressurized or if there is a load on the circuit. If a hose is disconnected while the circuit is pressurized or under load, the load will fall. Machine damage or serious injury or death to personnel may result.

________________________________________________________________ 10 CM445 Continuous Miner

_________________________________________ Cutter Motor Torque Shaft Removal Procedure

To remove the cutter motor torque shaft (Fig. 2): 1. Raise the cutter head to a comfortable working height. Block it in this position under the support frame.

2. Disconnect and lockout the trailing cable. Follow all applicable regulations regarding lockout/tagout.

3. Remove the two (2) M12X20-10.9 socket head cap screws that secure the end cap to the clutch cover and remove the end cap.

4. Remove the six (6) 5/16-18X1-1/4 hex head bolts and 5/16 lock washers that secure the seal cap and remove the cap to access the shaft.

5. Remove the internal snap ring from the torque limiter and remove shims.

6. Insert a 5/8-11 puller bolt into the end of the torque shaft and remove the shaft.

Installation Procedure

To install the cutter motor torque shaft (Fig. 2): 1. Verify that power is removed from the miner and that the miner is locked/ tagged out.

2. Verify that the cutter head is securely blocked.

3. Grease the torque shaft with NGLI No. 2.5 white lithium grease.

4. Insert the torque shaft in the motor, making sure that the splines are engaged and that the shaft is fully seated.

5. Replace shims and then the internal snap ring. Measure the gap between the shims and the internal snap ring. Add or remove shims as needed to achieve a gap of 0.091 to 0.115 inches.

6. Install seal cap and secure with six (6) 5/16-18X1-1/4 hex head cap screws and six (6) 5/16 lock washers. Torque to 25 ft-lbs (dry).

7. Replace the clutch cover end cap and secure with two (2) M12X20-10.9 socket head cap screws and torque to 93 ft-lbs.

______________________________________________________________ A6474X441 REV 0 11

Cutter Motor Torque Shaft _________________________________________ Fig. 2: Cutter motor torque shaft removal and installation

7 6 3

4

5

1 2 1.

2.

3.

4.

5.

6.

7.

M12X20-10-9 socket head cap screw (2) Clutch cover end cap 5/16-18X1-1/4 hex head cap screw (6) 5/16 lock washer (6) Seal cap Shims Torque shaft

________________________________________________________________ 12 CM445 Continuous Miner

_______________________________________ Cutter Head (Shear) Cylinder Introduction

The following procedure is for the removal and installation of the cutter head (shear) cylinder.

Tool Set

Basic Tool Set Slide Hammer Lifting Device

Safety

When removing or installing a cutter head (shear) cylinder, observe the following safety precautions:

!

!

Cutter Head Safety Support Blocking Grease gun with Spec. 100-3 grease

WARNING Do not rely on load holding valves when working under the cutter head. Always block the cutter head in the elevated position. Serious injury or death may occur if the cutter head is not mechanically blocked.

WARNING Never work under any assembly or component of this machine that is elevated. Always install enough blocking to support the machine or component or lower the component to ground level.

!

WARNING You could be seriously injured or killed by falling loads. Observe the safe working load limits of all lifting and blocking devices and keep a safe distance from suspended loads.

!

WARNING Failure to follow all applicable lockout/tagout procedures may result in machine damage or serious injury or death of personnel.

!

WARNING Never disconnect a hydraulic hose if the circuit is pressurized or if there is a load on the circuit. If a hose is disconnected while the circuit is pressurized or under load, the load will fall. Machine damage or serious injury or death to personnel may result.

______________________________________________________________ A6474X441 REV 0 13

Cutter Head (Shear) Cylinder _______________________________________ Removal Procedure

Shear cylinder assembly removal and installation To remove a shear cylinder (Fig. 3): 1. Lower the gathering head until it touches the floor. Lower the conveyor tail section until it is even with the floor.

2. Raise the cutter head assembly and install the cutter boom safety supports (Fig. 6).

3. Disconnect and lockout the trailing cable. Follow all applicable lockout/ tagout procedures.

4. Attach a lifting device to the cylinder and take up slack so that the weight of the cylinder is supported by the lifting device.

5. Cycle the shear cylinder control lever several times to release hydraulic pressure.

6. Remove the shear cylinder frame mounting pin: a. Open the front rub rail. b. Remove the four (4) M20 hex head cap screws that secure the two side covers and remove the covers to allow access to the rod mounting pin retainer plate. c.

Remove the two (2) M20X45-8.8 hex head cap screws and M20 lock washers that secure the pin keeper plate and remove the keeper plate.

d. Disconnect and cap the grease line going to the pin. e. Remove the grease fitting adapter from the end of the pin. f.

Insert a slide hammer into the treaded hole (M24X3.0) in the end of the pin and pull the pin.

8. Connect the trailing cable to energize the machine.

9. Start the pump motor.

10. Retract the shear cylinder to pull the rod bearing free from the mounting clevis.

11. Disconnect and lockout the trailing cable. Follow all applicable lockout/ tagout procedures.

12. Cycle the shear cylinder several time to release hydraulic pressure.

13. Disconnect, tag, and cap the hydraulic lines to the cylinder.

14. Block the cylinder so that it will not move when the boom clevis pin is removed.

________________________________________________________________ 14 CM445 Continuous Miner

_______________________________________ Cutter Head (Shear) Cylinder 15. Remove the shear cylinder boom clevis pin. a. Remove the two (2) M20X60-8.8 screws and M20 lock washers that secure the cylinder pin keeper plate. b. Remove the grease fitting adapter from the end of the pin. c.

Installation Procedure

Insert a slide hammer into the treaded hole in the end of the pin and pull the pin.

To install a shear cylinder (Fig. 3): 1. Attach an appropriate lifting device to the shear cylinder and position the cylinder so that the cylinder clevis is aligned in the mounting clevis on the cutter head.

2. Install the boom clevis pin. a. Install the pin from the inside, toward the outside, of the machine with the threaded hole end of the pin toward the outside of the machine.

Note: The pin should be inserted so that it’s retaining channel remains outside the bushing. b. Insert the pin keeper plate and secure with two (2) M20X60-8.8 socket head cap screws and M20 lock washers. c.

Install the grease fitting into the end of the pin.

3. Attach the hydraulic hoses to the cylinder.

4. Connect the trailing cable to energize the machine.

5. Slowly extend the shear cylinder so that the rod clevis can be inserted into the frame mounting clevis.

6. Disconnect and lockout the trailing cable. Follow all applicable lockout/ tagout procedures.

7. Install the frame clevis pin. a. Install the pin from the inside, toward the outside, of the machine so that the threaded hole end is toward the outside of the machine. Note: The pin should be inserted so that it’s retaining channel remains outside the bushing. b. Insert the pin keeper plate and secure with two (2) socket head cap screws and lock washers. c.

Install the grease fitting into the end of the pin.

d. Attach the grease line to the grease fitting in the pin.

8. Close and secure the front covers.

______________________________________________________________ A6474X441 REV 0 15

Cutter Head (Shear) Cylinder _______________________________________ 9. Grease the pins with Spec. 100-3 grease.

10. Check the hydraulic oil level and add Spec. 100-1 oil as needed.

11. Connect the trailing cable to energize the machine.

12. Start the pump motor.

13. Remove the cutter head safety support and all blocking.

14. Raise and lower the cutter head to check for correct cylinder function.

________________________________________________________________ 16 CM445 Continuous Miner

_______________________________________ Cutter Head (Shear) Cylinder Fig. 3: Cutter head (shear) cylinder removal and installation

11

12

4

10

9

2 1

6 5 3 8

7

1. Cap screw (4) 2. Washer (4) 3. Frame mounting pin 4. Shear cylinder 5. Rub rail 6. Side cover 7. M20X45-8.8 hex head cap screw (2) 8. Pin keeper 9. M20X60-8.8 ?type screw (2) 10. M20 washer (2) 11. Pin keeper 12. Boom clevis mounting pin

______________________________________________________________ A6474X441 REV 0 17

Cutter Head (Boom) Assembly ______________________________________ Introduction

The following procedure is for the removal and installation of the cutter head (boom) assembly.

Tool Set

Basic Tool Set Slide Hammer

Safety

When removing or installing the cutter head (boom) assembly, observe the following safety precautions:

!

!

Blocking Grease gun with Spec. 100-3 grease

WARNING Do not rely on load holding valves when working under the cutter head. Always block the cutter head in the elevated position. Serious injury or death may occur if the cutter head is not mechanically blocked.

WARNING Never work under any assembly or component of this machine that is elevated. Always install enough blocking to support the machine or component or lower the component to ground level.

!

WARNING You could be seriously injured or killed by falling loads. Observe the safe working load limits of all lifting and blocking devices and keep a safe distance from suspended loads.

!

WARNING Failure to follow all applicable lockout/tagout procedures may result in machine damage or serious injury or death of personnel.

!

WARNING Never disconnect a hydraulic hose if the circuit is pressurized or if there is a load on the circuit. If a hose is disconnected while the circuit is pressurized or under load, the load will fall. Machine damage or serious injury or death to personnel may result.

________________________________________________________________ 18 CM445 Continuous Miner

_____________________________________ Cutter Head (Boom) Assembly Removal Procedure

To remove the cutter head assembly (Fig. 4): 1. Lower the gathering head to the floor.

2. Raise the cutter head to allow access to the upper cutter head (shear) cylinder mounting pin. Securely block the cutter head.

3. Disconnect and lock out the electrical power to the miner. Follow all applicable regulations regarding lockout/tagout procedures.

4. Turn off the water supply to the machine.

5. Remove the motor access covers (left and right) by removing the bolts that secure the covers to the cutter head frame.

6. Disconnect and tag the power cables from both cutter motors. Be sure to tape the power cables as power will be restored to the machine.

7. Disconnect, tag, and cap the water hoses from both cutter motors 8. Disconnect the water hoses to the dust suppression sprays.

9. Remove the two (2) boom pivot pins. a. Remove the two (2) 5/8-11X2-1/2 socket head cap screws from the retaining plate on the right and left pivot pins and remove the retaining plate. b. On either side, force the main pivot pin inward from the outboard side, using the two (2) 1-8X1-1/2 puller holes, if necessary.

10. Connect electrical power to the machine.

11. Extend the shear cylinders to push the boom pivots out of their tractor frame clevises.

12. Block the boom and shear cylinders to keep them stationary during pin removal.

13. Disconnect and lock out the electrical power to the miner. Follow all applicable regulations regarding lockout/tagout procedures.

14. Remove the shear cylinder boom clevis pins. a. Remove the two (2) M20X60-8.8 cap screws and M20lock washers that secure the cylinder pin keeper plates on each side of the machine. b. Insert a slide hammer into the treaded hole in the end of the pin and remove the pin from each side of the machine.

15. Connect electrical power to the machine.

16. Retract the shear cylinders to pull their clevises free from the boom clevises.

17. Disconnect, tag, and cap the hydraulic lines from the shear cylinders and the boom.

______________________________________________________________ A6474X441 REV 0 19

Cutter Head (Boom) Assembly ______________________________________ 18. Raise the rear of the boom assembly until it is above the top edge of the gathering head backboard.

19. Slowly tram the machine backwards until the cutter boom pivot points clear the front of the gathering head.

Installation Procedure

To install the cutter head (boom) assembly (Fig. 4): 1. Slowly tram the machine forward towards the raised end of the boom until the pivot pins clear the gathering head backboard.

2. Lower the boom pivot points until the shear cylinders can reach their clevises. Block the boom to keep it in a secure position.

3. Reconnect the hydraulic lines.

4. Extend the shear cylinders until the cylinder clevis can be inserted into the cutter boom clevises.

5. Disconnect and lock out the electrical power to the miner. Follow all applicable regulations regarding lockout/tagout procedures.

6. Align the boom clevis and the cylinder clevis and insert the shear cylinder boom clevis pin.

!

WARNING Do not use your fingers to check the alignment of the rod bearing in the clevis. Shifting of the parts could result in serious injury.

7. Insert the keeper plate and secure to the boom clevis with the two (2) M20X45-8.8 hex head cap screws and M20 lock washers.

8. Repeat steps 5 and 6 for the other shear cylinder.

9. Connect electrical power to the machine.

10. Once the shear cylinders are secured to the cutter boom remove the boom blocking to allow boom movement.

11. Retract the shear cylinders to pull the cutter boom pivot points into position in the tractor frame boom pivot clevises.

Note: In addition to the shear cylinders, the stabilizer and gathering head can be used to adjust the cutter boom’s position to allow easier installation of the cutter boom pivot pins.

12. Install both cutter boom pivot pins. a. Insert the main pivot pin from the inside toward the outboard side of the clevis. b. Insert the retainer plate and secure with the two (2) 5/8-11X2-1/2 socket head cap screws.

________________________________________________________________ 20 CM445 Continuous Miner

_____________________________________ Cutter Head (Boom) Assembly 13. Disconnect and lock out the electrical power to the miner. Follow all applicable regulations regarding lockout/tagout procedures.

14. Connect the power cables and water cables to the cutter motors (see Cutter motor installation procedure in this chapter).

15. Connect the water hoses to the dust suppression sprays.

16. Connect all hydraulic and lubrication hoses.

17. Grease all pins with Spec. 100-3 grease.

18. Check the hydraulic oil level and add Spec. 100-1 oil as required.

19. Connect electrical power to the machine.

______________________________________________________________ A6474X441 REV 0 21

Cutter Head (Boom) Assembly ______________________________________ Fig. 4: Cutter head (boom) assembly removal and installation

3

2

1

9 7 8

6 5

1.

2.

3.

4.

5.

6.

7.

8.

9.

4

Boom pivot pin (2) 5/8-11X2-1/2 (2 each pin) Pin retainer (2) M20X60-8.8 (2 each keeper) M20 lock washer (2 each keeper) Cylinder boom clevis pin (2) Pin keeper (2) Shear cylinder (2) Motor access cover (2)

________________________________________________________________ 22 CM445 Continuous Miner

______________________________________________ Cutter Motor Clutch Introduction

The following procedure is for the removal and installation cutter motor clutch.

Tool Set

Basic Tool Set Blocking Snap Ring Pliers

Safety

When removing or installing the cutter motor clutch, observe the following safety precautions:

!

WARNING Never work under any assembly or component of this machine that is elevated. Always install enough blocking to support the machine or component or lower the component to ground level.

!

WARNING You could be seriously injured or killed by falling loads. Observe the safe working load limits of all lifting and blocking devices and keep a safe distance from suspended loads.

!

WARNING Failure to follow all applicable lockout/tagout procedures may result in machine damage or serious injury or death of personnel.

______________________________________________________________ A6474X441 REV 0 23

Cutter Motor Clutch _______________________________________________ Removal Procedure

To remove the cutter motor clutch (Fig. 5): 1. Raise the cutter head to a comfortable working height and block it in this position under the support frame.

2. Disconnect and lockout the trailing cable. Follow all applicable regulations regarding lockout/ tagout procedures.

3. Remove the eight (8) 5/8-11X1-3/4 hex head bolts and 5/8 washers that secure the clutch cover to the motor and remove clutch cover.

4. Remove the torque shaft (see Torque shaft removal procedure).

5. Split the clutch by removing the bolts.

6. Remove the clutch retaining nut.

7. Remove the rear half of the clutch.

Installation Procedure

To install the cutter motor clutch (Fig. 5): 1. Ensure that power is removed from the machine and that the trailing cable is locked out.

2. Ensure that the cutter head is securely blocked.

3. Install the rear half of the clutch.

4. Install the clutch retaining nut.

5. Install the bolts that secure the two halves of the clutch together. NOTE: You must follow the manufacturer’s torque specifications when installing these bolts. The instructions are supplied with each new clutch assembly.

6. Install the torque shaft (see Torque shaft installation procedure).

7. Install the clutch cover and secure with the eight (8) 5/8-11X1-3/4 hex head bolts and 5/8 washer..

________________________________________________________________ 24 CM445 Continuous Miner

______________________________________________ Cutter Motor Clutch Fig. 5: Cutter motor clutch removal and installation

5 6

12 13

11 13 1 2

1. M12X20-10.9 socket head cap screw (2) 2. Motor end cap 3. 5/8-11X1-3/4 hex head cap screw (8) 4. 5/8 lock washer (8) 5. Clutch cover 6. Seal (behind clutch cover) 7. Shims 8. Clutch retaining nut 9. 5/16-18X1-1/4 socket head cap screw (6) 10. 5/16 lock washer (6) 11. Seal cap 12. Snap ring 13. Torque shaft 14. Clutch half

3

4

7 9

8

10

______________________________________________________________ A6474X441 REV 0 25

Cutter Motor _____________________________________________________ Introduction

The following procedure is for the removal and installation of a cutter motor.

Tool Set

Basic Tool Set Lifting Device

Safety

When removing or installing a cutter motor, observe the following safety precautions:

!

Blocking

WARNING Never work under any assembly or component of this machine that is elevated. Always install enough blocking to support the machine or component or lower the component to ground level.

!

WARNING You could be seriously injured or killed by falling loads. Observe the safe working load limits of all lifting and blocking devices and keep a safe distance from suspended loads.

!

WARNING Failure to follow all applicable lockout/tagout procedures may result in machine damage or serious injury or death of personnel.

________________________________________________________________ 26 CM445 Continuous Miner

____________________________________________________ Cutter Motor Removal Procedure

To remove the cutter drum drive motor (Fig. 6): 1. Raise the cutter head to a comfortable working height. Block it in this position under the support frame.

2. Disconnect and lockout the trailing cable. Follow all applicable regulations regarding lockout/tagout.

3. Remove the hex head capscrews that secure the side motor cover and remove the cover to expose the side of the motor and the motor’s junction box.

4. Remove the hex head capscrews that secure the junction box cover and then remove the cover.

5. Locate the three (3) power lug connections and tag the lugs for correct reconnection. Remove the hex head capscrews that secure the three power cable lugs to the three motor lugs.

6. Remove the socket head capscrews that secure the global plug to the junction box.

7. Slide the global plug out of the junction box. At this point, the power cable should be completely disconnected from the motor.

!

WARNING Power should not be reconnected to the miner while the motor power cable is disconnected. Damage to the miner or personal injury or death could result.

8. To prevent damage to the motor power cable lugs and gland assembly, cover the power cable and secure it to the miner in a safe location.

9. Disconnect, tag, and cap the two (2) water hoses from the motor cooling water fittings. Remove the two water fittings from the motor and store for reuse during installation. Plug the motor cooling water ports to prevent contamination.

10. Disconnect, tag, and cap the motor bearing grease lines.

11. Securely block the motor so that it will not fall when the mounting bolts are removed.

12. Remove the torque shaft (see Torque shaft removal procedure).

13. Remove the four (4) 1-1/4-7X9 hex head cap screws and elastic lock nuts that secure the motor to the frame.

14. Carefully lower the motor out of the frame.

______________________________________________________________ A6474X441 REV 0 27

Cutter Motor _____________________________________________________ Installation Procedure

To install the cutter drum drive motor (Fig. 6):

!

WARNING MSHA requires that mining equipment electrical components be inspected by a certified electrician before the equipment can be operated.

!

WARNING This procedure involves attaching an electrical power cable to a motor. The trailing cable must be disconnected and locked and tagged out to safely perform this operation.

1. Block cutter motor in position against the rear of the boom so that the motor’s mounting holes align with the boom’s motor mounting holes.

2. Insert the four (4) 1-1/4-7X9 hex head mounting bolts and elastic lock nuts to secure the motor to the boom and torque to 1924 ft-lbs.

3. Install the two motor cooling water fittings into the cooling water ports on the motor.

4. Attach the cooling water hoses to the fittings.

5. Remove the four (4) hex head capscrews that secure the junction box cover and remove the cover.

6. Insert the three lugs of the power cable (with gland and stuffing box already installed) into the motor’s junction box.

7. Tighten the two socket head capscrews to secure the gland to the junction box.

8. Inside the junction box, locate the three motor power lug connections.

Match the motor lugs with the corresponding power cable lugs.

9. Attach the first motor lug to its corresponding power cable lug by inserting a hex head capscrew through the motor lug, the power cable lug, a flat washer, and a lock washer. Secure the capscrew with a hex nut. Repeat for the other two lugs.

10. When all three connections have been secured, wrap each of the three connections with a layer of rubber tape, then a layer of black tape, and then a layer of glass tape.

11. Connect electrical power to the machine and verify correct phasing. If necessary, rewire to obtain correct rotation 12. Disconnect and lockout the trailing cable. Follow all applicable regulations regarding lockout/tagout.

13. Replace the junction box o-ring and cover and secure with the four hex head capscrews.

14. Attach the grease lines to the grease fittings on the motor.

15. Install the torque shaft (see Torque shaft installation procedure)..

________________________________________________________________ 28 CM445 Continuous Miner

____________________________________________________ Cutter Motor Fig. 6: Cutter motor removal and installation

3

12 13

11

2

10

4

1 9 8 5

6

7

1. MX12X20-10.9 socket head cap screw (2) 2. Clutch cover end cap 3. 1-1/4-7 elastic stop nut 94) 4. Motor 5. 5/16-18X1-1/4 socket head cap screw (6) 6. 5/16 lock washer (6) 7. Seal cap 8. Shims 9. Clutch retaining nut 10. Torque shaft 11. Junction box 12. Side cover 13. 1-1/4-7X9 hex head cap screw (4)

______________________________________________________________ A6474X441 REV 0 29

Cutter End Drum _________________________________________________ Introduction

Tool Set Safety

!

The following procedure is for the removal and installation of a cutter end drum.

The procedure is the same for the right and the left drums.

Basic Tool Set Torque Wrench

Blocking

When removing or installing a cutter end drum, observe the following safety precautions:

WARNING Never work under any assembly or component of this machine that is elevated. Always install enough blocking to support the machine or component or lower the component to ground level.

!

WARNING You could be seriously injured or killed by falling loads. Observe the safe working load limits of all lifting and blocking devices and keep a safe distance from suspended loads.

!

WARNING Failure to follow all applicable lockout/tagout procedures may result in machine damage or serious injury or death of personnel.

________________________________________________________________ 30 CM445 Continuous Miner

_________________________________________________ Cutter End Drum Removal Procedure

To remove an end drum (Fig. 7): 1. Place the miner so that the cutting head is easily accessible and there is side clearance to pull the end drum off of the cutting head.

2. Disconnect and lockout the trailing cable. Follow all applicable regulations regarding lockout/tagout procedures.

3. There may be an optional cap on the end of the drum. If the end cap is present, remove the eight (8) 7/8-9X2-1/2 socket head cap screws that secure it to the drum. Apply heat as necessary to liquify Loctite used when the cap screws were installed.

4. Using the four puller holes in the end cap and four of the eight socket head screw just removed, remove the end cap. Note: If the assembly is seized, it may be necessary to pry on the edges. Care must be taken not to damage the o-ring or its seal land.

5. Attach a lifting device to the end drum and apply tension so that the weight of the drum is supported by the lifting device.

6. Loosen the eighteen (18) 1-8X2-3/4 socket head cap screws that secure the drum to the cutting head hub.

7. Match mark both the end drum and the cutting head hub so that the cutting bit arrangement is not disturbed upon reassembly.

8. Remove the weld securing each key to the end drum and remove the keys.

9. Slowly pull the end drum off of the main assembly, maneuvering it away from the miner.

______________________________________________________________ A6474X441 REV 0 31

Cutter End Drum _________________________________________________ Installation Procedure

To install an end drum (Fig. 7) 1. Verify that power is disconnected and that the trailing cable is properly locked and tagged out. Follow all Mine, State, and Federal lockout/tagout procedures.

2. Attach a lifting device to the end drum.

3. Using the match marks made when the end drum was removed, align the end drum and the cutting head hub.

4. Install the two (2) keys and weld keys to end drum (reference drawing 397038).

5. Install the eighteen (18) 1-8X2-3/4 socket head cap screws to secure the drum to the cutting head hub and torque to 595ft-lbs.

6. Coat the threads of the eight (8) 7/8-9X2-1/2 socket head cap screws with Loctite 242 (blue) and install the eight socket head cap screws to secure the end cap and torque to 490 ft-lbs.

________________________________________________________________ 32 CM445 Continuous Miner

_________________________________________________ Cutter End Drum Fig. 7: Cutter end drum removal and installation

5

6

4

1

3 2

1.

2.

3.

4.

5.

6.

Socket head cap screw, 7/8-9X2-1/2 (8) End cap O-ring End drum Key (2) 3/4-10X1 cup point set screw (2 per key)

______________________________________________________________ A6474X441 REV 0 33

Cutter Center Drum _______________________________________________ Introduction

The following procedure is for the removal and installation of the cutter center drum.

Tool Set

Basic Tool Set Torque Wrench

Safety

When removing or installing the cutter center drum, observe the following safety precautions:

!

WARNING Never work under any assembly or component of this machine that is elevated. Always install enough blocking to support the machine or component or lower the component to ground level.

!

WARNING You could be seriously injured or killed by falling loads. Observe the safe working load limits of all lifting and blocking devices and keep a safe distance from suspended loads.

!

WARNING Failure to follow all applicable lockout/tagout procedures may result in machine damage or serious injury or death of personnel.

________________________________________________________________ 34 CM445 Continuous Miner

_______________________________________________ Cutter Center Drum Removal Procedure

To remove the center cutter drum (Fig. 9): 1. Lower the gathering head assembly to the floor.

2. Slowly rotate the cutter head until on of the center drum seams appears directly in front and one appears directly in the rear of the cutter head.

3. Lower the cutter head assembly until it is resting on the floor.

4. Disconnect and lockout the trailing cable. Follow all applicable regulations regarding lockout/tagout procedures.

5. Remove the twenty-four (24) 1-8X6-1/2 hex head bolts that secure the two halves of the center drum to each other. Make sure to collect the bolts, the forty-eight (48) flat washers, and the twenty-four 1-8 lock nuts for use in reassembly.

6. Attach a lifting device to the top half of the center drum and lift the it off of the assembly. It may be necessary to use a pry bar or other force to break the seal between the top and bottom halves of the center drum before the top half can be lifted off.

7. Remove the four (4) alignment keys from the bottom half of the center drum and store for use in reassembly.

8. Connect the trailing cable to energize the machine.

9. Slowly raise the cutter head assembly until it is clear of the bottom half of the center drum.

10. Slowly tram the miner backwards away from the bottom half of the center drum.

______________________________________________________________ A6474X441 REV 0 35

Cutter Center Drum _______________________________________________ Installation Procedure

To install the center cutter drum (Fig. 9 1. Place the four (4) alignment keys into the keyway slots around the outer edges of the bottom half of the center drum.

2. Slowly tram the miner into position so that the cutter head assembly is position over the bottom half of the center drum.

3. Slowly rotate the cutter head until the center drum drive keys are positioned directly on top and bottom of the cutter head assembly.

4. Slowly lower the cutter head assembly onto the bottom half of the center drum.

5. Disconnect and lockout the trailing cable. Follow all applicable regulations regarding lockout/tagout procedures.

6. Attach a lifting device to the upper half of the center drum.

7. Lower the upper half of the center drum onto the cutter head assembly, making sure that the keyways align with the keys on the bottom half.

8. Check that the upper half of the center drum is fully seated on the bottom half. Using a rod, check the bolt holes for alignment. Adjust the position of the upper half of the center drum as necessary to align the bolt holes.

9. Install the twenty-four (24) 1-8X6/12 hex head bolts that secure the two halves of the center drum to each other, placing a flat washer under the head of the bolt and between the bolt and the nut. Install the bolt heads in the direction of rotation, if lacing permits.

10. Torque the bolts to 595 ft-lbs using the pattern shown in Fig. 8.

Fig. 8: Center drum bolt torque pattern

________________________________________________________________ 36 CM445 Continuous Miner

_______________________________________________ Cutter Center Drum Fig. 9: Cutter center drum removal and installation

1

2

3

1.

2.

3.

4.

Lock nut, 1-8 (24) Alignment key (4) Hex head bolt, 1-8X6/12 (24) Flat washer, 1 inch (48) (not shown)

______________________________________________________________ A6474X441 REV 0 37

Cutter Gear Case _________________________________________________ Introduction

The following procedure is for the removal and installation of the cutter gear case. The cutter head gear case may be removed with cutter drum installed but it is easier with it removed.

Tool Set

Basic Tool Set Torque Wrench

Safety

When removing or installing the cutter gear case, observe the following safety precautions:

!

Blocking

WARNING Never work under any assembly or component of this machine that is elevated. Always install enough blocking to support the machine or component or lower the component to ground level.

!

WARNING You could be seriously injured or killed by falling loads. Observe the safe working load limits of all lifting and blocking devices and keep a safe distance from suspended loads.

!

WARNING Failure to follow all applicable lockout/tagout procedures may result in machine damage or serious injury or death of personnel.

________________________________________________________________ 38 CM445 Continuous Miner

_________________________________________________ Cutter Gear Case Removal Procedure To remove the cutter drum drive gear case (Fig. 10): 1. Remove the cutter head center drum (see Cutter center drum removal procedure in this manual).

2. Remove the cutter head end drums (see Cutter end drum removal procedure in this chapter).

3. Ensure that the cutter head assembly is adequately blocked.

4. Securely block the cutter head gear case so that it will not fall when it is unbolted from the frame.

!

WARNING During the removal of the cap screws that secure the gear case to the frame, it may be necessary to adjust the blocking under the gear case. Ensure that the gear case is securely blocked at all times and that it does not shift as it is unbolted.

5. Carefully loosen and remove the forty (40) 1-1/4 hex head cap screws that secure the cutter head gear case to the cutter head support frame.

6. Connect the trailing cable to energize the miner.

7. Slowly tram the miner away from the gear case.

!

CAUTION

Use care when tramming the miner away from the gear case. While each cutter motor is supported by a bracket at the rear of the motor, excessive bumping could cause the motor to fall.

______________________________________________________________ A6474X441 REV 0 39

Cutter Gear Case _________________________________________________ Installation Procedure

To install the cutter drum drive gear case (Fig. 10): 1. Ensure that the gear case is securely blocked so that the miner can be trammed into position behind it.

2. Slowly tram the miner into position behind the gear box.

3. Disconnect and lockout the trailing cable. Follow all applicable regulations regarding lockout/tagout procedures.

4. Using a metal rod, check for alignment between the mounting holes on the miner and the mounting holes in the gear case.

5. Install the forty 1-1/4 hex head cap screws that secure the gear case to the miner. Torque to 1924 ft-lbs.

6. Install the end drums (see Cutter end drum installation procedure in this manual).

7. Install the center drum (see Cutter center drum installation procedure in this manual).

________________________________________________________________ 40 CM445 Continuous Miner

_________________________________________________ Cutter Gear Case Fig. 10: Cutter gear case removal and installation

Spray block location

Bolt (40) Washer (40)

______________________________________________________________ A6474X441 REV 0 41

_______________________________________________________________

________________________________________________________________ 42 CM445 Continuous Miner