CAT CM445 Continuous Miner Operation and Maintenance Manual BI016891

BI016891-03 (EN-US) A6474X367 January 2015

Operation and Maintenance Manual CM445 Continuous Miner A6474X367 (Mechanical - Cutter) Serial Number GE500796, GE500797, GE500800, GE500806, GE500812

SAFETY.CAT.COM

BI016891-03 (EN-US)

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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 manuf actured 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 saf e 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 2013 ALL RIGHTS RESERVED

BI016891-03 (EN-US)

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Table of contents Saf ety Instructions...................................................................4 Torque Values ........................................................................7 Component Weights ................................................................9 Cutter motor torque shaft..........................................................10 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

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Safety Instructions______________________________________________ Safety Precautions

The following saf ety 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.

Do not attempt to operate this continuous miner until you have been sufficiently trained ! WARNING 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.

Follow all applicable laws requiring temporary roof supports be in place before ap! WARNING proaching 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.

Only use the Emergency Stop Override to tram the miner away from the rib, releasing the ! WARNING 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.

The Continuous Miner is radio remote controlled during production operations. Manual ! WARNING 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.

Before performing maintenance or repair work on this machine, the circuit breaker must ! WARNING 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.

Some procedures or test may require the cover of the electrical controller to be removed ! WARNING 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. All electrical work must be supervised and inspected by an electrician with the proper certifications required by local regulations.

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

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______________________________________________ Safety Instructions Do not use an emergency or stop device as a means of disconnecting power to the min! WARNING er. 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.

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

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

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

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

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

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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 f rom 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 identif ied in the procedure.

Safety Supports

There are two cutter boom saf ety supports (Fig. 1), one on each side of the cutter boom (Right Support Part No. DBT619343; Left Support Part No. DBT619342). The supports are used to block up the cutter boom during maintenance and service operations.

Raised, elevated, and unsecured equipment must be securely blocked to prevent move! WARNING ment before miners position themselves under or between movable components of the equipment.

Before installing safety supports, lower the gathering head to the ground or onto an Illustrations ! WARNING appropriate support.

Before Maintenance

The illustrations used in this manual are for a typical machine and may vary f rom your machine. If repair work is required, always ref er to the specif ic drawing in the parts book supplied with your machine.

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 an electrician with the proper certifications required by local regulations.

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

5. Always ref er to the appropriate engineering drawing when replacing compo______________________________________________________________ nents.

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______________________________________________ Safety Instructions Fig. 1: Cutter head safety supports

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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 5/8 212 106 3/4 376 188 7/8 606 303 1 909 454 1-1/8 1287 644 1-1/4 1875 938 1-3/8 2382 1191 1-1/2 3161 1581 1-3/4 4988 2494 2 7500 3750 2-1/4 10969 5484 2-1/2 15000 7500 2-3/4 17794 8897 3 23507 11753 3-1/4 30286 15143 3-1/2 38266 19133 3-3/4 47545 23773 4 58100 29085

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__________________________________________________ Torque Values Metric Bolts Metric Bolts Torque Recommendations (calculated at 75% proof load)

Property Class 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 M7 X 1.00 M8 X 1.25 M10 X 1.50 M12 X 1.75 M14 X 2.00 M16 X 2.00 M18 X 2.50 M20 X 2.50 M22 X 2.50 M24 X 3.00 M27 X 3.00 M30 X 3.50 M33 X 3.50 M36 X 4.00

(54) (92) (156) (2250 37 65 104 161 222 314 428 543 796 1079 1468 1886

(41) (69) (116) (169) 28 49 78 121 167 235 321 407 597 809 1101 1415

(78) (133) (222) (333) 53 93 148 230 318 449 613 776 1139 1543 2101 2699

(59) (99) (167) (242) 40 69 111 172 238 337 460 582 854 1158 1576 2024

(91) (156) (260) (377) 62 108 173 269 372 525 716 908 1331 1804 2455 3154

(68) (116) (195) (284) 47 81 130 202 279 394 537 681 998 1353 1842 2366

8.8

10.9

12.9

M6 - M16: 800 M20 - M30: 830

1040

1220

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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 f rom 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 (w hole) 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)

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________________________________________ 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

Cutter Head Saf ety Support Lif ting Device

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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 f rame.

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 f rom 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 f rom 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.

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________________________________________ Cutter Motor Torque Shaft Fig. 2: Cutter motor torque shaft removal and installation

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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

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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

Blocking Grease gun with Spec. 100-3 grease

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____________________________________ Cutter Head (Boom) Assembly Removal Procedure

To remove the cutter head assembly (Fig. 3): 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 f rame.

6. Disconnect and tag the power cables f rom 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 f rom 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 f rame 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 f rom 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.

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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. 3): 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.

Do not use your fingers to check the alignment of the rod bearing in the clevis. Shifting ! WARNING 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 f rame 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 f rom 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.

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____________________________________ 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.

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Cutter Head (Boom) Assembly ____________________________________ Fig. 3: Cutter head (boom) assembly removal and installation 1 2 3

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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)

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_____________________________________________ 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

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Cutter Motor Clutch _____________________________________________ Removal Procedure

To remove the cutter motor clutch (Fig. 4): 1. Raise the cutter head to a comfortable working height and block it in this position under the support f rame.

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. 4): 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..

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_____________________________________________ Cutter Motor Clutch Fig. 4: Cutter motor clutch removal and installation

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6

4 3

1 2

10

13

12 8

9 7

16

14 15

11

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 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. Socket head cap screw (6) 15. Clutch half 16. Clutch half

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Cutter Motor ___________________________________________________ Introduction

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

Tool Set

Basic Tool Set Lif ting Device

Blocking

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___________________________________________________ Cutter Motor Removal Procedure

To remove the cutter drum drive motor (Fig. 5): 1. Raise the cutter head to a comfortable working height. Block it in this position under the support f rame.

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 f rom the motor.

Power should not be reconnected to the miner while the motor power cable is discon! WARNING nected. 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 saf e location.

9. Disconnect, tag, and cap the two (2) water hoses f rom the motor cooling water fittings. Remove the two water f ittings f rom 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 f all 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 f rame.

14. Caref ully lower the motor out of the f rame.

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Cutter Motor ___________________________________________________ Installation Procedure

To install the cutter drum drive motor (Fig. 5):

All electrical work must be supervised and inspected by an electrician with the proper ! WARNING certifications required by local regulations.

This procedure involves attaching an electrical power cable to a motor. The trailing ca! WARNING ble 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 f ittings into the cooling water ports on the motor.

4. Attach the cooling water hoses to the f ittings.

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)..

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___________________________________________________ Cutter Motor Fig. 5: Cutter motor removal and installation 13

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8

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10

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)

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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.

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________________________________________________Cutter End Drum Removal Procedure

To remove an end drum (Fig. 6): 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 f rom the miner.

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Cutter End Drum _______________________________________________ Installation Procedure

To install an end drum (Fig. 6) 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.

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________________________________________________Cutter End Drum Fig. 6: Cutter end drum removal and installation

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3 1

1.

2.

3.

4.

5.

6.

7.

2

Socket head cap screw, 7/8-9X2-1/2 (8) End cap O-ring Cap screw, 1-8X2-3/4 (18) End drum Key (2) 3/4-10X1 cup point set screw (2 per key)

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Cutter Center Drum _____________________________________________ Introduction

Tool Set

The following procedure is for the removal and installation of the cutter center drum.

Basic Tool Set Torque Wrench

______________________________________________________________ 30 CM445 Continuous Miner

BI016891-03 (EN-US)

_____________________________________________ Cutter Center Drum Removal Procedure

To remove the center cutter drum (Fig. 8): 1. Lower the gathering head assembly to the f loor.

2. Slowly rotate the cutter head until on of the center drum seams appears directly in f ront and one appears directly in the rear of the cutter head.

3. Lower the cutter head assembly until it is resting on the f loor.

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 f rom 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.

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Cutter Center Drum _____________________________________________ Installation Procedure

To install the center cutter drum (Fig. 8): 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. 7.

Fig. 7: Center drum bolt torque pattern

______________________________________________________________ 32 CM445 Continuous Miner

BI016891-03 (EN-US)

_____________________________________________ Cutter Center Drum Fig. 8: 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)

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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

Blocking

______________________________________________________________ 34 CM445 Continuous Miner

BI016891-03 (EN-US)

_______________________________________________ Cutter Gear Case Removal Procedure

To remove the cutter drum drive gear case (Fig. 9): 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 f all when it is unbolted f rom 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. Caref ully 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 f rame.

6. Connect the trailing cable to energize the miner.

7. Slowly tram the miner away f rom the gear case.

Use care when tramming the miner away from the gear case. While each cutter motor is ! WARNING supported by a bracket at the rear of the motor, excessive bumping could cause the motor to fall.

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Cutter Gear Case _______________________________________________ Installation Procedure

To install the cutter drum drive gear case (Fig. 9): 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).

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BI016891-03 (EN-US)

_______________________________________________ Cutter Gear Case Fig. 9: Cutter gear case removal and installation

Spray block location

Washer (40)

Bolt (40)

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