CAT HW300 Highwall Miner Operation and Maintenance Manual SN HWM00174 - PDF DOWNLOAD

BI644112-00 (EN-US) February 2016

Operation and Maintenance Manual HW300 Highwall Miner Serial Number HWM00174

SAFETY.CAT.COM

BI644112-00 (EN-US)

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California Proposition 65 Warning This product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

Battery posts, terminals and related accessories contain lead and lead compounds.

Wash hands after handling.

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Literature Information This manual should be read carefully before using this product for the first time and before performing maintenance. This manual should be stored in the product literature holder or in the product literature storage area. Immediately replace this manual if lost, damaged, or unreadable. This manual may contain safety information, operation instructions, transportation information, lubrication information, and maintenance information. Some photographs or illustrations in this publication show details or attachments that may differ from your product. Guards and covers might have been removed for illustrative purposes. Continuing improvement and advancement of product design might have caused changes to your product which are not included in this publication. Whenever a question arises regarding your product, or this publication, consult your dealer for the latest available information.

Safety The safety section, if present, lists basic safety precautions. In addition, this section identifies the text and locations of safety messages used on the product. Read and understand the basic precautions listed in the safety section before operating or performing lubrication, maintenance, and repair on this product.

Operation The operation section, if present, is a reference for the new operator and a refresher for the experienced operator. This section includes a discussion of gauges, switches, controls, attachment controls, transportation, and towing information (if applicable). Photographs and illustrations guide the operator through correct procedures of checking, starting, operating, and stopping the product. Operating techniques outlined in this publication are basic. Skill and techniques develop as the operator gains knowledge of the product and its capabilities.

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Product Information The product information section, if present, may provide specification data on intended use, product identification plate locations, and certification information.

Maintenance The maintenance section, if present, is a guide to equipment care. Proper maintenance and repair are essential to keep the equipment and systems operating correctly. As the owner, you are responsible for the performance of the required maintenance listed in the Owner Manual, and Service Manual. The Maintenance Interval Schedule lists the items to be maintained at a specific service interval. Items without specific intervals are listed under the “When Required” service interval. The Maintenance Interval Schedule lists the page number for the step-by-step instructions required to accomplish the scheduled maintenance. Use the Maintenance Interval Schedule as an index or “one safe source” for all maintenance procedures.

Maintenance Intervals Use the service hour meter to determine servicing intervals. Calendar intervals shown (daily, weekly, monthly, etc.) can be used instead of service hour meter intervals if they provide more convenient servicing schedules and they approximate the indicated service hour meter reading. Recommended service should always be performed at the interval that occurs first. Under extremely severe, dusty, or wet operating conditions, more frequent lubrication than is specified in the maintenance intervals chart might be necessary. Perform service on items at multiples of the original requirement. For example, at every 500 service hours or 3 months, also service those items listed under every 250 service hours or monthly and every 10 service hours or daily.

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Product Capacity Additional attachments or modifications may exceed product design capacity, which can adversely affect product performance characteristics, safety, reliability, and applicable certifications. Contact your dealer for further information.

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Table of Contents _________________________________________________ Safety Section Safety Messages ......................................... 8 Crushing Hazard ................................... 8 Electrical Power Lines ........................... 8 High Pressure Cylinder .......................... 8 High Pressure Gas ................................ 8 Hot Surface & Pressurized System ........ 8 General Hazard Information ......................... 9 Personal Protective Equipment .................... 10 Pressurized Air and Water ........................... 10 Trapped Pressure ........................................ 10 Fluid Penetration.......................................... 10 Containing Fluid Spillage ............................. 11 Asbestos Information ................................... 11 Dispose of Waste Properly ........................... 11 Crushing Prevention and Cutting Prevention 11 Burn Prevention ........................................... 12 Coolant.................................................. 12 Oils........................................................ 12 Batteries ................................................ 12 Fire Prevention and Explosion Prevention .... 13 General ................................................. 13 Battery and Battery Cables .................... 13 Wiring.................................................... 14 Lines, Tubes, and Hoses ....................... 14 Fire Extinguisher ................................... 14 Fire Safety ................................................... 15 Fire Extinguisher Location............................ 15 Electrical Storm Injury Prevention ................ 15 Before Operation ......................................... 15 Visibility Information ..................................... 16 Restricted Visibility....................................... 16 Restricted Area ............................................ 16 Operation..................................................... 17 Machine Operating Temperature Range 17 Machine Operation ................................ 17 Hydraulic Pump Motor Stopping............. 17 Work Tools .................................................. 17

Operator Controls ........................................ 19 Displays ................................................ 20 Gauge Panels ....................................... 20 Emergency Machine Shutdown ............. 21 Control System Monitors On/Off ............ 21 Control System ..................................... 21 Public Address System.......................... 21 CB Radio System .................................. 21 Control System ............................................ 22 Main Page............................................. 22 Creating a User Account ....................... 28 System Setup........................................ 29 Setup Page and Calibration ................... 32 Flow/Temperature Page ........................ 35 Shear Page ........................................... 39 Shear Calibration Page ......................... 46 Cutter Module Calibration ....................... 47 Custom Cutter Modules ......................... 50 Cutter Module Rack Page ..................... 53 Navigation Interface Page ..................... 56 CM Steering Cylinder Calibration........... 61 Gamma Page ........................................ 64 Power Head Page ................................. 69 Stop Blocking/String Blocking Cylinder Calibration .......................... 78 Power Head Position Calibration ........... 79 Power Head Extended Options.............. 80 PTM2 Setup .......................................... 84 PTM2 Calibration .................................. 90 PTM2 Extended Options ....................... 91 PTM2 Trolley MDSD Calibration ............ 96 PTM2 Cradle MDSD Calibration ............ 97 Pump 1 Pressure Calibration ................. 99 Pump 1 MDSD Calibration .................... 100 Pump 2 and Pump 3 MDSD Calibration . 101 Super Beam Page ................................. 102 Super Beam Level Calibration ............... 116 Track Steering Calibration ..................... 111 Tracks Extended Option ........................ 112 Miner Setup 995 VFD ............................ 114 Miner Operation Page ........................... 118 Test Page ............................................. 122 Tram Page ............................................ 134 Mine Set Page ...................................... 138 Auto Mine Page..................................... 142 Auto Retract Page ................................. 156 Navigation Interface page...................... 158 Contour Graph Page ............................. 161 Cutter Head Steering Operation ............ 163 System Status Page .................................... 163 Power Meter Page ................................ 166 VFD Controls Page ................................ 168 480V VFD Drive Page............................ 169 Miner Status Main Page….…………………...170 Down Time Flags Page.......................... 172

Product Information Section General Information ..................................... 19 Product Identification Number ...................... 19 Specifications .............................................. 19 Dimensions ........................................... 19 Weights ................................................. 19 Intended Use ............................................... 19 Operating Slope........................................... 19 Operation Section Before Operation ......................................... 19 Mounting and Dismounting .................... 19 Daily Inspection ..................................... 19 Machine Operation ...................................... 19 Seat Adjustment .......................................... 19 Seat Belt ...................................................... 19

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_________________________________________________ Table of contents Motor Amps/Pressure Page ................... 173 Motor Hours Page .................................. 177 Motor Faults Page.................................. 178 Miner Warnings Page............................. 179 Force Page - Main Menu .................................... 181 Analog Inputs & Outputs .............................. 183 Digital Inputs................................................ 186 Digital Outputs ............................................. 188 Help Page.................................................... 189 Ground Man Controls ......................................... 192 Operating Procedures ........................................ 193 Safety .......................................................... 193 Startup......................................................... 193 PTM II Trolley Position ................................. 196 Maintenance Section Fluid Recommendations ............................. 201 S·O·S Information ........................................ 202 System Pressure Release ............................ 203 Prepare the Machine for Maintenance .......... 204 Maintenance Interval Schedule .................... 205 Maintenance Procedures ............................. 206

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Safety ___________________________________________________________ Safety Messages Never enter a mined entry under any circumstance.

Do not operate or work on this machine unless you have read and understand the instructions and warnings in the Operation and Maintenance Manual (OMM). Failure to follow the instructions or heed the warning could result in injury or death. Any Caterpillar dealer can provide new OMM’s.

(Europe) and 5 m (17 ft) for 50 kV (USA). Failure to follow warnings will cause serious injury or death.

High Pressure Cylinder This message is located in the operator’s compartment.

Crushing Hazard This message is located in the operator’s compartment.

Illustration 3

High pressure cylinder! Do not remove any part from the cylinder until all pressure, hydraulic and grease, has been relieved. Hydraulic fluid and grease under pressure can penetrate the skin, causing personal injury or death.

High Pressure Gas Illustration 1

Crushing hazard exists when the PTM is in motion.

Failure to stay clear of the PTM when the machine is in operation can result in personal injury or death.

This message is located in the operator’s compartment.

Electrical Power Lines This message is located in the operator’s compartment.

Illustration 4

Illustration 2

Electrocution hazard! Keep the machine and attachments a safe distance from elevated electric power lines and ground level power cables. The owner of the electric power line should advise a minimum clearance distance. The minimum clearance distance is 6 m (20 ft) for 220 V to 33 kV

The system contains high pressure gas. Failure to follow the instructions and warnings could cause an explosion, resulting in possible injury or death. Do not expose to fire. Do not weld. Do not drill.

Relieve pressure before discharging. See OMM for charging and discharging instructions. Any Caterpillar dealer can supply tools.

Hot Surface and Pressurized System This message is located in the operator’s compartment.

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__________________________________________________________ Safety

Illustration 5

Pressurized system and rotating parts hazard!

Rotating parts can cause serious injury. Deenergize the electric circuit before removing guards.

Stay clear of the BPM Room if the hydraulic pump motor is still running. Hot parts or hot components can cause burns or personal injury. Do not allow hot parts or hot components to contact your skin. Use protective clothing or protective equipment to protect your skin. The hydraulic tank and circuit contains hot oil. Hot hydraulic oil can cause serious burns. Wear suitable protective clothing and goggles. To prevent burns from the sudden release of hot oil, shut off the hydraulic pump motor, wait until the tank is cool. Hot coolant can cause serious burns. Wear suitable protective clothing and goggles. To prevent burns from the sudden release of hot coolant, shut off the coolant pump motor and wait until the cooling system components are cool.

General Hazard Information Adhere to the Lock Out / Tag Out system for motor circuit breakers and controls before performing any maintenance on a system moved by a motor.

Illustration 6

Attach a “Do Not Operate” warning tag or similar warning tag to the start switch or to the controls.

Attach the warning tag before you service the equipment or before you repair the equipment. The warning tags (Special Instruction, SEHS7332) are available from your Cat dealer.

Operating the machine while distracted can result in the loss of machine control. Use extreme caution when using any device while operating the machine. Operating the machine while distracted can result in personal injury or death.

Know the width of your machine in order to maintain proper clearance when you tram the machine near fences or near boundary obstacles. Be aware of high voltage power lines and power cables that are buried.

If the machine comes in contact with these hazards, serious injury or death may occur from electrocution.

Good practice is to have a spotter on the ground with a well suited means of communication.

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Safety ___________________________________________________________ Personal Protective Equipment

necessary repairs.

Do not allow unauthorized personnel on the equipment.

Unless you are instructed otherwise, perform maintenance with the equipment in the servicing position. Refer to the Operation and Maintenance Manual for the procedure for placing the equipment in the servicing position.

When you perform maintenance above ground level, use appropriate devices such as ladders or man lift machines. If equipped, use the machine anchorage points and use approved fall arrest harnesses and lanyards.

Pressurized Air and Water

Illustration 7

Wear a hard hat, protective glasses, safety footwear, high visibility vest, and other protective equipment such as gloves, respirators and hearing protection as required.

Do not wear loose clothing or jewelry that can snag on controls or on other parts of the equipment.

Make sure that all protective guards and all covers are secured in place on the equipment.

Keep the equipment free from foreign material.

Remove debris, oil, tools, and other items from the deck, from walkways, and from steps.

Secure all loose items such as lunch boxes, tools, and other items that are not a part of the equipment.

Know the appropriate work site hand signals and the personnel that are authorized to give the hand signals. Accept hand signals from one person only.

Pressurized air and/or water can cause debris and/or hot water to be blown out. The debris and/or hot water could result in personal injury.

When pressurized air and/or pressurized water is used for cleaning, wear protective clothing, protective shoes, and eye protection. Eye protection includes goggles or a protective face shield.

The maximum air pressure for cleaning purposes must be reduced to 205 kPa (30 psi) when the nozzle is deadheaded and the nozzle is used with an effective chip deflector and personal protective equipment. The maximum water pressure for cleaning purposes must be below 275 kPa (40 psi).

Avoid direct spraying of water on electrical connectors, connections, and components. When using air for cleaning, allow the machine to cool to reduce the possibility of fine debris igniting when redeposited on hot surfaces.

Trapped Pressure

Do not smoke when you service an air conditioner.

Also. Do not smoke if refrigerant gas may be present.

Inhaling the fumes that are released from a flame that contacts air conditioner refrigerant can cause bodily harm or death. Inhaling gas from air conditioner refrigerant through a lit cigarette can cause bodily harm or death.

Never put maintenance fluids in glass containers.

Drain all liquids into suitable containers.

Pressure can be trapped in a hydraulic system.

Releasing trapped pressure can cause sudden machine movement or attachment movement. Use caution if you disconnect hydraulic lines or fittings.

High pressure oil that is released can cause a hose to whip. High-pressure oil that is released can cause oil to spray. Fluid penetration can cause serious injury and death.

Fluid Penetration

Obey all local regulations for the disposal of liquids.

Use all cleaning solutions with care. Report all

Pressure can be trapped in the hydraulic circuit long after the hydraulic pump motor has been stopped.

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__________________________________________________________ Safety The pressure can cause hydraulic fluid or items such as pipe plugs to escape rapidly if the pressure is not relieved correctly.

Do not remove any hydraulic components or parts until pressure has been relieved or personal injury may occur. Do not disassemble any hydraulic components or parts until pressure has been relieved or personal injury may occur. Refer to the Service Manual for any procedures that are required to relieve the hydraulic pressure.

shipped from Caterpillar are asbestos free.

Caterpillar recommends the use of only genuine Cat replacement parts. Use the following guidelines when you handle any replacement parts that contain asbestos or when you handle asbestos debris.

Use caution. Avoid inhaling dust that might be generated when you handle components that contain asbestos fibers. Inhaling this dust can be hazardous to your health. Components that may contain asbestos fibers include: brake pads, brake bands, lining material, clutch plates, and some gaskets. The asbestos that is used in these components is bound in a resin or sealed in some way. Normal handling is not hazardous unless airborne dust that contains asbestos is generated.

If dust that may contain asbestos is present, there are several guidelines that should be followed:

Illustration 8

Always use a board or cardboard when you check for a leak. Leaking fluid that is under pressure can penetrate body tissue. Fluid penetration can cause serious injury and possible death. A pin hole leak can cause severe injury. If fluid is injected into your skin, you must get treatment immediately. Seek treatment from a doctor that is familiar with this type of injury.

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Never use compressed air for cleaning.

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Avoid brushing materials that contain asbestos.

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Avoid grinding materials that contain asbestos.

Use a wet method in order to clean up asbestos materials.

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A vacuum cleaner that is equipped with a high efficiency particulate air filter (HEPA) can also be used.

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Use exhaust ventilation on permanent machining jobs.

Containing Fluid Spillage Care must be taken in order to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the equipment. Prepare to collect the fluid with suitable containers before opening any compartment or disassembling any component that contains fluids.

Refer to Special Publication, NENG2500, “Caterpillar Dealer Service Tool Catalog” for the following items:  

Wear an approved respirator if there is no other way to control the dust.

Comply with applicable rules and regulations for the work place. In the United States, use Occupational Safety and Health Administration (OSHA) requirements. These OSHA requirements can be found in “29 CFR 1910.1001”. 

Tools that are suitable for collecting fluids and equipment that is suitable for collecting fluids

Obey environmental regulations for the disposal of asbestos.

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Tools that are suitable for containing fluids and equipment that is suitable for containing fluids

Stay away from areas that might have asbestos particles in the air.

Dispose of Waste Properly

Obey all local regulations for the disposal of liquids.

Asbestos Information Cat equipment and replacement parts that are

Improperly disposing of waste can threaten the environment. Potentially harmful fluids should be disposed of according to local regulations.

Always use leak-proof containers when you drain

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Safety ___________________________________________________________ fluids. Do not pour waste onto the ground, down a drain, or into any source of water.

object.

Burn Prevention Do not touch any part of an operating hydraulic pump motor, hydraulic circuit, or hydraulic pumps.

Allow the hydraulic circuit to cool before any maintenance is performed on the hydraulics. Relieve all pressure in the air, hydraulic oil, lubrication, and cooling systems prior to disconnecting any lines, fittings, or related items.

Illustration 9

Crushing Prevention and Cutting Prevention Support all equipment properly before you perform any work or maintenance beneath that equipment.

Do not depend on the hydraulic cylinders to hold up equipment. Equipment can fall if a control is moved, or if a hydraulic line breaks.

Do not work beneath any component of the machine unless it is properly supported.

Unless you are instructed otherwise, never attempt adjustments while the machine is in production.

Never apply jumpers “Test cables” across relays or terminals in order to start the hydraulic pump motor.

Unexpected machine movement could result.

Stay clear of areas that may have a sudden change in clearance with machine movement or equipment movement.

Stay clear of all rotating and moving parts.

If it is necessary to remove guards in order to perform maintenance, always install the guards after the maintenance is completed.

Keep objects away from unguarded rotating parts.

The unguarded rotating part can throw or cut objects.

Make sure that the area is clear of people when you strike a push beam connection pin. A dead blow hammer should be used to prevent pin fracture. To avoid injury to your eyes, wear protective glasses when you strike a push beam connection pin.

Chips or other debris can fly off an object when you strike an object. Ensure that no nearby individuals can be injured by flying debris before striking any

Coolant When the machine is at operating temperature, the machine coolant is hot. The coolant is also under pressure. The radiators and all lines to the machine contain hot coolant.

Any contact with hot coolant or with steam can cause severe burns. Allow cooling system components to cool before draining the cooling system.

Some electric motors on the machine require coolant to flow through them. Check the coolant level only from the site tube on the coolant tank in the BPM room.

Cooling system conditioner contains alkali. Alkali can cause personal injury. Do not allow alkali to contact the skin, the eyes, or the mouth.

Oils Hot oil and hot components can cause personal injury. Do not allow hot oil to contact the skin. Also, do not allow hot components to contact the skin.

Remove the hydraulic tank filler cap only after the hydraulic pump motor has been stopped. The filler cap must be cool enough to touch with a bare hand.

Follow the standard procedure in this manual in order to remove the hydraulic tank filler cap.

Batteries The liquid in a battery is an electrolyte. Electrolyte is an acid that can cause personal injury. Do not allow electrolyte to contact the skin or the eyes.

Do not smoke while checking the battery electrolyte levels. Batteries give off flammable fumes which can explode.

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__________________________________________________________ Safety Always wear protective glasses when you work with batteries. Wash hands after touching batteries. The use of gloves is recommended.

Fire Prevention and Explosion

Do not weld or flame cut on tanks or lines that contain flammable fluids or flammable material.

Empty and purge the lines and tanks. Then clean the lines and tanks with a nonflammable solvent prior to welding or flame cutting. Ensure that the components are properly grounded in order to avoid unwanted arcs.

Dust that is generated from machine operations may be flammable and/or explosive. Repair such components in a ventilated area away from open flames or sparks. Use suitable Personal Protection Equipment (PPE).

Illustration 10

General All fuels, most lubricants, and some coolant mixtures are flammable.

To minimize the risk of fire or explosion, Caterpillar recommends the following actions.

Always perform a Walk-Around Inspection, which may help you identify a fire hazard. Do not operate a machine when a fire hazard exists. Contact your Cat dealer for service.

Understand the use of the primary exit and alternative exit on the machine. Refer to Operation and Maintenance Manual, “Alternative Exit”.

Inspect all lines and hoses for wear or deterioration.

Replace damaged lines and hoses. The lines and the hoses should have adequate support and secure clamps. Tighten all connections to their recommended torque. Damage to the protective cover or insulation may provide fuel for fires.

Store lubricants in properly marked containers away from unauthorized personnel. Store oily rags and flammable materials in protective containers. Do not smoke in areas that are used for storing flammable materials.

Use caution when you are adding fluids to the machine. Do not smoke while you are adding fluids to the machine. Do not add fluids to the machine near open flames or sparks. Always stop the hydraulic pump motor before fueling. Properly clean areas of spillage. Never store flammable fluids in the

Do not operate a machine with a fluid leak. Repair leaks and clean up fluids before resuming machine operation. Fluids that are leaked or spilled onto hot surfaces or onto electrical components can cause a fire. A fire may cause personal injury or death.

Remove flammable material such as leaves, twigs, papers, trash, and so on. These items may accumulate in or around hot areas and hot parts on the machine.

Keep the access doors to major machine compartments closed and access doors in working condition in order to permit the use of fire suppression equipment, in case a fire should occur.

Clean all accumulations of flammable materials such as fuel, oil, and debris from the machine.

Illustration 11

Battery and Battery Cables Caterpillar recommends the following in order to minimize the risk of fire or an explosion related to a battery.

Do not operate a machine if the battery cables or related parts show signs of wear or damage.

Contact your Cat dealer for service.

Do not operate the machine near any flame.

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Safety ___________________________________________________________ Do not charge a frozen battery. This may cause an explosion.

Gases from a battery can explode. Keep any open flames or sparks away from the top of a battery. Do not smoke in battery charging areas.

Never check the battery charge by placing a metal object across the terminal posts. Use a voltmeter in order to check the battery charge.

Perform daily battery cables inspections. Inspect cables, clips, straps, and other restraints for damage. Replace any damaged parts.

Check for signs of the following, which can occur over time due to use and environmental factors:       

Fraying Abrasion Cracking Discoloration Cuts on the insulation of the cable Fouling Corroded terminals, damaged terminals, and loose terminals

Replace damaged battery cables and lugs.

Eliminate any fouling, which may have caused insulation failure or related component damage or wear. Ensure that all components are reinstalled correctly.

An exposed wire on the battery cable may cause a short to ground if the exposed area comes into contact with a grounded surface. A battery cable short produces heat from the battery current, which may be a fire hazard.

Repair components or replace components before servicing the machine. Fire on a machine can result in personal injury or death. Exposed battery cables that come into contact with a grounded connection can result in fires. Replace cables and related parts that show signs of wear or damage. Contact your Cat dealer.

Wiring Check electrical wires daily. If any of the following conditions exist, replace parts before you operate the machine.

• Fraying • Signs of abrasion or wear

• Cracking • Discoloration • Cuts on insulation • Other damage Make sure that all clamps, guards, clips, and straps are reinstalled correctly. This will help to prevent vibration, rubbing against other parts, and excessive heat during machine operation. Attaching electrical wiring to hoses and tubes that contain flammable fluids or combustible fluids should be avoided.

Consult your Cat dealer for repair or for replacement parts. Keep wiring and electrical connections free of debris. Lines, Tubes, and Hoses Do not bend highpressure lines. Do not strike high-pressure lines. Do not install any lines that are bent or damaged. Use the appropriate backup wrenches in order to tighten all connections to their recommended torque.

Lines, Tubes, and Hoses Check lines, tubes, and hoses carefully. Wear Personal Protection Equipment (PPE) in order to check for leaks. Always use a board or cardboard when you check for a leak. Leaking fluid that is under pressure can penetrate body tissue. Fluid penetration can cause serious injury and possible death. A pin-hole leak can cause severe injury. If fluid is injected into your skin, you must get treatment immediately.

Seek treatment from a doctor that is familiar with this type of injury.

Replace the affected parts if any of the following conditions are present: • End fittings are damaged or leaking.

• Outer coverings are chafed or cut.

• Wires are exposed.

• Outer coverings are swelling or ballooning.

• Flexible parts of the hoses are kinked.

• Outer covers have exposed embedded armoring.

• End fittings are displaced.

Make sure that all clamps, guards, and heat shields are installed correctly. During machine operation, this will help to prevent vibration, rubbing against other parts, excessive heat, and failure of lines, tubes, and hoses.

Fire Extinguisher As an additional safety measure, keep a fire extinguisher on the machine.

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__________________________________________________________ Safety Be familiar with the operation of the fire extinguisher. Inspect the fire extinguisher and service the fire extinguisher regularly. Follow the recommendations on the instruction plate.

Consider installation of an aftermarket Fire Suppression System, if the application and working conditions warrant the installation.

Fire Safety If you find that you are involved in a machine fire, your safety and that of others on site is the top priority. The following actions should only be performed if the actions do not present a danger or risk to you and nearby people. At all times, you should assess the risk of personal injury and move away to a safe distance as soon as you feel unsafe.

Move the machine away from nearby combustible material such as fuel/oil stations, structures, trash, mulch, and timber.

Shut down the machine as soon as possible.

Notify emergency personnel of the fire and your location.

If your machine is equipped with a fire suppression system, follow the manufacture’s procedure for activating the system.

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Tanks, accumulators, hoses, and fittings can rupture in a fire, spraying fuels and shrapnel over a large area.

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Nearly all fluids on the machine are flammable, including coolant and oils. Additionally, plastics, rubbers, fabrics, and resins in fiberglass panels are also flammable.

Fire Extinguisher Location Make sure that a fire extinguisher is available. Be familiar with the operation of the fire extinguisher.

Insect the fire extinguisher and service the fire extinguisher regularly. Obey the recommendations on the instruction plate.

Fire extinguisher mounting locations must not damage any safety features. The mounting location must not obstruct the operator compartment and must not obstruct the operator from accessing or exiting the operator’s compartment.

Electrical Storm Injury Prevention When lightning is present in the vicinity of the machine, stop the work that is being performed.

The machine operator is to remain in the cab and ground personnel should seek shelter.

Before Operation

Note: Fire suppression systems need to be regularly inspected by qualified personnel. You must be trained to operate the fire suppression system.

Alert all workers or personnel on or around the vicinity of the machine prior to starting the hydraulic pump motor or electric motor circuits.

Use the on-board fire extinguisher and use the following procedure:

Clear all personnel from the machine and from the restricted areas.

1. Pull the pin.

Clear all obstacles from the machine's path.

2. Aim the extinguisher or nozzle at the base of the fire.

Beware of hazards (wires, ditches, etc.).

3. Squeeze the handle and release the extinguishing agent.

4. Sweep the extinguisher from side to side across the base of the fire until the fire is out.

If the fire grows out of control, be aware of the following risks:

Be sure that all windows are clean.

Secure the doors in the open position or in the shut position.

Adjust the cameras for the best visibility around the machine.

Make sure that the horn, the travel alarm, and all other warning devices are working properly.

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Safety ___________________________________________________________ If equipped, fasten the seat belt securely.

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A system of communication

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Communication between workers and operators prior to approaching the machine

Warm up the hydraulic oil before operating the machine if necessary.

Before moving the machine, check the position of the tracks. Ensure that all tracks are pointed in the intended direction of travel.

Modifications of the machine configuration by the user that result in a restriction of visibility shall be evaluated.

Visibility Information

Restricted Visibility

Before you start the machine, perform a walkaround inspection in order to ensure that there are no hazards around the machine.

While the machine is in operation, constantly survey the area around the machine in order to identify potential hazards as hazards become visible around the machine.

Pay special attention to the high wall. Notify the proper personnel promptly to alert them of any potential hazards.

Your machine may be equipped with visual aids.

Examples of visual aids are cameras. Before operating the machine, ensure that the visual aids are in proper working condition and that the visual aids are clean. Adjust the visual aids for maximum visibility.

It may not be possible to provide direct visibility on large machines to all areas around the machine.

Appropriate job site organization is required in order to minimize hazards introduced by restricted visibility. Job site organization is a collection of rules and procedures that coordinates machines and people that work together in the same area.

Examples of job site organization include the following:

The size and configuration of this machine may result in areas that can not be seen when the operator is seated.

The machine is equipped with visual aids that provide visibility to some of the restricted visibility areas. For all areas that are not covered by the optional visual aids, job site organization must be utilized to minimize hazards due to restricted visibility. For more information regarding job site organization, refer to Operation and Maintenance Manual, “Visibility Information”.

Restricted Area The restricted area is the area in which persons are in danger due to the movements of the: 

Machine

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Work and additional equipment

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Mined material

This also includes the area affected by falling material, equipment, or by parts which are thrown out. The danger area must be extended by 0.5 m (20 inch) in the immediate vicinity of: 

Stacker belt

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Safety instructions

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Discharge method of coal on the machine

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Controlled patterns of machine movement and vehicle movement

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Loading or unloading of push beams

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Workers that direct traffic to move when safe

Seal off the restricted area if it is not possible to keep a safe distance.

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Restricted areas

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Operator training

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Warning symbols or warning signs on machines or on vehicles

Start work only if all persons have left the restricted area.

Stop work immediately if personnel enter the restricted area.

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__________________________________________________________ Safety If a warning tag is attached to the start switch or to the controls, do not start the hydraulic pump motor.

Before you start the hydraulic pump motor or electric motors, make sure that all workers and personnel are made aware.

Operation Machine Operating Temperature Range The machine must function satisfactorily in the anticipated ambient temperature limits that are encountered during operation. The machine configuration is intended for use within an ambient temperature range of −40 °C (-40 °F) (With Cold Weather Package) to 50 °C (122 °F) (With tropical Package).

Machine Operation Only operate the machine while you are in the operator seat. The seat belt must be fastened while you operate the machine. Check for proper operation of all controls and of all protective devices while you operate the machine. Make sure that no personnel will be endangered before you move the machine. Never use the work tool for a work platform. Report any machine damage that was noted during machine operation. Make any necessary repairs. Do not tram the machine close to an overhang, to the edge of a cliff, or to the edge of an excavation. If the machine begins to sideslip on a grade, immediately stop all machine operations. Be careful to avoid any ground condition which could cause the machine to slip.

Slipping can occur when you tram on hills, on banks, or on slopes. When possible, operate the machine up slopes and down slopes. Avoid operating the machine across slopes. Keep the machine under control. Do not overload the machine beyond capacity. Use caution when changing the direction of travel on a slope. This could result in side slipping of the machine. Make sure that the towing eyes and the towing devices are adequate for your needs. Never connect trailing equipment to the machine. Never straddle a wire cable. Never allow other personnel to straddle a wire cable. Check the local regulations, state codes, and/or directives of the job site for a specific minimum distance from obstacles. Before you operate the machine, check with local utilities for the locations of underground pipes and for the locations of buried cables. Know the maximum

dimensions of your machine. Be aware of the position of the work tool.

Hydraulic Pump Motor Stopping Do not stop the hydraulic pump motor immediately after the machine has been operated under load.

This action can cause overheating and accelerated wear of pump and or hydraulic valve components.

After the machine is parked, allow the hydraulic pump motor to run for 5 minutes before shutdown.

Running the hydraulic pump motor for 5 minutes before shutdown allows hot areas of the hydraulic pumps to cool gradually.

Work Tools Only use work tools that are approved by Caterpillar for use on Cat machines. Use of work tools, including cutter modules, which are outside of Caterpillar's recommendations or specifications for weight, dimensions, flows, pressures, etc. may result in less-than-optimal machine performance, including but not limited to reductions in production, stability, reliability, and component durability.

Caterpillar recommends appropriate work tools for our machines to maximize the value our customers receive from our products.

Caterpillar understands that special circumstances may lead a customer to use tools outside of our specifications. In these cases, customers must be aware that such choices can reduce machine performance and will affect their ability to claim warranty in the event of what a customer may perceive as a premature failure.

Work tools and work tool control systems, that are compatible with your Cat machine, are required for safe machine operation and/or reliable machine operation. If you are in doubt about the compatibility of a particular work tool with your machine, consult your Cat dealer.

Make sure that all necessary guarding is in place on the host machine and on the work tool. Keep all doors closed on the host machine. Always wear protective glasses. Always wear the protective equipment that is recommended in the operation manual for machine operation. Wear any other protective equipment that is required for the operating environment. To prevent personnel from being struck by flying objects, ensure that all personnel are out of the work area.

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Product Information _______________________________________________ General Information

Dimensions

Product Identification Number (if applicable) Effective First Quarter 2001 the Product Identification Number (PIN) has changed from 8 to 17 characters. In an effort to provide uniform equipment identification, construction equipment manufacturers are moving to comply with the latest version of the product identification numbering standard. Non -road machine PINs are defined by ISO 10261.

The new PIN format will apply to all machines and generator sets. The PIN plates and frame marking will display the 17 character PIN. The new format will look like the following:

Illustration 13

All dimensions are approximate.

(A) Overall Width (base) 10 m (33.6 ft) (B) Overall Height 8.4 m (28.0 ft) (C) Overall Length (base) 16.6 m (55.3 ft)

Weight Illustration 12

Where: 1. World Manufacturing Code (characters 1-3)

The overall weight of the machine is approximately 225,000 kg (496,040 lb). Note: Machine weight may vary depending on machine configuration and options chosen.

2. Machine Descriptor (characters 4-8)

Operating Slope

3. Check Character (character 9)

The HW300 Highwall Miner can generally be operated on slopes applicable to standard roadways.

For questions regarding specific slopes, contact your Technical Service Representative.

4. Machine Indicator Section (MIS) or Product Sequence Number (characters 10-17), These were previously referred to as the Serial Number.

Machines and generator sets produced before First Quarter 2001 will maintain their 8 character PIN format.

Components such as engines, transmissions, axles, etc. and work tools will continue to use an 8 character Serial Number (S/N).

Specifications

Intended Use The HW300 Highwall Miner is a mining machine.

This is a self-propelled track machine with an onboard material conveying system. It is intended for the following application: extraction of coal from the highwall to a depth of 305 m (1000 ft) and transport of the coal from the front of machine to a discharge point on the rear of the machine.

Note: Materials and specifications are subject to change without notice.

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________________________________________________________Operation Before Operation Mounting and Dismounting Mount the machine and dismount the machine only at locations that have steps, ladders, and/or handholds. Before you mount the machine, clean the steps, ladders, and/or handholds. Inspect the steps, ladders, and handholds. Make all necessary repairs.

Face the machine whenever you get on the machine and whenever you get off the machine.

Maintain a three-point contact with the steps and with the handholds.

Note: Three-point contact can be two feet and one hand or one foot and two hands.

Do not mount a moving machine. Do not dismount a moving machine. Never jump off the machine.

Daily Inspection For a maximum service life of the machine, complete a thorough walk-around inspection before you mount the machine and before you start the machine.

Inspect the area around the machine and under the machine. Visually inspect the condition of all major components. Look for loose bolts, trash buildup, oil leakage, coolant leakage, broken parts, and worn parts.

Note: If you suspect a leak or you observe a leak, qualified personnel should complete an inspection before you operate the machine.

Remove any trash or debris.

Report any abnormalities to your supervisor.

Qualified personnel should complete an inspection before you operate the machine.

Inspect cutter head bits.

Inspect cutter head bit holders.

other foreign materials.

Inspect coolant tank for leaks.

Perform the following daily procedures for your machine: 

Input Cutter Head Gear Case Oil Level - Check



Reach Gear Case Oil Level - Check



Final Cutter Head Gear Case Oil Level - Check



CLA Head Pot Assembly Oil Level - Check



CLA Head Transfer Case Oil Level - Check



Shear Boom Pins - Grease



Conveyor Chain Tail Roller - Grease



Cutter Module Bearings, Front and Rear - Grease

Note: Reference the Maintenance Section for procedure.

Machine Operation Seat Note: Adjust the seat for a different operator or at the beginning of each shift. The operator should be seated against the seat backrest.

Seat Adjustment Ensure that the seat is properly adjusted before operating the machine.

Seat Belt Note: This machine was equipped with a seat belt when the machine was shipped from Caterpillar. See your Caterpillar dealer for all replacement parts.

Always check the condition of the seat belt and the condition of the mounting hardware before you operate the machine.

Seat Belt Adjustment

Inspect steps, ladders and hand rails for damage.

Ensure the seat belt is adjusted to properly secure the operator before beginning machine operation.

Inspect fasteners on steps, ladders, and hand rails.

Operator Controls

Make sure all windows are clean. Make sure that the operator’s vision is not impaired by dust, mud, or

Note: Your machine may not be equipped with all of the controls that are described in this topic.

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Operation ________________________________________________________ Displays

1

1

2

3

2

3

2 4

Illustration 14

5

6

(1)

Data Collection and Documentation Access

Illustration 15

(2)

Human Machine Interface (HMI) Touchscreens

(1)

Left Cutter Motor AC Amps

(3)

Closed Circuit Camera Monitor

(2)

Left Horizontal Motor AC Amps

(3)

Gathering Head Motor AC Amps

(4)

Right Cutter Motor AC Amps

(5)

Chain Conveyor Motor AC Amps

(6)

Right Horizontal Motor AC Amps

(7)

Right Angle Motor AC Amps (if equipped)

Data Collection and Documentation Access (1) This monitor is used to access machine data and documentation.

HMI Touchscreens (2) These two monitors are used to access the machine control functions. For more information, see the Operation and Maintenance Manual, “Control System”.

Closed Circuit Camera Monitor (3) This monitor receives input from the machine mounted camera. It provides the operator visibility around the outside of the machine.

Gauge Panel

7

Left Cutter Motor AC Amps (1), Right Cutter Motor AC Amps (4) These gauges continuously monitor the current draw of the left and right cutter head motors.

Left Horizontal Motor AC Amps (2), Right Horizontal Motor AC Amps (6) These gauges continuously monitor the current draw of the left and right horizontal motors.

Gathering Head Motor (3) This gauge continuously monitors the current draw of the gathering head motors.

Chain Conveyor Motor (5) This gauge continuously monitors the current draw of the chain conveyor motor.

Right Angle Motor (7) This gauge continuously monitors the current draw of the right angle conveyor motor if it is equipped.

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________________________________________________________Operation Emergency Machine Shutdown

1 1

2

Illustration 18

Illustration 16

(1)

(1)

Emergency Stop

Public Address System (1)

(2)

Emergency Stop Power Shutdown

Depress the button on the side of the control to turn on the microphone for the machine mounted public address speakers. Release the button to turn the microphone off.

Emergency Stop (1) Depress the button to shutdown the hydraulic pump motor, thereby shutting down all machine hydraulic functions.

Public Address System

CB Radio System

Emergency Stop Power Shutdown (2) Depress the button to interrupt electrical power to the machine, thereby shutting down all machine functions.

1

Control System Monitors On/Off

Illustration 19 (1)

CB Radio System

CB Radio System (1)

1

The CB radio is used as a communication system with other CB’s outside of the operator’s cab.

Illustration 17 (1)

Control System Monitors On/Off

Control System Monitors On/Off (1) Depress the switch to turn on the two control system touch screen monitors. Depress the button again to turn off the monitors.

Public Address System

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Operation ________________________________________________________ A description of all pages including the top row “sub pages” is given in the following section.

HMI Touchscreen Control System The control system is used to setup, calibrate, operate, and monitor the miner.

There are two rows of navigation buttons at the bottom of each page. The bottom row of buttons controls the options displayed in the top row.

Each bottom row button has a “Main Page” that is displayed when pressed.

Top row buttons in the “Force Pages” will not function until a desired I/O type is selected: 

Ix for Digital Inputs



Qx for Digital Outputs



AIx for Analog Inputs



AQx for Analog Outputs

Main Operation Page

Main Miner Status Page

Main Settings Page

Main Miner Force Page

Miner Force Page Extended

Miner System Status Page

Illustration 20

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________________________________________________________Operation Miner System Setup Page

Miner Help Page

Illustration 20, continued

Table 1 explains the meaning of the symbols used in the navigation rows Table 1 Symbol

Description

Bottom Row “Main Page” Icons Displays Miner Operation – Main Page

Displays Miner Status – Main Page.

Displays Miner Setup – Main Page.

Displays the force home page for base unit remote I/O.

Displays the force home page for extended options remote I/O. (Cooling rack, VFDs, cutter head I/O) Displays Miner System Status – Main Page.

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Operation ________________________________________________________ Table 1 Symbol

Description

Displays Miner System Setup – Main Page.

Displays Miner Help. – Main Page.

Miner Operation Page Icons Auto Mine Page

Auto Retract Page

Mine Set Page

Testing Page

Tram Operations Page

Plot Chart

Miner Status Page Icons Motor Amps / Pressures

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________________________________________________________Operation Table 1 Symbol

Description

Motor Hour Meters

Opens list of Shutdown Faults and Offers reset option.

Opens list of fault warnings and Offers reset option.

Miner Setup Page Icons Shear

Power Head

Super Beam

Tracks

Flow/Temperatures

PTM2

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Operation ________________________________________________________ Table 1 Symbol

Description

Hose Reel Relief

Saminco VFDs

Force Page Icons ECM I/O force pages.

BPM I/O force pages.

Back Right I/O force pages.

Front Left I/O force pages.

Front Right I/O force pages.

Power Head I/O force pages.

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________________________________________________________Operation Table 1 Symbol

Description

PTM2 I/O force pages.

CAB I/O force pages.

Miner System Status Page Icons PAC3200 Power Meter Readings

480V Sinamics VFDs

995V Saminco VFDs

System History

Mine Set Page Icons HMI Touchscreen Settings

Miner Help Page Icons Calculator

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Operation ________________________________________________________ Operating Procedures User Administration Group levels are used to control security privileges.

The higher the group level number, the more access the user has to settings. Group levels are number 1 through 9.

Creating a User Account To create a user account:

Illustration 22

Illustration 21

1. Log in with an account that has Group 9 access.

2. Scroll to the bottom of the User Administration box.

The system setup screen, which is also the user log -in screen, provides access to set the operating parameters of the control system.

Table 2 describes the icons on the system setup screen.

3. Enter the desired user name and press enter.

4. Select the password box.

5. Enter the desired password and press enter.

6. Assign the appropriate Group Level.

7. Set the Logoff Time.

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________________________________________________________Operation System Setup (MP377 Setup) Table 2 Symbol

Description

Function

Date & Time Date and Time

Enter the current date and time using the mm/dd/yyyy hh:mm:ss AM format.

Enters the date and time

Writes the new date and time to the touch screen and PLC.

Language Language

Press a flag to select a language.

Previous language

Previous available panel language.

Next language

Next available panel language.

Onscreen keyboard Minimize onscreen keyboard

Minimizes the onscreen keyboard.

Maximize onscreen keyboard

Maximizes the onscreen keyboard.

Turn off onscreen keyboard

Prevents the onscreen keyboard from appearing when clicking on a box that requires input.

Turn on onscreen keyboard

Allows the onscreen keyboard to appear when clicking on a box that requires input.

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Operation ________________________________________________________ Table 2 Symbol

Description

Function

Screen Settings Screen cleaning

Disables the touch input so that the screen can be cleaned.

Screen calibration

Starts the touch screen calibration.

Volume Volume off

Turns off the touch confirmation tone.

Low volume

Turns the touch confirmation tone on low.

High volume

Turns the touch confirmation tone on high.

Runtime Settings Windows Explorer

Opens Windows Explorer.

Control Panel

Opens the control panel.

Command Prompt

Opens Windows command prompt.

Task Manager

Opens the task manager.

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________________________________________________________Operation Table 2 Symbol

Description

Function

Runtime settings, continued Download Project

Exits the runtime and prepares the panel download.

Exit Runtime

Closes the runtime application.

User Administration User Login

Logs users into secure areas of the touch screen. Passwords and security levels can be changed from this screen.

User Logout

Logs the current user out.

Export User List

Exports the current user list to the compact flash drive.

Import User List

Imports a user list from the flash drive into the project.

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Operation ________________________________________________________ Setup Page and Calibration

Illustration 23 (1)

1

Miner Setup Page

To access the setup page, press the Miner Setup button (1) on the Navigation bar at the bottom of the page.

Illustration 24

Table 3 describes the icons on the Miner Setup screen.

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________________________________________________________Operation Table 3 Symbol

Description

Function

Rear Discharge

Rear Discharge Option

Allows the selection of setup options associated with a rear discharge PTM 2 machine.

G-Man Room

Configures the program for changes necessary with the Ground Man Room option.

PTM Table Side Left

Configures the program for the PTM table to be on the left side of the miner.

PTM Table Side Right

Configures the program for the PTM table to be on the right side of the miner.

Tail Piece Options Right Angle Conveyor

Configures the program for the right angle conveyor.

Right Angle Ground Clearance Switch

Configures the program for the option of using right angle ground clearance switches.

Right Angle Conveyor Manual Shutoff

When selected, the right angle conveyor will not shut off between beams.

Right Angle Conveyor Shutoff Automatic.

When selected, the right angle conveyor will shut off between beams.

Stacker Belt Options Stacker Belt

Configures the program for the stacker belt.

Stacker Belt Slip Alarm Timer

Allows adjustment of a stacker belt slip alarm timer.

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Operation ________________________________________________________ Table 3 Symbol

Description

Function

Stacker Shutoff Manual

When selected, the stacker belt will not shut off between beams.

Stacker Shutoff Automatic

When selected, the stacker belt will shut off between beams.

Stacker Belt Slip Switch

Configures the program with a stacker belt slip switch.

System Options

System Options

Allows selection of the system options.

Measurement Mode

Configures the program to use either metric or standard units of measure with either psi or bar measurement of pressure.

Cab Level Installed

If a cab leveling system is installed, this option configures the program to allow it to work.

Force 995 No Present Alarm

Disables the 995 Volt Present Alarm.

Save/Recall Miner Setup Save/Recall Miner Setup

Allows for saving the miner setup at any given time and recalling that setup at a later time.

Save

Saves the miner setup.

Save/Date and Time

Time and date that the Save button was last pressed.

Recall

Recalls an earlier saved setup.

Recall/Date and Time

Time and date the recall button was last pressed.

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________________________________________________________Operation Flow/Temperature Page 1

Illustration 25 (1)

Flow/Temperature

To access the flow and temperature setup page, press the Flow/Temperature button (1) on the Navigation bar at the bottom of the page.

Illustration 26

Table 4 on the following pages describes the icons on the Flow/Temperature screen.

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Operation ________________________________________________________ Table 4 Symbol

Description Cooling Rack Installation option

Function Option to use a non-VFD cooling system that uses a S7 I/O rack instead

Hydraulic Temperature Settings Hydraulic Temperature Settings

Allows configuration of temperature settings.

Hot Temperature Alarm

Configures the temperature at which the hot oil alarm turns on.

Very Cold Temperature Alarm

Configures the temperature at which the very cold temperature alarm turns on.

Pre-Heat Maximum Temperature

Controls the temperature at which oil pre-heating turns off.

Fan On Temperature

Controls when the oil cooling fans will come on.

Fan Off Temperature

Controls when the oil cooling fans will shut off.

Cooling Temperature Settings

Cooling Temperature Settings Box

Allows for setting flow alarm and fan controls for cooling.

Low Flow Alarm

Temperature at which the low water flow will turn on. A warning alarm turn on at 2 gpm (7.6 Lpm) above this setting.

Fan On Temperature

Temperature at which the water cooling fans turn on.

Fan Off Temperature

Temperature at which the water cooling fans turn off.

Fans Installed

When selected configures program for three cooling fans.

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________________________________________________________Operation Table 4 Symbol

Description

Function

Hydraulic Tank Level Calibration

Hydraulic Oil Level

Allows setting controls for hydraulic oil level.

Raw

26000 Current raw count reading from hydraulic oil level sensor.

Tank Level:

2915.22 Current Hydraulic oil tank level.

Raw Captured: above icon)

27648 Captured raw count against the “Level In Tank”

Level In Tank:

3100 Sight reading that is entered to calibrate the sensor.

Minimum Level of Hydraulic Oil

3000 Minimum level of hydraulic oil required in tank.

Alarm Delay Setting.

3.00 Alarm delay time for hydraulic oil level alarm.

Hydraulic System Total

3298.43 Capacity of hydraulic oil tank.

Hydraulic Oil Level Sensor

When checked configures program for a hydraulic tank level sensor.

Hydraulic Tank Icon

Used to capture raw count for calibrating to a full hydraulic oil tank.

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Operation ________________________________________________________ Table 4 Symbol

Description

Function

Hydraulic Valve Heating

Hydraulic Valve Heating Selection and Setup Box

Allows for selection and setup of hydraulic valve heaters.

Hydraulic Valve Heater Selection

When checked configures program for hydraulic valve heaters installed (IF EQUIPPED),

Outdoor Temperature

Indicates the outdoor temperature.

Hydraulic Valve Heat On Temperature

Temperature at which the heaters for the hydraulic valve turn on.

Hydraulic Valve Heat On Time

Allows setup of how long hydraulic valve heaters will be on.

Hydraulic Valve Heat Off Time

Allows setup of how long hydraulic valve heaters will be on.

__________________________________________________________________ 38

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________________________________________________________Operation Shear Page 1

Illustration 27 (1)

Shear

To access the shear setup page, press the Shear button (1) on the Navigation bar at the bottom of the page.

Illustration 28

Table 5 describes the icons on the Shear screen.

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Operation ________________________________________________________ Table 5 Symbol

Description

Function

Controls Start the BPM motor and strokes P3, 3 seconds after the motor is started.

Start BPM

Cutter Motor Stop

Cutter Motor Stop

Manual – In auto mine the cutter motors will continue to run between beams.

With Horizontals – The cutter motors will shut down between each beam.

Cutter Head Start Mode

Cutter Head Start Mode

There are 2 options for starting the Cutter Head Motors. If Simultaneous is selected then both right and left cutter motors start at the same time. If Staggered is selected then the right or left motor starts alone and then the other motor starts. The motor that will start first is the motor that started last the time before.

Transducer 3 Options: 1. Left Side – Uses Input PIW710 if using front right I/O Transducer

2. Right Side – Uses Input PIW712 if using front right I/O 3. Pendulum Pot – Uses Input PIW712 if using front right I/O

Cutter Head Type Options

Allows setup of cutter module type and calibration settings

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________________________________________________________Operation Table 5 Symbol

Description

Function

Cutter Head Type Configures the cutter module for the type selected.

Three types of cutter module selections: Cutter Module Type

1. CAT 2. MSCM 3. Low Seam Configures the sump mode. Three options are available:

Sump Mode

1. Sump Bottom Only 2. Sump Top and Bottom 3. Continuous Sump Note: “Sump Bottom Only” is the only valid selection when configured with low seam cutter module.

Right and Left Arrow Buttons

Default cutter module specifications are already entered into the program. Use these buttons to select the appropriate cutter module .

Automatic – Automatically transfers cutter module setting to the PLC as they are viewed with the right and left arrow buttons.

Transfer Mode

Manual – The download button must be pressed to send the information to the PLC. Manual mode is used for any custom cutter module created.

Download

Enters cutter module information into the PLC.

Drum, Span, Width

Displays the cutter drum diameter and span in inches and centimeters. The left side shows the information to be downloaded to the PLC. The right side displays the information currently in the PLC.

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Operation ________________________________________________________ Table 5 Symbol

Description

Function

Shear MDSD Calibration

Shear MDSD Calibration

These buttons allow setup and calibration of the shear MDSD card. It is important to remember to only perform MDSD Calibration with the BPM Pump MOTOR TURNED OFF.

Side A Maximum

This button sends 5 Volts to the MDSD card when pressed. It is for calibrating shear up maximum output.

Side A Minimum

This button sends 0.5 Volts to the MDSD card when pressed. It is for calibrating shear up minimum output.

Side B Maximum

This button sends -5 Volts to the MDSD card when pressed. It is for calibrating shear down maximum output.

Side B Minimum

This button sends -0.5 Volts to the MDSD card when pressed. It is for calibrating shear up minimum output.

Extended Options

Displays the Miner Setup: Shear Settings Additional Settings Page

Extended Options

Extended Option

Allows options of cutter head camera or gamma sensors or an I/O in the cutter head (CH Rack) and setup options for the CH Rack and Gamma Sensors.

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________________________________________________________Operation Table 5 Symbol

Description

Function

Cutter Module Camera

Configures program for a Cutter Module Camera installation.

Cutter Module I/O Rack Option

Configures program for Cutter Module with an I/O Rack and allows for setup of that rack.

Setup for CM Rack Button

Opens CM Rack Setup page.

Gamma Sensors Setup

Opens Gamma Setup page.

CM Level Calibration

CM Level Calibration

Allows for calibration of level for the Cutter Module (CM).

Raw

Displays the CHM Level Raw Counts. (If using front right I/O, Analog Input PIW714.)

CM Level Degrees

Displays the current CM Level in degrees.

CM Level Indicator

Provides a visual representation of the position of the cutter module. The indicator updates every 1 degree.

Captured

Displays the raw count calibration point.

Calibrate CM Level

Calibrates current CM raw counts at 0.0 degrees.

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Operation ________________________________________________________ Table 5 Symbol

Description

Function

Camera/Gamma/CH Rack, continued Restore Factory Setting

Sets CHM Level 0 degrees to 13,824 raw counts.

Shear Level

Shear Level Calibration Box

Allows for calibration of shear level and shear top.

It also indicates the raw count for right and left transducers.

Raw

Displays the Shear Position Raw Counts. (If using front right I/O left side PIW710 and right side PIW712.)

Captured Raw Count

Displays the shear height raw count captured and shows which transducer is being used. (Example: LS is the left side.)

Captured Raw Count for Transducer not being used.

Indicates captured raw count for transducer that is not being used. (Example: RS/PP is the right side or pendulum pot.)

Set Shear Top Calibration

Calibrates the shear top position.

Set Shear Level Calibration

Calibrates the shear at level position.

Restore Factory Settings

Sets Shear Top Calibrated Raw Counts = 27648 and Shear Level Calibrated Raw Counts = 1717.

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________________________________________________________Operation Table 5 Symbol

Description

Function

Cutter Drum Operations

Cutter Head Operations

Allows shear control of the cutter drum from the setup page.

Shear Top Current Position

Displays the current position of the top of the cutter drum. Measurements can be displayed in metric or standard units based on the selection switch on the Miner Setup page.

Shear Top Set Point

Allows the operator to enter the desired stopping position for the top of the cutter drum.

Shear Top +

Adds 1 inch or 1 centimeter to the top set point.

Shear Top -

Subtracts 1 inch or 1 centimeter to the top set point.

Shear Up

Shears the cutter drum up.

Shear Down

Shears the cutter drum down.

Shear Bottom Current Position

Displays the current position of the bottom of the cutter drum. Measurements can be displayed in metric or standard units based on the selection switch on the Miner Setup page.

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Operation ________________________________________________________ Table 5 Symbol

Description

Function

Shear Level, continued Shear Bottom +

Adds 1 inch or 1 centimeter to the bottom set point.

Shear Bottom -

Subtracts 1 inch or 1 centimeter to the bottom set point.

Shear Calibration

1

2

1. Calibrate the CHM Level. See Operation and Maintenance Manual, “CHM Level”.

2. Calculate shear span: a. Position the cutter drum so that it will cut level (usually, the bit will extend approximately 50 mm (2 inches) below the bottom of the cutter module). b. Raise the cutter drum all the way up and take a measurement from the same point on the ground to the same point on the drum. c.

Subtract the two measurements: i.

Low Seam Span = Top Measurement Bottom Measurement

ii.

Mid to High Seam Span = (Top Measurement - Bottom Measurement) + Drum Diameter

Table 6 lists the shear span settings.

3

Table 6

4

5

6

Illustration 29

Type

Shear Span Setting

Drum Diameter

XLSCM

61 inches (155 cm)

25.5 inches (65 cm)

LSCM

62 inches (158 cm)

MSCM HSCM

(1)

Cutter Module Type

(2)

Navigation arrows

25.5 inches (65 cm)

(3)

Set Level Calibration

120.5 inches (306 cm)

38 inches (97 cm)

(4)

Set Top Calibration

177 inches (450 cm)

38 inches (97 cm)

(5)

Shear Down

(6)

Shear Up

3. Select the correct cutter module from the Cutter Type box (1). Us the right and left Navigation Arrows (2) to scroll through the cutter head list.

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________________________________________________________Operation Note: Custom cutters can be entered, see the Operation and Maintenance Manual, “Shear Calibration - Entering Custom Cutter Heads”.

4. Raise the cutter drum all the way using the Shear Up button (6).

5. Press the Set Tip Calibration button (4).

6. Lower the cutter drum to level position by pressing the Shear Down button (5).

bubble level.

2. Press the Calibrate CM Level button (3).

3. Raw Count (1) and Current Level (2) (in degrees) are displayed. Should read 0.00° at calibrated point.

Shear Extended 1

7. Press the Set level Calibration button (3).

Cutter Head Module (CHM) Level Calibration 2

1

2 Illustration 31 (1)

Shear Setup

(2)

Miner Setup

3 Illustration 30 (1)

Raw Count

(2)

Current Level

(3)

CM Level

3 Illustration 32 (3) Shear Extended Options

Set the CM Level Calibration controls: 1. Level the cutter module from front to rear by adjusting the track lift cylinders. Check with a

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Operation ________________________________________________________

4 Illustration 33 (4)

Shear Extended Options page

Shear Extended Options button (3) is used to access the Shear Extended Options page (4) and is located on the Shear MDSD Calibration page. It is accessed by selecting Miner Setup (2) and then Shear Setup (1).

Table 7 describes the icons.

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________________________________________________________Operation Table 7 Symbol

Description

Function

Shear MDSD Settings

Side “A” Minimum

Sets the voltage output during A Side Minimum MDSD Calibration. A Side Minimum is set to 0.5 Volts.

Side “A” Maximum

Sets the voltage output during A Side Maximum MDSD Calibration. A Side Maximum is set to 5 Volts.

Shear Ramp Settings

Ramp

Controls how fast the program subtracts or adds voltage to the shear proportional output when it is ramping up or down. Allows 0.2 seconds to 1 second. The quickest the MDSD card will respond is 0.2 seconds. Ramp is set to 0.2 seconds.

Ramp Rate

Controls how much voltage the program subtracts or adds to the shear proportional output when it is ramping up or down. Allows 0.05 volts to 1.25 Volts. Ramp Rate is set to 0.05 Volts.

Max Shear Amps in Auto Mine

Controls the amount of amps that will adjust the sump rate while in auto mine.

Pushbutton is located in the bottom right corner of the navigation menu.

Restore Factory Settings

A Side Minimum = 0.5 Volts A Side Maximum = 5 Volts B Side Minimum = -0.5 Volts B Side Maximum = -5 Volts B Side Ramp = 0.2 Seconds Ramp Rate = 0.05 Volts

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Operation ________________________________________________________ Shear Calibration Page - Entering Custom Cutter Drums

1

3

2

4

The Shear Calibration page allows the user to add and calibrate custom cutter drum dimensions.

1

5 Illustration 35 (1)

Left Arrow

(2)

Entry field for new cutter head

(3)

Sump Field

Illustration 34

(4)

Right Arrow

(1)

(5)

Drum and Span Settings

Cutter Module Selection

1. To access the Shear Calibration page, select the correct cutter module type on the Miner Setup - Shear Page.

2. Us the Left Arrow (1) or Right Arrow (3) button to locate an empty space in the entry field (4). The Sump Type field (3) will turn white. a. Enter a description of the new cutter module in the entry field ((2). b. Enter the cutter drum information in the Drum and Span Settings fields (5).

Note: A save icon will be displayed next to the right arrow when you start typing in the new cutter head entry field (2).

1

Illustration 36 (1)

Download icon

3. Press the Download icon (1) to download the new cutter head information to the PC.

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________________________________________________________Operation 1 1

Illustration 37 (1)

Delete

Note: If necessary, custom cutter heads profiles can be deleted. To delete a custom cutter head profile, press the Delete icon (1).

1

Illustration 39 (1) Shear MDSD Calibration

2

3

2

Illustration 38 (1)

Set Top Calibration

(2)

Shear Level Calibration

(3)

Shear Down

4. Press the Set Top Calibration icon (1).

5. Raise the cutter head to level using the Shear Down icon (3).

6. Press the Shear Level Calibration icon (2).

Shear MDSD Calibration Illustration 40

Always perform the MDSD calibration with the BPM pump in the OFF position. Unexpected movement could occur if calibration is performed without the BPM pump OFF.

(2) MDSD Card

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Operation ________________________________________________________ Table 8 describes the MDSD Card.

Table 8

3

1 Potentiometer Number

Description

P1

Ramp Time- Adjust Counter Clockwise (All of the way)

P2

Ramp Time- Adjust Counter Clockwise (All of the way)

P3

A Maximum

P4

B Maximum

P5

A Minimum

P6

B Minimum

Illustration 42

P7

FACTORY SETUP

(1)

A Maximum

(2)

A Minimum

(3)

B Maximum

(4)

B Minimum

2

Table 9 lists the proportional valve minimum and maximum settings.

Table 9 Proportional Valve Power Head Sump/Tram PTM2 Cradle PTM2 Trolley Shear

Location BPM I/O Enclosure PTM2 I/O Enclosure PTM2 I/O Enclosure Front Right I/O Enclosure

Setting (Min)

Setting (Max)

300 mA

700 mA

750 mA

1500 mA

750 mA

1500 mA

750 mA

1500 mA

MDSD A Side Calibration 1. Ensure that the BPM pump motor is off.

4

Always perform the MDSD calibration with the BPM pump in the OFF position. Unexpected movement could occur if calibration is performed without the BPM pump OFF. 2. Press and hold the A Minimum icon (2) until Step 3 is complete.

Note: There should be approximately 0.5 Volts on terminals 9 and 12 on the MDSD card.

3. Place a meter in series with Pin 3 on the MDSD card. Adjust screw P5 (A Minimum) until the meter reads 750 mA. 4. Press and hold the A Maximum icon (1) until Step 5 is complete.

Note: There should be approximately 5 Volts on terminals 9 and 12 on the MDSD card.

5. Place a meter in series with Pin 3 on the MDSD card. Adjust screw P3 (A Maximum), until the meter reads 1500 mA. 6. Repeat Steps 2 through 5 until the A Minimum and A Maximum amps are steady.

MDSD B Side Calibration

Illustration 41

1. Ensure that the BPM pump motor is off.

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________________________________________________________Operation 2. Press and hold the B Minimum icon (4) until Step 3 is complete.

3

4

Note: There should be approximately -0.5 Volts on terminals 9 and 12 on the MDSD card.

Place a meter in series with Pin 5 on the MDSD card. Adjust screw P6 (B Minimum) until the meter reads 750 mA. 4. Press and hold the B Maximum icon (3) until Step 5 is complete.

Illustration 44 (3)

Shear Setup

Note: There should be approximately -5 Volts on terminals 9 and 12 on the MDSD card.

(4)

Miner Setup

5. Place a meter in series with Pin 5 on the MDSD card. Adjust screw P4 (B Maximum), until the meter reads 1500 mA.

To access the Cutter Module Rack page, press the Miner Setup button (4) and the Shear Setup button (3) on the navigation bar.

6. Repeat Steps 2 through 5 until the B Minimum and B Maximum amps are steady.

Access the Cutter Module Rack Extended Options page by pressing the extended options button (2)

Cutter Module Rack The cutter module rack page allows configuration of the cutter head rack system.

Illustration 45

Table 10 describes the icons on the Cutter Module Rack - Extended Options page.

1

2

Illustration 43 (1)

Cutter Module Rack option

(2)

CM Rack Extended options

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Operation ________________________________________________________ Table 10 Symbol

Description

Function

Cutter Module Rack I/O Options Cutter Module I/O Options

When checked provides more options for the cutter module rack system.

Cutter Module Rack Digital Options

This box is only available if Use Cutter Module Rack I/O is checked in the cutter module rack I/O Options Box is checked. This box provides additional options for CH setup.

CH 24V Present

Configures program to use cutter module rack 24 Volts present.

Camera “UP”

Configures program to use cutter module rack camera “up”.

Camera “Down”

Configures program to use cutter module rack camera “down”.

Gathering Pan “UP”

Configures program to use cutter module rack gathering pan “up”.

Gathering Pan “DOWN”

Configures program to use cutter module rack gathering pan “down”.

Recirculation Valve

Configures program to use cutter module recirculation valve with CM I/O Rack.

Cutter Module Rack Analog Options

Provide setup choices for cutter module rack Analog Options.

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________________________________________________________Operation Table 10 Symbol

Description

Function

Cutter Module Rack I/O Options, continued Shear Port A Pressure

Configures CH I/O Rack for input from Cutter Module Shear Port A pressure.

Shear Port B Pressure

Configures CH I/O Rack for input from Cutter Module Shear Port B pressure.

Gathering Motor 1 Amps.

Configures CH I/O Rack for input from Cutter Module Gathering Motor 1 Amps.

Gathering Motor 2 Amps

Configures CH I/O Rack for input from Cutter Module Gathering Motor 2 Amps.

Top Gamma Sensor

Configures CH I/O Rack for input from Cutter Module Top Gamma Sensor.

Bottom Gamma Sensor

Configures CH I/O Rack for input from Cutter Module Bottom Gamma Sensor.

CHM Level Pendulum Pot

Configures CH I/O Rack for input from Cutter Module CHM Level Pendulum Pot.

Gear Case Temperature IF EQUIPPED

Configures CH I/O Rack for input from Cutter Module Gear Case Temperature.

Left Shear Transducer

Configures CH I/O Rack for input from Cutter Module Left Shear Transducer.

Right Shear Transducer or Pendulum Pot

Configures CH I/O Rack for input from Cutter Module Right Shear Transducer or Pendulum Pot.

Shear Proportional Valve

Configures CH I/O Rack for output to Cutter Module Shear Proportional Valve.

Steering/ Navigation Interface Options

Provides setup options for Steering/Navigation Interface.

Navigation Interface Selection Box.

When checked configures program for use of a Inertial Navigation guidance system.

Navigation Provides extended options for setting up a Interface Extended navigation system.

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Operation ________________________________________________________ Table 10 Symbol

Description

Function

Cutter Module Rack I/O Options, continued EGI Interface Selection

When checked configures program for an EGI interface.

Octans Interface Selection

When checked configures program for an Octans interface.

Cutter Module Water Pump Options Cutter Module Water Pump Selection Cutter Module Water Pump Extended Options

Configures Program for use of a cutter module water pump.

Provides extended options for setting up cutter module water pump system.

Navigation Interface page

3

The Navigation Interface page allows configuration of the Navigation system.

4 Illustration 47

1

(3)

Shear Setup

(4)

Miner Setup

2

Illustration 46 (1)

Cutter Module Rack option

(2)

CM Rack Extended Options Button

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________________________________________________________Operation

6

5 Illustration 48 (5)

Navigation Interface Box

(6)

Extended Options

7

Illustration 49 (7)

Navigation Interface page

To access the Navigation Interface page (7), press the Miner Setup button (4) and the Shear Setup button (3) on the navigation bar. Next press the CM Rack Extended Options button (2). Press the Extended Options icon (6) in the Navigation Interface Box (5).

Table 11 describes the icons on the Navigation Interface page (7).

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Operation ________________________________________________________ Table 11 Symbol

Description

Function

Navigation Heading

Cutter head heading according to the Navigation unit.

CM roll left to right

Indicates the roll of the cutter module - right to left.

CM pitch front to back

Indicates the pitch of the cutter module – front to back.

Octans Refresh Button

This does a refresh on the Octans navigation unit which causes the unit to regenerate the heading information.

Navigation Status Information

Navigation Status Information

Provides status information on the Navigation system

Actual Heading

Top number displays the actual CM Heading.

Heading Set Point

Second number displays the programmed heading set point.

Deviation from Centerline

Third number displays the cutter module deviation from centerline.

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________________________________________________________Operation Table 11 Symbol

Description

Function

Navigation Initialization Parameters Navigation Initialization Parameters

Provides settings for Navigation Initialization.

Latitude Setting

Provides input for initial Latitude.

Longitude Setting

Provides input for initial Longitude.

Altitude

Provides input for initial Altitude.

Navigation Cutter Module Steering Settings

Navigation Cutter Head Steering Settings

Provides options and setup of Navigation Steering system.

Mode Selection

Offers steering mode selections.

Steering Left Raw Count.

Indicates Raw Count of left steering cylinder transducer.

Steer Left Button.

Provides steer left operation.

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Operation ________________________________________________________ Table 11 Symbol

Description

Function

Navigation Cutter Head Steering Settings Steering Right Raw Count

Indicates Raw Count of right steering cylinder transducer.

Steer Right Button

Provides steer right operation.

Captured Left Steer Cylinder In Raw Count

Indicates Raw Count for captured left cylinder in.

Capturing Button for Left Cylinder In

Captures or sets raw count for left steer cylinder in.

Captured Left Steer Cylinder Out Raw Count

Indicates Raw Count for captured left cylinder out.

Capturing Button for Left Cylinder Out

Captures or sets raw count for left steer cylinder out.

Captured Right Steer Cylinder In Raw Count

Indicates Raw Count for captured right cylinder in.

Capturing Button for Right Cylinder In

Captures or sets raw count for right steer cylinder in.

Captured Right Steer Cylinder Out Raw Count

Indicates Raw Count for captured right cylinder out.

Capturing Button for Right Cylinder Out

Captures or sets raw count for right steer cylinder out.

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________________________________________________________Operation Table 11 Symbol

Description

Function

Navigation Cutter Module Steering Settings, continued Cylinder Stroke Length

Length of the steer cylinder stroke.

Steer Length

Provides setting for how far the steer cylinders will extend.

Heading Delta Setting

Provides setting for how many degrees the heading can change before steering correction.

Ribbing Delta Setting

Provides setting for how many inches the ribbing can change before steering correction.

Correction Time Setting

Provides time setting for how long the steering correction will try to correct the heading.

Alarm Time Setting

Provides time setting for how long a heading deviation is present before there is an alarm

Cutter Module Steering Cylinder Calibration

1

4

2

5

3

6

Illustration 51

1 Illustration 50 (1)

(1)

Extend/Retract Left Steering Cylinder

(2)

Calibrate Left Steering Cylinder Down

(3)

Calibrate Left Steering Cylinder Up

(4)

Extend/Retract Right Steering Cylinder

(5)

Calibrate Right Steering Cylinder Down

(6)

Calibrate Right Steering Cylinder Up

Cutter Module Steering Controls

The Cutter Module Steering Controls (1) are accessed from the navigation Interface Extended Options screen.

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Operation ________________________________________________________ To calibrate the left steering cylinder: 1. Press the Extend Left Steering Cylinder icon (1).

2. Press the Calibrate Left Steering Cylinder Up icon (2).

3. Press the Retract Left Steering Cylinder icon (3).

4. Press the Calibrate Left Steering Cylinder Down icon (1).

(3)

Shear Setup

(4)

Miner Setup

(5)

Extended Options

Access the Cutter Module Water Pump Extended Options screen by first selecting the Shear Setup button (3) and then selecting the Cutter Module Rack Option (1). Next, select the Extended Options button (5).

To calibrate the right steering cylinder: 1. Press the Extend Right Steering Cylinder icon (4).

2. Press the Calibrate Right Steering Cylinder Up icon (5).

3. Press the Retract Right Steering Cylinder icon (6).

4. Press the Calibrate Right Steering Cylinder Down icon (4).

Illustration 53

Table 12 describes the icons on the Cutter Head Extended Options screen.

2 1 3

4

5 Illustration 52 (1)

Cutter Module Rack Option

(2)

Extended Options

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________________________________________________________Operation Table 12 Symbol

Description

Function

Motor Operation Motor Operation

Provides BPM motor operation from this page.

Cutter Head Water Pump Cutter Head Water Pump

Provides settings for cutter head water pump.

Raw count of water pump

Indicates raw count of water pump.

Water Pump On

Provides setting for water pump on.

Water Pump Off

Provides setting for water pump off.

Water Pump Alarm

Provides setting for water pump alarm.

Water Pump Alarm Delay

Provides setting for water pump alarm delay.

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Operation ________________________________________________________ Gamma 1

4

2

3

Illustration 54 (1)

Shear Setup

(2)

Miner Setup

(3)

Extended Options

(4)

Gamma Screen

The Gamma Screen (4) is accessed by pressing the Miner Setup button (2), the Shear Setup button (1), and then the Extended Options button (3).

Table 13 describes the icons on the Gamma Screen (4).

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________________________________________________________Operation Table 13 Symbol

Description

Function

Gamma Sensors Provides selection of Gamma Sensors installed.

Gamma Sensors Selection Box

Top Gamma Calibration

Top Gamma Calibration Box

Provides calibration options for Top Gamma Sensors.

Raw Count

Displays the raw count for the top gamma sensor input.

Captured

Displays the raw counts that were captured when the calibrate top minimum, coal pushbutton was pressed.

Calibrate Gamma Top Minimum Coal Position Minimum Coal Thickness

Calibrates the top gamma sensor with the shear in the top position. There would be a minimum amount of coal above the sensor.

Enter the amount of coal above the sensor when the head is sheared up.

Captured

Displays the raw counts that were captured when the calibrate top maximum coal pushbutton was pressed.

Calibrate Gamma Top Maximum Coal Position

Calibrates the top gamma sensor with the shear in the top position as far from the top that the sensor will read.

There would be a maximum amount of coal above the sensor.

Maximum Coal Thickness

Enter the amount of coal above the sensor when the head is sheared up with the most coal between the sensor and the top.

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Operation ________________________________________________________ Table 13 Symbol

Description

Function

Bottom Gamma Calibration

Bottom Gamma Calibration Box

Provides calibration options for Bottom Gamma Sensors.

Raw Count

Displays the raw count for the bottom gamma sensor input.

Captured

Displays the raw counts that were captured when the calibrate bottom maximum, coal pushbutton was pressed.

Calibrate Gamma Bottom Maximum Coal Position

Calibrates the bottom gamma sensor with the shear in the bottom position. There would be a maximum amount of coal above the sensor.

Minimum Coal Thickness

Enter the amount of coal between the sensor and the bottom when the head is sheared down.

Captured

Displays the raw counts that were captured when the calibrate bottom minimum coal pushbutton was pressed.

Calibrate Gamma Bottom Minimum Coal Position.

Calibrates the bottom gamma sensor with the shear in the bottom position with a minimum amount of coal between the sensor and the bottom.

Minimum Coal Thickness

Enter the amount of coal between the sensor and the bottom when the head is sheared down with the least amount of coal between the sensor and the bottom.

Cutter Drum Operations

Cutter Drum Operations Box

Provides operation options for cutter drum from this page.

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________________________________________________________Operation Table 13 Symbol

Description

Function

Shear top current position

Displays the current position of the top of the cutter drum. Measurements can be displayed on metric or standard based on the selection switch on the Miner Setup page.

Shear top set point

Allows the operator to enter the desired stopping position for the top of the cutter drum.

Shear top +

Adds 1 inch or 1 centimeter to the top set point.

Shear top -

Subtracts 1 inch or 1 centimeter to the top set point.

Shear Up

Shears the cutter head up.

Shear Down

Shears the cutter head down.

Shear bottom current position

Displays the current position of the bottom of the cutter drum. Measurements can be displayed on metric or standard based on the selection switch on the Miner Setup page.

Shear bottom set point

Displays the current position of the bottom of the cutter drum. Measurements can be displayed on metric or standard based on the selection switch on the Miner Setup page.

Shear bottom +

Adds 1 inch or 1 centimeter to the bottom set point.

Shear bottom -

Subtracts 1 inch or 1 centimeter to the bottom set point.

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Operation ________________________________________________________ 11

1 2

10 3

4

9

8

5

6

Illustration 55 (1)

Gamma Sensor Selection

(2)

Minimum Coal Thickness Value Adjustment

(3)

Minimum Coal Thickness Value

(4)

Shear Up

(5)

Maximum Coal Thickness Value

(6)

Maximum Coal Thickness Value Adjustment

(7)

Shear Down

(8)

Calibrate Bottom Minimum Coal Thickness

(9)

Calibrate Bottom Maximum Coal Thickness

(10) Calibrate Top Maximum Coal Thickness (11) Calibrate Top Minimum Coal Thickness

To calibrate top gamma sensor: 1. Press the Shear Up button (4) to raise the cutter head until there is a minimum amount of coal between the top gamma sensor and the top.

2. Enter the amount of coal between the sensor and the top in the Minimum Coal Thickness

7

Value cell (3). Use the Minimum Coal Thickness Value Adjustment icons (2) to adjust the thickness value.

3. Press the Calibrate Top Minimum Coal Thickness icon (11).

4. Press the Shear Down icon (7) until the raw counts from the top gamma sensor quit changing.

5. Press the Shear Up icon (4) until the raw counts start changing.

6. Measure the amount of coal between the sensor and the top. Enter the measurement in the Maximum Coal Thickness Value cell (5). Use the Maximum Coal Thickness Value Adjustment icons (6) to adjust the thickness value.

7. Press the Calibrate Top Maximum Coal Thickness icon (10).

To calibrate bottom gamma sensor: 1. Press the Shear Up button (4) to raise the cutter head until there is a minimum amount of coal between the bottom gamma sensor and the

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________________________________________________________Operation bottom.

1

2. Enter the amount of coal between the sensor and the bottom in the Minimum Coal Thickness Value cell (3). Use the Minimum Coal Thickness Value Adjustment icons (2) to adjust the thickness value.

3. Press the Calibrate Bottom Minimum Coal Thickness icon (8).

2

4. Press the Shear Down icon (7) until the raw counts from the bottom gamma sensor quit changing.

5. Press the Shear Up icon (4) until the raw counts start changing.

6. Measure the amount of coal between the sensor and the bottom. Enter the measurement in the Maximum Coal Thickness Value cell (5). Use the Maximum Coal Thickness Value Adjustment icons (6) to adjust the thickness value.

7. Press the Calibrate Bottom Maximum Coal Thickness icon (9).

Power Head The Power Head page provides access to the setup of the power head controls such as sumping, stop blocking cylinders and push beam separation.

3 Illustration 56 (1)

Power Head Setup

(2)

Miner Setup

(3)

Power Head Page

To access the Power Head Page (3), press the miner setup icon (2) and then the Power Head Setup icon (1).

Table 14 describes the icons on the Power Head Page (3).

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Operation ________________________________________________________ Table 14 Symbol

Description

Function

Power Head Calibration

Power Head Calibration Box

Allows calibration of Power Head controls.

Sets Power Head Calibration points to a predefined position.

Restore Factory Settings

4-20 mA Rear Position = 27648 4-20mA Front Position = 0 20-4 mA Rear Position = 0 20-4mA Front Position = 27648 String Encoder Rear Position = 0

Raw: - top left hand corner

Displays the current Raw counts of the power head position input

Lower PH Latches in Retract

Provides option of automatically lowering Power Head Latches during retract or not.

Left Raw and Right Raw Count

Displays the current raw count for both transducers.

Extended Options

Displays the Miner Setup – Power Head Additional Settings Page.

Captured Raw Count for Reverse

Displays the raw counts captured for reverse for left transducer and right transducer if available.

Captured Raw Count for Forward

Displays the raw counts captured for forward for left transducer and right transducer if available.

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________________________________________________________Operation Table 14 Symbol

Description

Function

Power Head Calibration continued Calibrate Rear Position

Sets the current raw counts = to -1.1 inches.

Calibrate Front Position

Sump Cylinder Linear Transducers require the front stop to be calibrated.

Left Raw Count for Power Head Latches

Left Raw: 0 Displays left transducer raw count for left power head latch transducer.

Captured: Captured Raw Count for Left Power Head Latch

Right Raw Count for Power Head Latches

Captured: Captured Raw Count for Right Power Head Latch

Captured: 0 27648 First value is captured raw count for left power head latch transducer for power head latch up.

Second value is captured raw count for left power head latch transducer for power head latch down.

These values change every time a position is calibrated. They store the value of the 4 - 20 mA position sensor signal at that location.

Right Raw: 0 Displays right transducer raw count for right power head latch transducer.

Captured: 0 27648 First value is captured raw count for left power head latch transducer for power head latch up.

Second value is captured raw count for left power head latch transducer for power head latch down.

These values change every time a position is calibrated. They store the value of the 4 - 20 mA position sensor signal at that location.

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Operation ________________________________________________________ Table 14 Symbol

Description

Function

Power Head Calibration, continued

Power Head Unlatching Jacks Down

Power Head Unlatching Jacks Up

Extends the power head unlatching jacks to the down position.

Retracts the power head unlatching jacks to the up position.

(Retract button only appears when the power head jacks are extended.)

Calibrate Push beam latches down

Transfers the current raw count into the calibrated down/extended position, therefore calibrating the jacks down position.

Calibrate Push beam latches up

Transfers the current raw count into the calibrated up/ retracted position, therefore calibrating the jacks up position.

Position Source type of signal for Power Head Position

Allows choice of power head position signal.

Sump/Tram MDSD Calibration

Sump/Tram MDSD Calibration Box

Allows calibration of Sump/Tram MDSD Card. It is important to shut off the BPM pumps when calibrating the MDSD card.

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________________________________________________________Operation Table 14 Symbol

Description

Function

Sump/Tram MDSD Calibration, continued Side A Maximum.

Sends 5 Volts to the MDSD card while button is pressed. This allows calibration of the maximum output of the MDSD card that controls the Sump/Tram Proportional valve.

Side A Minimum.

Sends 0.5 Volts to the MDSD card while button is pressed. This allows calibration of the minimum output of the MDSD card that controls the Sump/Tram Proportional valve.

Extended Options.

Displays the Miner Setup – Power Head Additional Settings Page.

Cylinder Calibration / Configuration Stop Blocking/ String Blocking Cylinder Calibration Box

Allows setup and calibration of blocking, unlatching, and string blocking cylinders.

Retracts the blocking jacks when pressed.

Blocking Down

(Retract button only appears when the blocking jacks are extended.)

Calibrate Blocking Down

Transfers the current raw count into the calibrated down/retracted position, therefore calibrating the blocking jacks down position.

Calibrate Blocking Up

Transfers the current raw count into the calibrated up/ extended position, therefore calibrating the jacks up position.

Front Left Raw

10 Displays the front left stop blocking raw count position input.

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Operation ________________________________________________________ Table 14 Symbol

Description

Function

Cylinder Calibration / Configuration, continued Front Left Raw

10 Displays the front left stop blocking raw count position input.

Captured count above “calibrate stop blocking jacks down”

0 Displays the captured raw counts for the front left stop blocking jack down position.

Captured count above “calibrate stop blocking jacks up”

27648 Displays the captured raw counts for the front left stop blocking jacks up position.

Front Right Raw

10 Displays the front right stop blocking raw count position input.

Captured count below “calibrate stop blocking jacks down”

0 Displays the captured raw counts for the front right stop blocking jack down position.

Captured count below “calibrate stop blocking jacks up”

27648 Displays the captured raw counts for the front right stop blocking jacks up position.

String Blocking Jacks up

Extends the string blocking jacks.

Retracts the string blocking jacks.

String Blocking Jacks down

Calibrate String Blocking Jacks down

(Retract button only appears when the string blocking jacks are extended.)

Transfers the current raw count into the calibrated down/retracted position, therefore calibrating the string blocking jacks down position.

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________________________________________________________Operation Table 14 Symbol

Description

Function

Cylinder Calibration / Configuration, continued Calibrate String Blocking Jacks up

Transfers the current raw count into the calibrated up/ extended position, therefore calibrating the string blocking jacks up position.

Front Left Raw Count

10 Displays the front left string blocking raw count position input.

Captured above “calibrate string blocking jacks down”

0 Displays the captured raw counts for the string blocking jacks down position.

Captured above “calibrate string blocking jacks up”

27648 Displays the captured raw counts for the string blocking jacks up position.

Front Right Raw Count

10 Displays the back right string blocking jack raw count position input

Captured below “calibrate string blocking jacks down”

0 Displays the captured raw counts for the front right string blocking jack up position.

Captured below “calibrate string blocking jacks up”

27648 Displays the captured raw counts for the front right string blocking jack down position.

Restore Factory Settings

Sets calibrated up raw position to 27,648 and calibrated down raw position to 0 for the blocking and unlatching jacks.

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Operation ________________________________________________________ Table 14 Symbol

Description

Function

Cylinder Calibration / Configuration, continued Selects when string blocking will be used.

String Blocking selection box

Push Beam Separation selection box

Configures program for push beam separation cylinders when install is selected.

Power Head Operations

Power Head Operations Box

Power Head Operation.

Box above reverse

Minimum reverse speed.

Box above forward

Minimum forward speed.

Power Head Reverse

Moves the power head backwards at the minimum speed settings.

Power Head Forward

Moves the power head forward at the minimum speed settings.

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________________________________________________________Operation Table 14 Symbol

Description

Function

Power Head Operations, continued Power Head proportional valve output percentage

0.0% Displays the output from the MDSD card to the sump proportional valve. The voltage being output from the analog output card can be calculated by multiplying the percentage by .05

Raw Position

The value at the analog input for power head position.

The input can be changed on the power head setup page.

Actual Position

Displays the power head actual position. This number will be displayed in inches or centimeters based on the metric or standard selection on the Miner Setup page.

Actual Speed

Displays the power head speed in inches/second or centimeters/second. Metric or standard measurements change according to the selection on the Miner Setup – Home Page.

Current Depth

Displays the current hole depth. Hole depth is calculated when the miner is in Auto Mine Mode and the power head latches are down.

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Operation ________________________________________________________ Stop Blocking / String Blocking Cylinder Calibration

To calibrate stop blocking jack: 1. Press the Raise/Lower Blocking Jack icon (2).

2. Press the Calibrate Blocking Jack Up icon (4).

3. Press the Raise/Lower Blocking Jack icon (2).

4. Press the Calibrate Blocking Jack Down icon (3).

To calibrate the string blocking jack: 1. Press the Raise/Lower String Blocking Unlatching Jack icon (5).

2. Press the Calibrate String Blocking Jack Up icon (7).

3. Press the Raise/Lower String Blocking Jack icon (5).

1 2

3

4

5

6

7

4. Press the Calibrate String Blocking jack Down icon (6).

Illustration 57 (1)

Stop Blocking / String Blocking Cylinder Calibration

(2)

Raise/Lower Stop Blocking Jack

(3)

Calibrate Stop Blocking Jack Down

(4)

Calibrate Stop Blocking Jack Up

(5)

Raise/Lower String Blocking Unlatching Jack

(6)

Calibrate String Blocking Jack Down

(7)

Calibrate String Blocking Jack Up

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________________________________________________________Operation Power Head Position Calibration

4

5

2

Illustration 59

1

3

(1)

Calibrate Rear Position

(2)

Calibrate Forward Position

(3)

Position Source

(4)

Power Head Reverse

(5)

Power Head Forward

Illustration 58

To calibrate the power head position:

(1)

Power Head Position Page

(2)

Power Head Calibration

1. Select the correct position in the power head Position Source box (3).

(3)

Power head operations

The power head position calibration controls (2), (3), are located on the Power Head Position Page (1).

2. Press the Power Head Reverse icon (4) to move the power head to the rear position.

3. After the power head is all the way back, press the Calibrate Rear Position icon (1).

4. Press the Power Head Forward icon (5) and move the power head to the override position.

5. After the power head is all the way forward, press the Calibrate Forward Position icon (2).

Note: Row counts and captured values will be displayed in the calibration box.

1

2

3

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Operation ________________________________________________________ Power Head Extended Options (5) Power Head Extended Options Page

1

2

4

3

The Power Head Extended Options page (5) provides calibration options for power head positions and options such as horizontal auger setup positions. This page is accessed by pressing the Miner Setup icon (2) and the Power Head Setup icon (1) followed by pressing the Extended Options icon (3) in the bottom left corner of the power head calibration box or the Extended Options icon (4) in the bottom left corner of the Sump/Tram MDSD Calibration box.

Table 15 describes the icons on the Power Head Extended Options page (5).

5 Illustration 60 (1)

Power Head Setup

(2)

Miner Setup

(3)

Extended Options button

(4)

Extended Options button

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________________________________________________________Operation Table 15 Symbol

Description

Function

Power Head MDSD Settings Power Head MDSD Settings

Provides options for setting voltage for calibrating the Sump/Tram MDSD card.

A-MAX and A-MIN calibration set points

Configures the range of the MDSD card during calibration. Default values are Minimum = 0.5 Volts and Maximum = 5.0 Volts

Power Head Setup

Power Head Setup Box

Provides setup and calibration options for power head positions and pressures.

Suggestions

Provides some suggestions for power head position settings.

Override

Sets the maximum forward position of the miner.

Maximum

Sets the position the power head will stop at under normal manual operation.

Retract Box

Provides power head position setting for stopping in retract going forward.

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Operation ________________________________________________________ Table 15 Symbol

Description

Function

Power Head Setup, continued Front Slow Down

Controls where the power head slows down in Auto Retract.

In Position Window

Sets a plus or minus window around other power head set points. When the power head position is within this range it will be considered at that specific position.

String Blocking Tolerance Box

Provides a setting for a window around the string blocking position.

String Connection

Sets the position where the power head will stop to connect to the string (Push beams in front of the miner) in auto mine.

Beam Connection

Sets the position where the power head connects to the rear of the push beam in the miner.

Minimum

Defines the maximum rear position.

Ramp

Controls how fast voltage will be taken from or added to the MDSD card when starting or stopping power head movement. Default = 0.2 seconds.

Ramp Rate

Controls how much voltage is taken off or added to the MDSD card when starting or stopping power head movement. Default = 1.25 Volts.

Cylinders in position window

When the stop blocking or power head unlatching jacks are within this many counts of the calibrated positions they will be considered at the calibrated position.

Motion Alarm Box

Provides a time setting for how much time can pass without power head movement before an alarm.

P1 Pressure Calibration

Controls how much voltage is sent to the MDSD card when setting up the MDSD card.

Maximum Pull Pressure Setting

Provides setting for maximum pull pressure and a timer for how much time it can pull at this setting without an alarm.

Forward Brake Valve Timer

Time setting for how long forward brake valve is on after stopping power head forward motion.

Reverse Brake Valve Timer

Time setting for how long reverse brake valve is on after stopping power head reverse motion.

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________________________________________________________Operation Table 15 Symbol

Description

Function

Horizontal Motor Control Horizontal Motor Controls Box

Provides setup options for Horizontal Auger Motor Controls.

Reset Factory Settings

Resets options to a factory default setting.

Alternate Horizontal Auger Motor Starting Box

Provides alternate options for starting horizontal auger motors.

Horizontal Protection

Enables Horizontal Protection. Horizontal Protection will delay the auto mine cycle when motor amps have exceeded the current and time set points.

Current

Specifies the amount of current the horizontal motors must see before pausing the auto mine cycle.

Time

Specifies the amount of time the horizontal auger amps must exceed the current set point before pausing the auto mine cycle.

Extended Options

Provides some extended options for the VFD controls.

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Operation ________________________________________________________ PTM2 Setup 2

1

3 Illustration 61 (1)

Miner Setup

(2)

PTM2 Setup

(3)

PTM2 Setup Page

The PTM2 Setup Page (3) provides setup and calibration options for the PTM2 system. To access the PTM2 Setup Page (3), press the Miner Setup icon (1) and then the PTM2 Setup icon (2).

Note: The PTM2 Setup icon (2) only appears on the navigation bar if the rear discharge and PTM2 option are selected on the miner setup page.

Table 16 describes the icons on the PTM2 Setup Page (3).

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________________________________________________________Operation Table 16 Symbol

Description

Function

PTM2 Settings PTM2 Settings Box

Provides settings of PTM2 system.

Table Side Left

PTM Table Side Left.

Table Side Right

PTM Table Side Right.

Type2 Traverse Design

The original PTM2 requires the cylinders to be uninstalled and switched from one side of the machine to the other. Type2 allows the PTM2 to be moved from one side to the other without uninstalling anything.

Two options:

Trolley Feedback list box

Front (towards hose reel) – Trolley Feedback position comes from analog input PIW802.

Rear (towards cab) - Trolley Feedback position comes from analog input PIW804.

Extended Options

Displays the Miner Setup –PTM2 Settings Additional Settings Page.

Cradle Lift MDSD Calibration

Cradle Lift MDSD Calibration Box

Provides Calibration options for the Cradle Lift MDSD card. It is important while doing these calibrations to turn off the BPM pumps.

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Operation ________________________________________________________ Table 16 Symbol

Description

Function

Cradle Lift Calibration, continued Raw Count

Displays the cradle lift raw count position.

Captured count above “Calibrate Cradle Up “

27648 The Cradle Raw Count Position when the cradle up pushbutton was pressed.

Calibrate Cradle Up

Stores the cradle position raw counts when the cradle is in the up position.

Captured count to the left of “calibrate top beam”

5000 Displays the cradle raw count position that was recorded when calibrate top beam pushbutton was pressed.

Calibrate top beam

Stores the cradle position raw counts when the cradle is at the top beam position.

Captured above “calibrate bottom beam”

0 Displays the cradle raw count position that was recorded when calibrate bottom beam pushbutton was pressed.

Calibrate bottom beam

Stores the cradle position raw counts when the cradle is at the bottom beam position.

Cradle Shift Raw Count

0 Displays the cradle shift raw count position.

Captured count above cradle “shift calibrate forward position”

0 Displays the cradle shift position raw counts stored when the calibrate cradle shift forward pushbutton was pressed.

Calibrate Cradle Shift Forward

Stores the cradle shift position raw counts when the cradle shift is in the forward position.

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________________________________________________________Operation Table 16 Symbol

Description

Function

Cradle Lift Calibration, continued Captured count above “calibrate cradle shift rear”

Displays the cradle shift position raw counts stored when the calibrate cradle shift backward pushbutton was pressed.

Calibrate cradle shift rear

Stores the cradle shift position raw counts when the cradle shift is in the backward position.

Trolley Calibration

Trolley Calibration Box

Provides Calibration Options for trolley system.

Restore Factory Settings

Sets trolley out calibration to 0 and trolley in calibration to 27648.

Raw Count

Displays the trolley raw count position

Captured above “trolley out calibration”

0 - Displays the trolley position raw counts stored when the trolley out pushbutton was pressed.

Calibrate Trolley Out

Stores the Trolley position raw counts when the Trolley is in the out position.

Captured above “calibrate trolley in”

27648 - Displays the trolley position raw counts stored when the trolley in pushbutton was pressed.

Calibrate trolley in

Stores the Trolley position raw counts when the Trolley is in the in position.

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Operation ________________________________________________________ Table 16 Symbol

Description

Function

PTM2 Operations

PTM2 Operations Box

Provides the ability to operate and provides status information about the PTM2 system on this page.

Cradle Position count

Displays the raw count input from the cradle position transducer.

Trolley Position count

Displays the raw count input from the trolley position transducer.

Cradle Shift Position count

Displays the raw count input from the cradle shift position transducer.

Beams on the table

Displays the number of beams on the table. The program ramps the cradle movement up and down based on the number of beams on the table.

PTM2 Safe

Displays the current status of the PTM2. The PTM2 Safe light will be green as long as the cradle is in the up position.

Cradle Up Indicator

Turns green when the cradle is at the calibrated up position.

Cradle Down Indicator

Turns green when the cradle is at the calibrated down position.

Trolley In Indicator

Turns green when the trolley is at the calibrated in position.

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________________________________________________________Operation Table 16 Symbol

Description

Function

PTM2 Operations continued Trolley Out Indicator

Turns green when the trolley is at the calibrated out position.

PTM2 push beam gripper Status

Displays the current status of the PTM2 push beam grippers.

PTM2 push beam gripper release

Opens the PTM2 push beam grippers.

PTM2 close push beam gripper

Closes the PTM2 push beam grippers.

Cradle Up

Raises the PTM2 cradle. Motion is latched in when the miner is in auto mine. To stop motion press the cradle down pushbutton.

Cradle Down

Moves the PTM2 cradle down.

Trolley In

Moves the PTM2 trolley into the miner.

Trolley Out

Moves the PTM2 trolley out.

Cradle Shift Forward

Moves the PTM2 cradle towards the hose reel.

Cradle Shift Backward

Moves the PTM2 cradle towards the cab.

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Operation ________________________________________________________

1

2 3

6

5

4

(1)

Cradle Up

(2)

Cradle Down

(3)

PTM2 Trolley In

(4)

PTM2 Trolley Out

(5)

Cradle Shift Forward

(6)

Cradle Shift Rear

(7)

Calibrate Cradle Up

(8)

Calibrate Top Beam Position

(9)

Calibrate Bottom Beam Position

(10) Calibrate Cradle Shift/Forward (11) Calibrate Cradle Shift/Rear

7

(12) Calibrate Trolley Out (13) Calibrate Trolley In

8

To calibrate the PTM2 position:

9

1. Press the Cradle Up icon (1) to raise the cradle all the way up.

2. Press the Calibrate Cradle Up icon (7).

3. Press the PTM2 Trolley Out icon (4) to move the PTM2 trolley to the outside position.

4. Press the Calibrate Trolley Out icon (12).

5. Press the Cradle Down icon (2) to lower the cradle to the top beam position (there must be two beams on the table).

6. Press the Calibrate Top Beam Position icon (8).

11

10

7. Use the Cradle Up icon (1) to raise the cradle and remove the top beam from the table.

8. Press the Cradle Down icon (2) to lower the cradle to the bottom beam position (there must be only on beam on the table).

9. Press the Calibrate Bottom Beam Position icon (13).

10. Raise the cradle all the way up.

11. Trolley the PTM2 in.

12

13

12. Press the calibrate trolley in icon (13)

Illustration 62

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________________________________________________________Operation To calibrate the PTM2 shift cylinder: 1. Press the Cradle Shift Forward icon (6) to position the cradle all the way forward.

2. Press the Calibrate Cradle Shift/Forward icon (10).

(1)

Miner Setup

(2)

PTM2 Setup

(3)

Extended Options

(4)

Extended Options

(5) Extended Options

3. Press the Cradle Shift Rear icon (5) to position the cradle to the rear position.

4. Press the Calibrate Cradle Shift/Rear icon (11).

PTM2 Extended Options 2

1

3

Illustration 64

The PTM2 Extended Options Page (6) provides access to additional setup parameters for the PTM2 system. It is accessed by pressing the Miner Setup icon (1) and then the PTM2 Setup icon (2). Next press the Extended Options icon (3) on the PTM2 Settings box, the Extended Options icon (4) on the Cradle Lift MDSD Calibration box, or the Extended Options icon (5) on the Trolley MDSD Calibration box.

4

Table 17 describes the icons on the PTM2 Extended Options Page.

5

Illustration 63

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Operation ________________________________________________________ Table 17 Symbol

Description

Function

PTM2 Cradle MDSD Settings PTM2 Cradle MDSD Settings Box

Provides options for setting up the Cradle MDSD card.

Side “A” Minimum

Sets the voltage output during A Side Minimum MDSD Calibration. A Side Minimum is set to 0.5 Volts.

Side “A” Maximum

Sets the voltage output during A Side Maximum MDSD Calibration. A Side Maximum is set to 5 Volts.

PTM2 Time Settings

PTM2 Time Settings Box

Provides alarm timers for no movement.

Cradle Motion Alarm

When a command is given to move the cradle and the raw counts do not change after this time frame the cradle no motion alarm will come on.

Trolley Motion Alarm

When a command is given to move the trolley and the raw counts do not change after this time frame the trolley no motion alarm will come on.

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________________________________________________________Operation Table 17 Symbol

Description

Function

PTM2 Trolley Settings PTM2 Trolley MDSD Settings Box

Provides options for setting the MDSD card for the trolley motion.

Side “A” Minimum

Sets the voltage output during A Side Minimum MDSD Calibration. A Side Minimum is set to 0.5 Volts.

Side “A” Maximum

Sets the voltage output during A Side Maximum MDSD Calibration. A Side Maximum is set to 5 Volts.

PTM2 Cradle Proportional Valve Settings PTM2 Cradle Proportional Valve Settings Box

Provides window options and other settings for the cradle setup options.

Minimum Down

Sets the minimum voltage sent to the card. This voltage will be used on the setup page and will be the voltage the PTM2 starts moving at when ramping up or ends at when ramping down.

Minimum Up

Sets the minimum voltage sent to the card. This voltage will be used on the setup page and will be the voltage the PTM2 starts moving at when ramping up or ends at when ramping down.

With Beam Down

Sets the maximum speed to be used when the grippers are closed going down.

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Operation ________________________________________________________ Table 17 Symbol

Description

Function

PTM2 Cradle Proportional Valve Settings, continued With Beam Up

Sets the maximum speed to be used when the grippers are closed going up.

Without Beam Down

Sets the maximum speed to be used when the grippers are open going down.

Without Beam Up

Sets the maximum speed to be used when the grippers are open going up.

Setup up and down

This sets the speed of the PTM2 cradle when on the setup page when calibrating.

In Position

When the cradle is plus or minus this many raw counts of a calibrated position the program will see it as being in that position.

Slow down windows

Defines how soon the cradle will start slowing down before a calibrated position.

Slow Ramp

Defines how much voltage is added or subtracted and how often when the cradle is moving with a beam.

Fast Ramp

Defines how much voltage is added or subtracted and how often when the cradle is moving without a beam.

PTM2 Trolley Proportional Valve Settings Box.

Provides window options and other settings for the trolley setup options.

Minimum Out

Sets the minimum voltage sent to the card. This voltage will be used on the setup page and will be the voltage the PTM2 starts moving at when ramping up or ends at when ramping down. This is the setting for the Trolley out command.

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________________________________________________________Operation Table 17 Symbol

Description

Function

PTM2 Cradle Proportional Valve Settings, continued

Minimum In

Sets the minimum voltage sent to the card. This voltage will be used on the setup page and will be the voltage the PTM2 starts moving at when ramping up or ends at when ramping down. This is the setting for the Trolley in command.

With Beam Out

Sets the maximum speed to be used when the grippers are closed going out.

With Beam In

Sets the maximum speed to be used when the grippers are closed going in.

Without Beam Out

Sets the maximum speed to be used when the grippers are open going out.

Without Beam In

Sets the maximum speed to be used when the grippers are open going in.

Setup In and out

This sets the speed for the setup page when calibrating the PTM2 Trolley.

In Position

When the trolley is plus or minus this many raw counts of a calibrated position the program will see it as being in that position.

Slow Down Window

Defines how soon the trolley will start slowing down before a calibrated position.

Slow Ramp

Defines how much voltage is added or subtracted and how often when the trolley is moving with a beam.

Fast Ramp

Defines how much voltage is added or subtracted and how often when the trolley is moving without a beam.

Set up and down

This sets the speed of the PTM cradle when on the setup page when calibrating.

Restore Defaults Restore Factory Settings

Pushbutton is located in the bottom right corner of the navigation menu.

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Operation ________________________________________________________ PTM2 Trolley MDSD Calibration Controls 1

2

3

4

MDSD Card (5).

Table 19 gives the minimum and maximum settings for the proportional valves.

Table 18 Potentiometer Number P1

P3

Ramp Time- Adjust Counter Clockwise (All of the way) Ramp Time- Adjust Counter Clockwise (All of the way) A Maximum

P4

B Maximum

P5

A Minimum

P6

B Minimum

P7

FACTORY SETUP

P2

5

Description

Table 19

Illustration 65 (1)

A Minimum

(2)

A Maximum

(3)

B Minimum

(4)

B Maximum

(5)

MDSD Card

Proportional Valve Power Head Sump/ Tram PTM2 - Cradle

Minimum Setting 300 mA

Maximum Setting 700 mA

750 mA

1500 mA

PTM2 - Trolley

750 mA

1500 mA

Shear

750 mA

1500 mA

Always perform the MDSD calibration with the BPM pump in the OFF position. Unexpected movement could occur if calibration is performed without the BPM pump OFF.

The PTM2 Trolley MDSD calibration controls (1), (2), (3) and (4) are located on the PTM2 page and the MDSD Card (5).

Table 18 describes the potentiometers located on the

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________________________________________________________Operation a. Adjust screw P4 (B Maximum) until there is 1,500 mA.

MDSD A Side Calibration: 1. Turn the BPM pump motor off.

2. On the Miner Setup - PTM2 page, press and hold the A Minimum icon (1) until Step 3 is complete.

6. Repeat this procedure until B Minimum and B Maximum are steady.

PTM2 Cradle MDSD Calibration

a. There should be approximately 0.5 Volts on terminals 9 and 12 on the MDSD Card (5).

1

3. Place a meter in series with Pin 3 on the MDSD card (5).

2

3

4

a. Adjust screw P5 (A Minimum) until there is 750 mA. 4. On the Miner Setup - PTM2 page, press and hold the A Maximum icon (2) until step 5 is complete. a. There should be approximately 5 Volts on terminals 9 and 12 on the MDSD Card (5).

5. Place a meter in series with Pin 3 on the MDSD Card (5). a. Adjust screw P3 (A Maximum) until there is 1,500 mA. 5

6. Repeat this procedure until A Minimum and A Maximum are steady.

MDSD B Side Calibration: 1. Turn the BPM pump motor off.

2. On the Miner Setup - PTM2 page, press and hold the B Minimum icon (3) until Step 3 is complete. a. There should be approximately -0.5 Volts on terminals 9 and 12 on the MDSD Card (5).

3. Place a meter in series with Pin 5 on the MDSD Card (5). a. Adjust screw P6 (B Minimum) until there is 750 mA. 4. On the Miner Setup - PTM1 page, press and hold the B Maximum icon (4) until step 5 is complete. a. There should be approximately -5 Volts on terminals 9 and 12 on the MDSD card.

5. Place a meter in series with Pin 5 on the MDSD Card (5).

Illustration 66 (1)

A Minimum

(2)

A Maximum

(3)

B Minimum

(4)

B Maximum

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Operation ________________________________________________________ (5)

MDSD Card

The PTM2 Cradle MDSD calibration controls (1), (2), (3) and (4) are located on the PTM2 page and the MDSD Card (5).

Table 20 describes the potentiometers located on the MDSD Card (5).

Table 21 gives the minimum and maximum settings for the proportional valves.

Table 20 Potentiometer Number P1

Description

P3

Ramp Time- Adjust Counter Clockwise (All of the way) Ramp Time- Adjust Counter Clockwise (All of the way) A Maximum

P4

B Maximum

P5

A Minimum

P6

B Minimum

P7

FACTORY SETUP

P2

3. Place a meter in series with Pin 3 on the MDSD Card (5). a. Adjust screw P5 (A Minimum) until there is 750 mA. 4. On the Miner Setup - PTM2 page, press and hold the A Maximum icon (2) until step 5 is complete. a. There should be approximately 5 Volts on terminals 9 and 12 on the MDSD Card (5).

5. Place a meter in series with Pin 3 on the MDSD Card (5). a. Adjust screw P3 (A Maximum) until there is 1,500 mA. 6. Repeat this procedure until A Minimum and A Maximum are steady.

MDSD B Side Calibration: 1. Turn the BPM pump motor off.

2. On the Miner Setup - PTM2 page, press and hold the B Minimum icon (3) until Step 3 is complete. a. There should be approximately -0.5 Volts on terminals 9 and 12 on the MDSD Card (5).

Table 21 Proportional Valve Power Head Sump/ Tram PTM2 - Cradle

Minimum Setting 300 mA

Maximum Setting 700 mA

750 mA

1500 mA

PTM2 - Trolley

750 mA

1500 mA

Shear

750 mA

1500 mA

MDSD A Side Calibration (reference Fig. 91 and 92): 1. Turn the BPM pump motor off.

2. On the Miner Setup - PTM2 page, press and hold the A Minimum icon (1) until Step 3 is complete.

3. Place a meter in series with Pin 5 on the MDSD Card (5). a. Adjust screw P6 (B Minimum) until there is 750 mA. 4. On the Miner Setup - PTM1 page, press and hold the B Maximum icon (4) until step 5 is complete. a. There should be approximately -5 Volts on terminals 9 and 12 on the MDSD Card (5).

5. Place a meter in series with Pin 5 on the MDSD Card (5). a. Adjust screw P4 (B Maximum) until there is 1,500 mA. 6. Repeat this procedure until B Minimum and B Maximum are steady.

a. There should be approximately 0.5 Volts on terminals 9 and 12 on the MDSD Card (5).

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________________________________________________________Operation Pump 1 (Sump/Tram) Pressure Calibration

proportional pump. The pump controls (1), (2), and (3) are located on the Pump 1 page (4).To calibrate the pressure: Caution: This procedure requires two people and must be performed with the machine running.

Follow all safety procedures to ensure the safety of all personnel.

2

3

1

4

1. Back the Tri-Pressure Relief Valve (6) and the Compensator Valve (7) set screws out.

2. Start the pumps.

3. Have the operator press the High Pressure icon (2). This will send 1.25 Volts to the MDSD card and cause the pump to stroke.

4. Turn the Tri-Pressure Relief Valve (6) and Compensator Valve (7) set screws in (alternating). You will hear the oil dump across the relief.

5. Repeat step 4 until the relief dumps at 4,800 psi (331 bar), then back the Compensator Valve (7) set screw out until a pressure of 4,000 psi (276 bar) is obtained. Adjust back to 4,400 psi (303 bar). Note: Always set the pressure on up stroke.

Illustration 67 (1)

Operations –Testing page

(2)

Pump 1 High Pressure

(3)

Pump 1 Medium Pressure

(4)

Pump 1 Low Pressure

5

6. Have the operator press the Medium Pressure icon (3). This will send 1.25 Volts to the MDSD card and energize the medium pressure relief.

6

7. Turn the Tri-Pressure Relief Valve (6) set screw until a pressure of 3,000 psi (207 bar) is obtained.

8. Have the operator press the Low Pressure icon (4). This will send 1.25 Volt s to the MDSD car and energize the low pressure relief.

9. Turn the Tri-Pressure Relief Valve (6) set screw until a pressure of 1,800 psi (124 bar) is obtained.

7 Illustration 68 (5)

Pump P1

(6)

Tri-Pressure Relief Valve

(7)

Compensator Valve

Pump P1 (4) is a pressure compensated,

10. Tighten all jam nuts against the set screws on the valves (6) and (7).

Note: The P1 pump (5) is the closest pump to the electric motor. The Compensator Valve (7) adjustment is located on the side of the pump, toward the front of the miner, beneath the proportional valve and the adjustment screw is facing toward the rear of the pump (5). The Tri-Pressure Relief Valve (6) is located on top of the pump (5).

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Operation ________________________________________________________ Pump 1 Sump/Tram MDSD Calibration 1

2

Table 22 describes the potentiometers located on the MDSD Card (4).

Table 23 gives the minimum and maximum settings of the proportional valves.

Table 22 Potentiometer Number P1

P3

Ramp Time- Adjust Counter Clockwise (All of the way) Ramp Time- Adjust Counter Clockwise (All of the way) A Maximum

P4

B Maximum

P5

A Minimum

P6

B Minimum

P7

FACTORY SETUP

P2

3 4

Description

Table 23 Proportional Valve Power Head Sump/ Tram PTM2 - Cradle

Minimum Setting 300 mA

Maximum Setting 700 mA

750 mA

1500 mA

PTM2 - Trolley

750 mA

1500 mA

Shear

750 mA

1500 mA

MDSD A Side Calibration: 1. Turn the BPM pump motor off.

2. On the Miner Setup - Power Head Page (3) Press and hold the A Minimum icon (1) until Step 3 is complete.

Illustration 69 (1)

Sump/Tram MSDS Calibration Controls - A Minimum

(2)

Sump/Tram MSDS Calibration Controls - A Maximum

(3)

Power Head Page

(4)

MDSD Card

The Pump 1 Sump/Tram MDSD Calibration Controls (1) and (2) are located on the Power Head Page (3) and the MDSD Card (4).

a. There should be approximately 0.5 Volts on terminals 9 and 12 on the MDSD Card (4).

3. Place a meter in series with Pin 3 on the MDSD Card (4). a. Adjust screw P5 (A Minimum) until there is 300 mA. 4. On the Miner Setup - Power Head Page (3), press and hold the A Maximum icon (2) until step 5 is complete. a. There should be approximately 5 Volts on terminals 9 and 12 on the MDSD Card (5).

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________________________________________________________Operation 5. Place a meter in series with Pin 3 on the MDSD Card (4). a. Adjust screw P3 (A Maximum) until there is 700 mA. 6. Repeat this procedure until A Minimum and A Maximum are steady.

Always perform the MDSD calibration with the BPM pump in the OFF position. Unexpected movement could occur if calibration is performed without the BPM pump OFF.

Pumps 2 and 3 Pressure Calibration

The Pump P2 Calibration icon (1) and Pump P3 Calibration icon (2) are used to set the pressure on pumps P2 and P3.

Pump P2 Pressure Calibration: Caution: This procedure requires two people and must be performed with the machine running. Follow all safety procedures to ensure the safety of all personnel.

1. Back the P2 Safety Relief Valve (4) adjusting screw all the way out. Screw requires a 3/16” Allen wrench and small crescent wrench.

2. Back the P2 Pressure Control Valve (3) adjusting screw all the way out. Screw requires 6mm Allen wrench and a small crescent wrench.

3. Have the operator start the pumps and press the P2 Pump Calibration icon (1). It will energize the P2 Unloading Valve (5).

4. Adjust P2 Safety Relief Valve (4) inward until you feel the screw contact the spring assembly.

Turn inward 1 full turn.

1

2

5. Adjust P2 Pressure Control Valve (3) inward.

Watch pressure gauge. Stop adjusting when pressure stops rising. Oil should now be flowing across the P2 Safety Relief Valve (4).

6. Turn the P2 Safety Relief Valve (4) inward (1) full turn. Oil should stop flowing across the P2 Safety Relief Valve (4) 7. Adjust P2 Pressure Control Valve (3) inward until the pressure matches the safety relief setting and oil begins to flow across the P2 Safety Relief Valve (4).

8. Repeat this procedure until the P2 Safety Relief Valve (4) is set at a pressure of 4,800 psi (331 bar).

(1)

Pump P2 Calibration

(2)

Pump P3 Calibration

9. Back the P2 Pressure Control Valve (3 ) outward until the pressure falls below 2,500 psi (172 bar). Turn P2 Pressure Control Valve (3) inward slowly and bring the pressure setting to 3,000 psi (207 bar).

(3)

Pressure Control Valve

10. Pump P2 pressure is now set.

(4)

Safety Relief Valve

Illustration 70

(5) Unloading Valve

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Operation ________________________________________________________ Pump P3 Pressure Calibration:

Super Beam Page

Caution: This procedure requires two people and must be performed with the machine running. Follow all safety procedures to ensure the safety of all personnel.

1

1. Back the P3 Safety Relief Valve (4) adjusting screw all the way out. Screw requires a 3/16” Allen wrench and small crescent wrench.

2. Back the P3 Pressure Control Valve (3) adjusting screw all the way out. Screw requires 6mm Allen wrench and a small crescent wrench.

2

3. Have the operator start the pumps and press the P3 Pump Calibration icon (1). It will energize the P3Unloading Valve (5).

4. Adjust P3 Safety Relief Valve (4) inward until you feel the screw contact the spring assembly.

Turn inward 1 full turn.

5. Adjust P3 Pressure Control Valve (3) inward.

Watch pressure gauge. Stop adjusting when pressure stops rising. Oil should now be flowing across the P3 Safety Relief Valve (4).

6. Turn the P3 Safety Relief Valve (4) inward (1) full turn. Oil should stop flowing across the P3 Safety Relief Valve (4) 7. Adjust P3 Pressure Control Valve (3) inward until the pressure matches the safety relief setting and oil begins to flow across the P3 Safety Relief Valve (4).

8. Repeat this procedure until the P3 Safety Relief Valve (4) is set at a pressure of 3,900 psi (269 bar).

9. Back the P3 Pressure Control Valve (3 ) outward until the pressure falls below 3,000 psi (207 bar). Turn P3 Pressure Control Valve (3) inward slowly and bring the pressure setting to 3,500 psi (241 bar).

3 Illustration 71 (1)

Super Beam Setup

(2)

Miner Setup

(3)

Super Beam Page

The Super Beam Page (3) contains the controls for calibration of the super beam level indicators. The page is accessed by pressing the Miner Setup icon (2) and then the Super Beam Setup Icon (1).

Table 24 describes the icons on the Super Beam Page (3).

10. Pump P3 pressure is now set.

Note: Tri-Pressure for oil circulating on P3 is 1,500 psi (103 bar).

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________________________________________________________Operation Table 24 Symbol

Description

Function

Front Super Beam Level

Front Super Beam Level Calibration Box

Allows calibration of the front super beam level.

Restore Factory Settings

Sets Front Super Beam Level 0 degrees to 13,824 raw counts.

Raw Count

Raw count from front super beam inclinometer.

Super Beam Level – Degrees

Displays the current super beam level in degrees.

Front Super Beam Level Indicator

Visual representation of the current super beam level.

Captured Raw Count

Indicates raw count captured for front super beam level.

Calibrate Front Super Beam Level

Sets the current raw counts to 0 degrees.

Rear Super Beam Level

Rear Super Beam Level Calibration Box

Allows calibration of the rear super beam level.

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Description

Function

Rear Super Beam Level, continued Raw count

Raw count from rear super beam inclinometer.

Restore Factory Settings

Sets Rear Super Beam Level 0 degrees to 13,824 raw counts.

Super Beam Level – Degrees

Displays the current super beam level in degrees.

Rear Super Beam Level Indicator

Visual representation of the current super beam level.

Captured Raw Count

Indicates raw count captured for rear super beam level.

Calibrate Rear Super Beam Level

Sets the current raw counts to 0 degrees.

Track Selection

Displays a representation of track steering location

Shows which tracks are selected to lift or lower.

Individual Track Selection.

Selects tracks individually.

Select all tracks

Selects all of the tracks.

Track Position

Displays the current track position in degrees.

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________________________________________________________Operation Table 24 Symbol

Description

Function

Tracks Lifting/Lowering Operations Tracks Lifting and Lowering Box

Allows control of lifting and lowering of tracks.

Up Arrow

Raise Selected Tracks.

Down Arrow

Lower Selected Tracks.

Extended Track Options

Offers extended track options.

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Operation ________________________________________________________ Super Beam Level Calibration 1

2

Rear super beam level calibration 4

3

1. Use the Track Selection icon (2) to select the rear tracks. Each track can be selected individually or both rear tracks can be selected together.

2. Lift or lower the rear tracks using the Track Lift (3) and Track Lower (4) icons, either individually or together, to level the rear super beam.

3. Using a level, verify that the rear super beam is level.

4. Press the Rear Super Beam Calibration icon (5).

The raw count, captured value, and level (in degrees) will be displayed.

Tracks Page

5

2

2

6

1

Illustration 72 (1)

Front Super Beam Calibration

(2)

Track Selection

(3)

Track Lift

(4)

Track Lower

(5)

Rear Super Beam Calibration

(6)

Super Beam Level Calibration Page

The Super Beam level Calibration controls (1), (2), (3), (4), and (5) are located on the Super Beam Level Calibration Page (6).

Front super beam level calibration 1. Use the Track Selection icon (2) to select the front tracks. Each track can be selected individually or both front tracks can be selected together.

2. Lift or lower the front tracks using the Track Lift (3) and Track Lower (4) icons, either individually or together, to level the front super beam.

3. Using a level, verify that the front super beam is level.

4. Press the Front Super Beam Calibration icon (1).

The raw count, captured value, and level (in degrees) will be displayed.

3 Illustration 73 (1)

Track Setup

(2)

Miner Setup

(3)

Tracks Page

The Tracks Page (3) is accessed by pressing the Miner Setup icon (2) and then the Track Setup icon (1). It contains the controls for track calibration.

Table 25 describes the icons on the Tracks Page (3).

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________________________________________________________Operation Table 25 Symbol

Description

Function

Tracks Calibrated Retracted Tracks Retract Calibration

Allows tracks retracted calibration.

Restore Factory Settings

Set the track retracted calibrated position as Front Left = 0 Front Right = 0 Back Left = 27648 Back Right = 27648

Calibrate Retracted Position

Stores the current track raw counts at the retracted position.

Captured Raw Count

Indicates raw counts captured for tracks retracted position.

Tracks Calibrated Center

Tracks Center Calibration

Restore Factory Settings

Allows tracks center calibration.

Set the track center calibrated position as Front Left = 13824 Front Right = 13824 Back Left = 13824 Back Right = 13824

Calibrate Center Position

Stores the current track raw counts at the center position.

Captured Raw Count

Indicates raw count captured for tracks center position.

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Description

Function

Tracks Calibrated Extended Calibration for Tracks Extended

Restore Factory Settings

Allows calibration of tracks extended.

Set the track extended calibrated position as Front Left = 27648 Front Right = 27648 Back Left = 0 Back Right = 0

Calibrate Extended Position

Stores the current track raw counts at the extended position.

Captured Raw Count

Indicates raw count captured for tracks extended position.

Track Selection

Displays a representation of track steering location. Also shows which tracks are selected.

Indicates raw count for each track steering position.

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________________________________________________________Operation Table 25

Symbol

Description

Function

Tracks Calibrated Extended, continued Individual Track Selection

Selects tracks individually.

Select all tracks

Selects all of the tracks.

Track Position

Displays the track position in degrees.

Tracks Calibration Operation Tracks Operation

Allows steering of selected tracks.

Retract Cylinder

Retracts selected track steering cylinder.

Extend Cylinder

Extends selected track steering cylinder.

Extended Options

Displays the Miner Setup – Tracks Settings Additional Settings Page.

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Description

Function

Tracks Calibrate Circle Circle Calibration for Tracks

Restore Factory Settings

Allows for circle calibration for tracks.

Set the track circle calibrated position as Front Left = 26527 Front Right = 26527 Back Left = 1121 Back Right = 1121

Calibrate Circle Position

Stores the current track raw counts at the circle position.

Captured Raw Count

Indicates raw count captured for tracks circle position.

Tram/Mine Mode Selection Tram/Mine Mode

Allows selection of tram or mine mode of operation.

Tram Mode Selection

Selects the position and configures the program for the tracks in tram mode.

Mine Mode Selection

Selects the position and configures the program for the tracks in mine mode.

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________________________________________________________Operation Tracks straight calibration:

Track Steering Calibration

1. Press the Tracks in Tram Mode icon (8).

2

1

4

3

5

2. Select all four tracks using the four Track Select icons (3).

3. Use the Steering Cylinder Extend icon (5) and Steering Cylinder Retract icon (4) to turn all four tracks so they are parallel with the base frame.

For accurate calibration, measure from the front of the track to the base frame and the rear of the track to the base frame. The two measurements should be the same.

4. Press the Tracks Calibrate Center icon (2).

Captured values will be displayed.

Tracks extended calibration: 1. Press the Tracks in Tram Mode icon (8).

6

3

7

8

9

Illustration 74 (1)

Tracks Calibrate Retracted

(2)

Tracks Calibrate Center

(3)

Track Select

(4)

Steering Cylinder Retract

(5)

Steering Cylinder Extend

(6)

Tracks Calibrate Extended

(7)

Tracks Calibrate Circle

(8)

Tracks in Tram Mode

(9)

Tracks in Mine Mode

2. Select all four tracks using the four Track Select icons (3).

3. Press the Steering Cylinder Extend icon (5) to fully extend all four steering cylinders.

4. Press Tracks Calibrate Extended icon (6). Note: captured values will be displayed.

Tracks circle calibration: 1. Press the Tracks in Tram Mode icon (8).

2. Use the Steering Cylinder Extend icon (5) and Steering Cylinder Retract icon (4) to turn the tracks to the desired circle position.

3. After all four tracks are in the desired position, press the Tracks Calibrate Circle icon (7). Note: Captured values are displayed:

The track steering calibration controls (1) through (9) are located on the Tracks Page.

Cylinders retracted calibration: 1. Press the Tracks in Tram Mode icon (8).

2. Select all four tracks using the four Track Select icons (3).

3. Press the Steering Cylinder Retract icon (4) and fully retract all four steering cylinders.

4. Press the Tracks Calibrate Retract icon (1).

Note: captured values will be displayed.

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Operation ________________________________________________________ Tracks Extended Options

2

1

4

3

Illustration 75 (1)

Miner Setup

(2)

Track Setup

(3)

Extended Options

(4)

Extended Options Page

The Tracks Extended Options Page (4) has the controls for setting track calibrations. The page is accessed by pressing the Miner Setup icon (1) and then the Track Setup icon (2). Next, press the Extended Options icon (3) in the lower left corner of the Tracks Calibration Options box.

Table 26 describes the icons on the Tracks Extended Options page (4).

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________________________________________________________Operation Table 26 Symbol

Description

Function

Track Position and Time Settings Track Position and Time Settings Box

Provides position and time settings.

In Position

Configures the + or – distance the tracks can be from a calibrated position before adjusting themselves.

Track Motion Alarm

Provides setting for how much time is allowed to pass, after request for steering, without any motion from track steering, before there is an alarm.

Track Ramp Settings Track Ramp Settings Box

Provides settings for track ramp time and voltage.

Ramp

Configures how quickly voltage will be taken away or provided to the Sump/Tram MDSD card when a tram command is given.

Ramp Rate

Configures how much voltage will be added or subtracted from the proportional valve when a tram command is given.

Track Disable Switch Settings Tram Disable Switch Settings Box

Provides options of selecting tram disable switch present.

Left Tram Disable

When checked configures program for a left tram disable switch operation.

Right Tram Disable

When checked configures program for a right tram disable switch operation.

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Operation ________________________________________________________ Miner Setup 995 VFD 2

1

3

Illustration 76

(1) Miner Setup (2) Miner Setup 995 VFD Button (3) Miner Setup 995 VFD Page The Miner Setup 995 VFD page (3) provides options for the VFD motor controls. To access the page, press the Miner Setup icon (1) then the page select (2) Table 27 describes the icons on the Miner Setup 995 VFD Page.

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________________________________________________________Operation Table 27 Symbol

Description

Function

Horizontal Motor Controls

Horizontal Motor Controls Box

Provides options for setting horizontal auger VFD motor controls.

Resets Factory Settings

Provides option of using factory settings.

Horizontal Protection

Enables Horizontal Protection. Horizontal Protection will delay the auto mine cycle when motor amps have exceeded the current and time set points.

Current

Specifies the amount of current the horizontal motors must see before pausing the auto mine cycle.

Time

Specifies the amount of time the horizontal auger amps must exceed the current set point before pausing the auto mine cycle.

VFD Protection

Enables VFD Protection. VFD Protection will delay the auto mine cycle when motor amps have exceeded the current and time set points.

Current

Specifies the amount of current the horizontal motors must see before pausing the auto mine cycle.

Time

Specifies the amount of time the horizontal auger amps must exceed the current set point before pausing the auto mine cycle.

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Operation ________________________________________________________ Table 27 Symbol

Description

Function

Horizontal Motor Controls Ramp Rate

Provides adjustment of the ramp rate frequency.

Manual Frequency

Provides setting for manually controlling VFD.

Auto Frequency

Provides setting for automatic controlling VFD.

Clean – Out Frequency

Provides setting for control of VFD during clean out time for horizontal augers.

Beam Change Frequency

Provides setting for control of VFD during beam change time.

Ramp Up and Ramp Down Time

Provides time settings for ramping up and down of the VFD controls.

Chain Conveyor VFD Controls

Chain Conveyor VFD Controls Box

Provides control options for chain conveyor VFD.

Resets Factory Settings

Provides option of using factory settings.

VFD Protection

Enables VFD Protection. VFD Protection will delay the auto mine cycle when motor amps have exceeded the current and time set points.

Current

Specifies the amount of current the chain conveyor motor must see before pausing the auto mine cycle.

Time

Specifies the amount of time the chain conveyor amps must exceed the current set point before pausing the auto mine cycle.

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________________________________________________________Operation Table 27 Symbol

Description

Function

Chain Conveyor VFD Controls, continued Manual Frequency

Provides setting for manually controlling VFD.

Auto Frequency

Provides setting for automatic controlling VFD.

Clean – Out Frequency

Provides setting for control of VFD during clean out time for chain conveyor.

Ramp Up and Ramp Down Time

Provides time settings for ramping up and down of the VFD controls.

Right Angle VFD Controls

Right Angle VFD Controls Box

Provides control options for right angle VFD.

Resets Factory Settings

Provides option of using factory settings.

VFD Protection

Enables VFD Protection. VFD Protection will delay the auto mine cycle when motor amps have exceeded the current and time set points.

Current

Specifies the amount of current the right angle motor must see before pausing the auto mine cycle.

Time

Specifies the amount of time the right angle motor amps must exceed the current set point before pausing the auto mine cycle.

Manual Frequency

Provides setting for manually controlling VFD.

Auto Frequency

Provides setting for automatic controlling VFD.

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Operation ________________________________________________________ Table 27 Symbol

Description

Function

Right Angle VFD Controls, continued Clean – Out Frequency Beam Change Frequency Ramp Up and Ramp Down Time

Provides setting for control of VFD during clean out time for right angle.

Provides setting for control of VFD during beam change time.

Provides time settings for ramping up and down of the VFD controls.

Mine Operation - Main Page

Illustration 77

The Miner Operation Page provides access to controls for the basic operation of the machine, as well as production information.

Table 28 describes the icons on the Miner Operation Page.

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________________________________________________________Operation Table 28 Symbol

Description

Function

Controls Start BPM

Start the BPM motor and strokes P3, 3 seconds after the motor is started.

Outside Lights

Turns the outside lights on and off

Water Spray list box

Three Possible Settings: 1. Off – Turns the water spray system off.

2. Hand – Places the water spray system in manual mode. The button below the list box will be 3. enabled so the sprays can be turned on and off.

4. Automatic – Places the water spray in automatic mode. The water sprays will turn on and off at different times according to the last motor to shut off in Auto Mine Mode. The motors are: a. Vertical Auger Motor. b. Right Angle Conveyor Motor. c. Stacker Motor. d. Tail Conveyor Belt.

Water Spray Type

Type 1 is old style water spray. This system includes the drain and spray solenoids. Type 2 is the new system that only has a pump.

Water Spray Manual On\Off Button

Can be activated only when the water spray system is in Hand Mode.

Hydraulic Oil Temperature

Displays the oil temperature in degrees Fahrenheit or degrees Celsius based on the metric or standard selection on the Miner Configuration page.

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Operation ________________________________________________________ Table 28 Symbol

Description

Function

Controls Heating Switch

Energizes the tri-pressure relief on P3 to heat oil quickly.

Hose Reel Oil Circulation On/ Off

Energizes the shear proportional valve and hose reel circulation valve to circulate oil throughout the cutter head and hose reel. Oil will automatically circulate through the shear valve at 100% down.

Production Information

Beam Mine

Current Beam Mine Time.

Beam Change

Current Beam Change Time.

Total Hole

Total amount of time between Start New Hole and End Hole events.

Retract Time

Total Retract time starting when the end hole button is pressed and ending when the beam counter = 0.

Beam Retract

Retract time for each individual beam during retract.

Time starts when the power head latches onto a beam at the clean out position. Time ends when the power head returns to the same position.

Move Over and Service Time

Starts timing when the beam counter = 0 and quits timing when the start new hole pushbutton is pressed.

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________________________________________________________Operation Table 28 Symbol

Description

Function

Production Information continued

Right Arrow Button

As a hole is mined the program calculates top and bottom hole contour positions from the start of the hole. The arrow button advances forward through the data samples one sample at a time. New information will be displayed above the arrow buttons.

Left Arrow Button

As a hole is mined the program calculates top and bottom hole contour positions from the start of the hole. The arrow button advances backward through the data samples one sample at a time. New information will be displayed above the arrow buttons.

Down Time Flags

Displays the down time configuration flag page. If needed you can enable and disable downtime configuration times and set times when the flags will activate.

Coal Density

Used to calculate production.

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Operation ________________________________________________________ Operations - Testing Page

Illustration 78

The Test Page provides access to control to test the basic functions of the machine, as well as certain pressures and water flow rates.

Table 29 describes the icons on the Test Page.

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________________________________________________________Operation Table 29 Symbol

Description

Function

Motor Operations Jog BPM Button

Jogs the P1 pump without stroking P3. This can be used to set rotation on the pumps.

BPM Top Indicator

Indicates the current status of the BPM contactor Input . I1.3

BPM Bottom Indicator

Indicates the current status of the BPM contactor Output Q0.6

Jog Left and Right Cutter Motors Button

Jogs the left and right cutter motors. Motors are started at the same time.

Jog Left Cutter Motor Button

Jogs the left cutter motor.

Jog Left Cutter Top Indicator

Indicates the current status of left cutter motor starter contactor input I2.3

Jog Left Cutter Bottom Indicator

Indicates the current status of the left cutter motor starter contactor output Q0.1

Jog Right Cutter Motor Button

Jogs the right cutter motor.

Jog Right Cutter Top Indicator

Indicates the current status of right cutter motor contactor input I2.6

Jog Right Cutter Bottom Indicator

Indicates the current status of the right cutter motor contactor output Q0.2

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Operation ________________________________________________________ Table 29 Symbol

Description

Function

Motor Operations, continued Jog Left Horizontal Auger Button

Jogs the left horizontal auger motor.

0.00 field reports current output frequency

Left Horizontal Bottom Left Indicator

Indicates the current status of the left horizontal auger VFD.

Left Horizontal Bottom Right Indicator

Indicates that left horizontal auger VFD has reached test frequency.

Jog Right Horizontal Auger Button

Jogs the right horizontal auger motor.

0.00 field reports current output frequency

Custom VFD target test Frequency box

57.00 Sets the target frequency for the manual motor test on both horizontal auger VFDs.

Right Horizontal Bottom Left Indicator

Indicates the current status of the right horizontal auger VFD.

Right Horizontal Bottom Right Indicator

Indicates that the right horizontal auger VFD has reached test frequency.

Jog Gathering Reverse Button

Jogs the gathering motors reverse.

Jog Gathering Reverse Top Indicator Jog Gathering Reverse Bottom Indicator

Indicates the current status of the gathering reverse contactor input I3.2 Indicates the current status of the gathering reverse contactor output Q0.4

Jog Gathering Forward Button

Jogs the gathering motors forward.

Jog Gathering Forward Top Indicator

Indicates the current status of the gathering forward contactor input I3.1

Jog Gathering Forward Bottom Indicator

Indicates the current status of the gathering forward contactor output Q0.3

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________________________________________________________Operation Table 29 Symbol

Description

Function

Motor Operations, continued Jog Right Angle Conveyor Reverse Button

Jogs the right angle conveyor backwards.

Jog Right Angle Conveyor Reverse Top Indicator

Indicates that the right angle discharge VFD is running in reverse

Jog Right Angle Conveyor Reverse BottomLeft Indicator

Indicates that the right angle discharge VFD is running.

Jog Right Angle Conveyor Reverse BottomRight Indicator

Indicates that the right angle discharge VFD has reached test frequency.

Jog Right Angle Conveyor Forward Button

Jogs the right angle conveyor forward.

Custom VFD target test frequency

52.00 Sets the target frequency for the manual motor test on the right angle discharge VFD.

VFD output frequency

0.00 Indicates current output frequency of the right angle discharge VFD.

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Operation ________________________________________________________ Table 29 Symbol

Description

Function

Motor Operations, continued Jog Chain Conveyor Reverse

Jogs the chain conveyor backwards.

Jog chain conveyor Reverse Top Indicator

Indicates that the chain conveyor VFD is running in reverse

Jog chain conveyor Reverse BottomLeft Indicator

Indicates that the chain conveyor VFD is running.

Jog chain conveyor Reverse BottomRight Indicator

Indicates that the chain conveyor VFD has reached test frequency.

Jog chain conveyor Forward Button

Jogs the chain conveyor forward.

Custom VFD target test frequency

60.00 Sets the target frequency for the manual motor test on the chain conveyor VFD.

VFD output frequency

0.00 Indicates current output frequency of the chain conveyor VFD.

Jog Stacker Pushbutton

Jogs the stacker belt.

Jog Stacker Top Indicator

Indicates the current status of the stacker belt contactor input, I3.5

Jog Stacker Bottom Indicator

Indicates the current status of the stacker belt starter output, Q0.5

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Description

Function

Motor Operations Pump Controls Jog P1 low Pressure Button

Activates P1 low pressure relief solenoid and strokes P1 pump by sending 1.25 volts to P1 proportional valve.

Jog P1 low pressure indicator.

Indicates the current status of the P1 low pressure relief output, Q50.0.

Jog P1 medium pressure Button

Activates P1 medium pressure relief solenoid and strokes P1 pump by sending 1.25 volts to P1 proportional valve.

Jog P1 medium pressure indicator

Indicates the current status of the P1 medium pressure relief output, Q90.0.

Jog P1 high Pressure Button

Strokes P1 pump by sending 1.25 volts to P1 proportional valve.

Jog P2 Button

Activates P2 unloading valve.

Jog P2 Indicator

Indicates the current status of the P2 unloading valve output, Q50.4

Jog P3 Button

Starts the BPM motor and energizes P3 unloading valve 3 seconds after the pump motor starts.

Jog P3 Indicator

Indicates the current status of the P3 unloading valve output, Q50.6

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Description

Function

Motor Operations Pump Controls, continued BPM Pump Pressure list box

Selecting a pressure here and using the power operations buttons will cause the power head to move at the selected pressure range.

Regen mode

This allows you to setup the Regen mode to run at medium force/Regen Speed. Or High force/Medium speed.

P1 Valve

Displays the voltage being sent to the P1 proportional valve.

SV1 Indicator

Displays when SV1 is active.

SV2 Indicator

Displays when SV2 is active.

SV3 Indicator

Displays when SV3 is active.

SV4 Indicator

Displays when SV4 is active.

SV5A Indicator

Displays when SV5A is active.

SV5B Indicator

Displays when SV5B is active.

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Description

Function

Cooling Fans and Pumps Jog #1 Oil Cooling Fan Button

Jogs the #1 Oil Cooling Fan. 0.0 field reports output frequency

Jog #1 Oil Cooling Fan Top Indicator

Indicates the current status of the #1 Oil Cooling Fan VFD activated setting.

Jog #1 Oil Cooling Fan Bottom Indicator

Indicates the current status of the #1 Oil Cooling Fan VFD running status.

Jog #2 Oil Cooling Fan Button

Jogs the #2 Oil Cooling Fan. 0.0 field reports output frequency

Jog #2 Oil Cooling Fan Top Indicator

Indicates the current status of the #2 Oil Cooling Fan VFD activated setting.

Jog #2 Oil Cooling Fan Bottom Indicator

Indicates the current status of the #2 Oil Cooling Fan VFD running status.

Jog #3 Oil Cooling Fan Button

Jogs the #3 Oil Cooling Fan. 0.0 field reports output frequency

Jog #3 Oil Cooling Fan Top Indicator

Indicates the current status of the #3 Oil Cooling Fan VFD activated setting.

Jog #3 Oil Cooling Fan Bottom Indicator

Indicates the current status of the #3 Oil Cooling Fan VFD running status.

Oil Temperature Display

Displays the current oil temperature. Reports degrees C or F according to setting.

Jog Oil Cooling Pump Button

Jogs the oil cooling pump.

0.0 field reports output frequency

Jog Oil Cooling Pump Top Indicator

Indicates the current status of the Oil Cooling Pump contactor input I52.1

Jog Oil Cooling Pump Bottom Indicator

Indicates the current status of the #2 Oil Cooling Pump contactor output Q52.0

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Description

Function

Cooling Fans and Pumps, continued Jog #1 Water Cooling Fan Button

Jogs the #1 Water Cooling Fan. 0.0 field reports output frequency

Jog #1 Water Cooling Fan Top Indicator

Indicates the current status of the #1 Water Cooling Fan VFD activated setting.

Jog #1 Water Cooling Fan Bottom Indicator

Indicates the current status of the #1 Water Cooling Fan VFD running status.

Jog #2 Water Cooling Fan Button

Jogs the #2 Water Cooling Fan. 0.0 field reports output frequency

Jog #2 Water Cooling Fan Top Indicator

Indicates the current status of the #2 Water Cooling Fan VFD activated setting.

Jog #2 Water Cooling Fan Bottom Indicator

Indicates the current status of the #2 Water Cooling Fan VFD running status.

Jog #3 Water Cooling Fan Button

Jogs the #3 Water Cooling Fan. 0.0 field reports output frequency

Jog #3 Water Cooling Fan Top Indicator

Indicates the current status of the #3 Water Cooling Fan VFD activated setting.

Jog #3 Water Cooling Fan Bottom Indicator

Indicates the current status of the #3 Water Cooling Fan VFD running status.

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Description

Function

Cooling Fans and Pumps, continued Water Temperature Display

Displays the current water temperature. This will switch between Fahrenheit and Celsius based on the metric or standard selection on the Miner Setup Page.

Jog Water Cooling Pump Button

Jogs the water cooling pump.

0.0 field reports output frequency

Jog Water Cooling Pump Top Indicator

Indicates the current status of the Water Cooling Pump contactor input I54.2

Jog Water Cooling Pump Bottom Indicator

Indicates the current status of the #2 Water Cooling Pump contactor output Q52.4

Power Head Options Power Head Reverse Minimum

Sets the minimum output to the P1 proportional valve. The minimum value is used within 6” of the front and rear stops and the power head is moving backward and any movement controlled by the operator while in auto mine mode.

Power Head Reverse Maximum

Sets the maximum output to the P1 proportional valve. The power head will ramp from the minimum to the maximum value while the power head is in hand and not within 6” of the front or rear stops.

Power Head Forward Minimum

Sets the minimum output to the P1 proportional valve. The minimum value is used within 6” of the front and rear stops and the power head is moving forward and any movement controlled by the operator while in auto mine mode.

Power Head Forward Maximum

Sets the maximum output to the P1 proportional valve. The power head will ramp from the minimum to the maximum value while the power head is in hand and not within 6” of the front or rear stops.

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Description

Function

Power Head Options, continued Power Head Backwards

Moves the power head backwards using the maximum and minimum reverse set speed.

Power Head Forward

Moves the power head forward using the maximum and minimum forward set speed.

Regen Reverse

Moves the power head backward at regen reverse speed. This will activate P1 and P2 and set the proportional valve to 100%. Access is blocked during auto mine mode.

Advance Fast Forward

Moves the power head forward at advance fast forward speed. This will activate P1 and P2 and set the proportional valve to 100%. Access is blocked during auto mine mode.

Power Head proportional valve output percentage

Displays the output from the MDSD card to the P1 proportional valve. The voltage being output from the analog output card can be calculated by multiplying the percentage by .05

Raw Position

The value at the analog input for power head position. The input can be changed on the power head setup page.

Actual Position

Displays the power head actual position. This number will be displayed in inches or centimeters based on the metric or standard selection on the Miner Setup page.

Actual Speed

Displays the power head speed in inches/second or centimeters/second. Metric or standard measurements change according to the selection on the Miner Setup – Home Page

Current Depth

Displays the current hole depth. Hole depth is calculated when the miner is in Auto Mine Mode and the power head latches are down.

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Description

Function

Pressures

Shear A Port.

Displays pressure at the A port on the shear valve. Measurements can be displayed on metric or standard based on the selection switch on the Miner Setup page.

Shear B Port.

Displays pressure at the B port on the shear valve. Measurements can be displayed on metric or standard based on the selection switch on the Miner Setup page.

Pump 1 (Sump/Tram)

Displays pressure for the Sump/Tram, P1, Pump in the BPM. Measurements can be displayed on metric or standard based on the selection switch on the Miner Setup page.

Pump 2 (Extra Oil)

Displays pressure for the Extra Oil, P2, Pump in the BPM. Measurements can be displayed on metric or standard based on the selection switch on the Miner Setup page.

Pump 3 (General Service)

Displays pressure for the General Service, P3, Pump in the BPM. Measurements can be displayed on metric or standard based on the selection switch on the Miner Setup page.

Water Flow Horizontal Auger Motor

Displays the water flow to the horizontal auger motors.

Cutter Head Motor

Displays the water flow to the cutter head motors.

VFD #1 Water Flow

Displays the water flow to the VFD #1.

VFD #2 Water Flow

Displays the water flow to the VFD #2.

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Tram Page

Illustration 79

The Tram Page provides access to the tram functions during both Tram and Mine Mode. Functions or operations will be visible according to the operation selected: Tram or Mine. Whenever changes are made via this page, the Auto Mine and Auto Tram icons will change, too.

Table 30 describes the icons on the Tram Page.

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Description

Function

Motor Operation Start BPM

Start the BPM motor and strokes P3, 3 seconds after the motor is started.

CHM Level

CHM Level

Displays Cutter head level position.

Tram/Mine Mode Selection Tram Mode Selection

Places the tracks in tram mode in the program.

This switch affects steering and tramming functions.

Mine Mode Selection

Places the tracks in mine mode in the program.

This switch affects steering and tramming functions.

Front and Rear Super Beam Level Super beam level position

Visually displays the super beam level position.

The picture is not displayed to scale but only used as a visual representation.

Not Categorized

Single Track selection

Selects each track for lifting, lowering, tram front, or tram rear.

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Description

Function

Not Categorized, continued

Quad Track selection

Selects all four tracks for “Quad” steering operations.

When in quad all four tracks will follow the front right track.

Quad mode selection switch

Selects if the rear tracks are to go in the opposite direction from the front right track for quad steering.

Quad mode selection switch.

Selects if the rear tracks are to follow the front right track for quad steering.

Tram Pump Rate Pump Rate

Default is 80% but can be adjusted according to operation.

Tram Operations

Forward Tram

Available only in tram mode. All four tracks will tram when this button is pressed. To stop the forward tram function, press the reverse tram function.

Reverse Tram

Available only in tram mode. All four tracks will tram when this button is pressed. To stop the reverse tram function, press the forward tram function.

Front Track Selection

In Mine mode, front track selection.

Allows you to only select the front tracks for tramming.

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Description

Function

Tram Operations, continued Rear track selection

In Mine mode, rear track selection. Allows you to only select the rear tracks for tramming.

Left tram

In Mine mode, after track selection has been made.

Allows you to tram selected tracks to the left.

Right tram

In Mine mode, after track selection has been made.

Allows you to tram selected tracks to the right.

Clockwise tram

Counter Clockwise tram

In Mine mode, tram all four tracks in the clockwise direction.

In Mine mode, tram all four tracks in the counter clockwise direction.

Lift tracks

Tracks to be lifted must be selected for this function.

Lower tracks

Tracks to be lowered must be selected for this function.

Steering Operations Straight steering operation

Turns all tracks to the calibrated straight position when selected. To stop the movements deselect the button.

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Description

Function

Steering Operations, continued Counter clockwise steering operation

Turns the selected tracks in the counter clockwise rotation when selected. To stop the movements deselect the button.

Clockwise Steering operation.

Turns the selected tracks in the clockwise rotation when selected. To stop the movements deselect the button.

Circle Steering operation.

In Mine mode, Turns the tracks into a calibrated circle position.

Mine Set Page

Illustration 80

The Mine Set Page provides access to operation functions and parameter setup.

Table 31 describes the icons on the Mine Set Page.

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Description

Function

Motor Operations Start BPM

Start the BPM motor and strokes P3, 3 seconds after the motor is started.

Advance FF and Regen Rev lock

This will allow you to unlock the Advance FF and Regen Rev. buttons on the mine page. When locked the buttons will be hidden.

Gathering Pan Operations Gathering pan operation

Controls for the gathering pan Select the Hold feature and then press the raise button. Then select the float feature to return to mining. (Should not go into mine mode while in hold position)

Flows and Temperature

Displays flows and temperature

This window displays the cooling water flow for the cutter head and the horizontals. It also displays the temperature of the hydraulic oil and the cooling water.

Hose Reel Operations Hose reel tension on

Select this button when you want the hose reel tension on.

Hose reel tension off

Select this button when you want the hose reel tension off.

Auto Mine Sump Parameter Auto mine sump parameter

Select the top and bottom sump depth, and sump rate.

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Description

Function

Auto Mine Sump Parameter, continued Auto mine Sump rate reset

Resets the sump rate to 5%.

Auto mine Sump speed

Select the speed that the power head is to travel in the forward and reverse direction minimum and maximum. When in Auto mine and you press a power head movement button.

Regen mode

This allows you to setup the Regen mode to run at medium force/Regen Speed. Or High force/ Medium speed.

Auto Mine Shear Parameter Auto mine Shear

Select the maximum and minimum speeds for both up and down on the sheer. These speeds will be used by normal operations and with the slow down.

Auto mine Shear Slow down

Select at what distance from the top and bottom set point, you want the shear valve to cutback/ slow down to the min shear percent. This setting will allow the drum to slow down before reaching the set point.

Auto mine Shear Shut down

Select at what distance from the top and bottom set point, you want the shear valve to shut off.

This setting will allow the drum to coast in that direction before reaching the set point.

Cutter Head Operation Shear top current position

Displays the current position of the top of the cutter drum. Measurements can be displayed on metric or standard based on the selection switch on the Miner Setup page.

Shear top set point.

Allows the operator to enter the desired stopping position for the top of the cutter drum.

Shear top +.

Adds 1 inch or 1 centimeter to the top set point.

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Description

Function

Cutter Head Operation, continued Shear top -

Subtracts 1 inch or 1 centimeter to the bottom set point.

Shear Up

Shears the cutter head up.

Shear Down

Shears the cutter head down.

Shear bottom current position

Displays the current position of the bottom of the cutter drum. Measurements can be displayed on metric or standard based on the selection switch on the Miner Setup page.

Shear bottom set point

Displays the current position of the bottom of the cutter drum. Measurements can be displayed on metric or standard based on the selection switch on the Miner Setup page.

Shear bottom +

Adds 1 inch or 1 centimeter to the bottom set point.

Shear bottom -

Subtracts 1 inch or 1 centimeter to the bottom set point.

CHM Level Indicator

Indicates the cutter head module level in degrees.

Clean Out Times Horizontal clean out time

Horizontal clean out time is the length of time that the motors will run after the mine cycle is complete.

Chain conveyor clean out time

Chain conveyor clean out time begins when horizontals shut off.

Right angle conveyor clean out time

Right angle conveyor clean out time begins when the chain conveyor shuts off. The shut off of the right angle is setup on the Miner setup page.

Stacker conveyor clean out time

Stacker conveyor clean out time begins when the right angle conveyor shuts off. The shut off of the Stacker is setup on the Miner setup page.

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Auto Mine Page

Illustration 81

The Auto Mine Page contains the controls that configure Auto Mine Mode. Icons are displayed according to configuration settings. Some of the controls that change with configuration settings are the tail swing belt functions, vertical auger, vertical conveyor functions, and PTM2 controls.

Tram Mode and Mine Mode are changed on the Tram Page.

To prevent system overload, the operator will be forced to start the system in order, even when starting motors in manual mode. There will be a three second delay after each motor start before the next motor can be started.

Table 32 describes the icons on the Auto Mine Page.

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Description

Function

Motor Operations Start BPM Button

0.00 field reports VFD speed in Hertz Start the BPM motor and strokes P3, 3 seconds after the motor is started.

Frequency feedback displayed on button.

Start Stacker Button

Turns the stacker on and off. The stacker must be selected on the Miner Setup page for this button to be accessible.

Right Angle Conveyor Forward Button

0.00 field reports VFD speed in Hertz Starts the right angle conveyor. The right angle conveyor must be selected on the Miner Setup page for this button to be accessible. Frequency feedback displayed on button.

Chain Conveyor Forward Button

0.00 field reports VFD speed in Hertz Starts the chain conveyor. Rear Discharge must be selected on the Miner Setup page for this button to be accessible. Frequency feedback displayed on button.

Start Left Horizontal Auger Button

0.00 field reports VFD speed in Hertz Starts the left horizontal auger motor. Auto mine can be paused if the horizontals become overloaded. This setting is on the power head setup page. Frequency feedback displayed on button.

Jog Left Horizontal Auger Button

Jogs the left horizontal auger motor.

Start Right Horizontal Auger Button

0.00 field reports VFD speed in Hertz Starts the right horizontal auger motor. Auto mine can be paused if the horizontals become overloaded. This setting is on the power head setup page. Frequency feedback displayed on button.

Jog Right Horizontal Auger Button

Jogs the left horizontal auger motor.

Start Gathering Motors Button

Starts the gathering motors. Cutter head must be selected on the Shear Setup page for this button to be accessible.

Starts the cutter motors. The cutter motors will ratchet start and can be set to start and stop with Start Cutter the horizontals in auto mine or run continuously in Motors Button auto mine. This setting is on the shear setup page. _______________________________________________________________ REV 0

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Description

Function

Motor Operations, continued Jog Chain Conveyor Forward

Jogs Chain Conveyor Forward while button is pressed.

Jog Chain Conveyor Reverse

Jogs Chain Conveyor Reverse while button is pressed.

Power Head Operations

Power Head Reverse

Moves the power head backwards using the maximum and minimum reverse set speed.

Power Head Regen Reverse

Moves the power head backward at regen reverse speed. This will activate P1 and P2 and set the proportional valve to 100%. Access is blocked during auto mine mode.

Power Head Reverse Minimum Percentage

Sets the minimum output to the power head proportional valve. The minimum value is used within 6” of the front and rear stops and the power head is moving backward and any movement controlled by the operator while in auto mine mode.

Power Head Reverse Maximum Percentage (bottom box)

Sets the maximum output to the power head proportional valve. The power head will ramp from the minimum to the maximum value while the power head is in hand and not within 6” of the front or rear stops.

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Description

Function

Power Head Operations, continued Power Head Forward

Moves the power head forward using the maximum and minimum forward set speed.

Power Head Advance Fast Forward

Moves the power head forward at advance fast forward speed. This will activate P1 and P2 and set the proportional valve to 100%. Access is blocked during auto mine mode.

Power Head Forward Minimum Percentage

Sets the minimum output to the power head proportional valve. The minimum value is used within 6” of the front and rear stops and the power head is moving forward and any movement controlled by the operator while in auto mine mode.

Power Head Forward Maximum Percentage

Sets the maximum output to the power head proportional valve. The power head will ramp from the minimum to the maximum value while the power head is in hand and not within 6” of the front or rear stops.

Stop Blocking Cylinders

Raises and lowers the blocking cylinders. The indicator above each cylinder displays the status of the output for each cylinder. If the indicator above the cylinder is on the power head latch should be up (unattached to beam.)

Power Head Unlatching Cylinders

Raises and lowers the power head unlatching cylinders. The indicator above each cylinder displays the status of the output for each cylinder.

The power head latch is up if the indicator above the cylinder is on.

Push Beam Separation Cylinder

Extends/retracts the Push Beam Separation Cylinder when pressed.

String Blocking Cylinder Down

Lowers/raises the string Blocking Cylinder when pressed

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Description

Function

Power Head Operations, continued Power Head proportional valve output percentage

0.4% Displays the output from the MDSD card to the sump proportional valve. The voltage being output from the analog output card can be calculated by multiplying the percentage by .05

Raw Position

27648 The value at the analog input for power head position. The input can be changed on the power head setup page.

Actual Position

685.80 cm Displays the power head actual position. This number will be displayed in inches or centimeters.

Actual Speed

0.00 cm/sec Displays the power head speed in inches/ second or centimeters/second.

Current Depth

0.00 m Displays the current hole depth. Hole depth is calculated when the miner is in Auto Mine Mode and the power head latches are down.

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Description

Function

Miscellaneous

Beam Mine Time

Displays the time to mine the current beam.

Timer starts when auto start all is pressed and ends when horizontal clean out time is complete. The miner must be in auto mine for the beam mine time to work.

Beam Change Time

Displays the time to set a beam during auto mine mode. The time starts when horizontal clean out time is complete and stops when the auto start all push button is pressed. The miner must be in auto mine for the beam change time to work.

Beam Number

Displays the number of beams that have been mined. The beam counter automatically adds one when horizontal clean out time is complete. The miner must be in auto mine for the beam counter to work.

Beam Counters

Adds or subtracts beams.

Shear A Port Pressure

Displays pressure at the A port on the shear valve. Measurements can be displayed on metric or standard based on the selection switch on the Miner Setup page.

Shear B Port Pressure

Displays pressure at the B port on the shear valve. Measurements can be displayed on metric or standard based on the selection switch on the Miner Setup page.

Pump 1 Pressure

Displays pressure for the Sump/Tram, P1, Pump in the BPM. Measurements can be displayed on metric or standard based on the selection switch on the Miner Setup page.

Pump 2 Pressure

Displays pressure for the Extra Oil, P2, Pump in the BPM. Measurements can be displayed on metric or standard based on the selection switch on the Miner Setup page.

Pump 3 Pressure

Displays pressure for the General Service, P3, Pump in the BPM. Measurements can be displayed on metric or standard based on the selection switch on the Miner Setup page.

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Description

Function

Auto Mine Message Auto Mine Message

Provides information on the current status of the miner in auto mine. Also prompts the operator for any input needed by the operator.

Automine Control Buttons Hand\Auto

Turns auto mine on and off. Once auto mine is turned on the mine message box will prompt for any needed actions.

Beam Pins Placed

Button to signal beam connection pins being in place

Auto Start All

Starts the Auto Mine Sequence.

Cutter Drum Ops and Steering/Nav

 Cutter Drum Operations and Steering/ Navigation (when installed)

 



Provides buttons for shearing the cutter drum and adjusting set points.

Reports cutter module mining angle.

Ribbing and heading information is reported if the CM is equipped with Steering and Navigation. In this case, the option to manually fire the steering cylinders is also provided.

Reports top and bottom coal thickness if gamma is equipped.

Shear top current position

Displays the current position of the top of the cutter drum. Top coal thickness shown in red.

Shear bottom current position

Displays the current position of the bottom of the cutter drum. Top coal thickness shown in red.

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Description

Function

Shear top set point

Allows the operator to enter the desired stopping position set point for the top of the cutter drum.

Shear bottom set point

Allows the operator to enter the desired stopping position set point for the bottom of the cutter drum.

Shear top +/-

Add/subtract 1 inch or 1 centimeter to the top set point.

Shear bottom +/-

Add/subtract 1 inch or 1 centimeter to the bottom set point.

Shear Up

Shears the cutter drum up.

Shear Down

Shears the cutter drum down.

CM Level Indicator

Indicates the cutter head module level in degrees.

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Description

Function

Cutter Head Operation, continued Heading in Degrees

Displays current heading in degrees (Top number in picture)

Heading Set point

Displays heading to maintain while mining (Second number in picture)

Inches right or left of Center

Displays how far the cutter head is from the center of the hole (Third number in picture)

Heading Error

Degrees from heading set point (Fourth number in picture)

Valid Heading Indicator

Large Indicator light next to heading set point Red when OCTANS heading reading is invalid.

Steer Left Cylinder Out Indicator

Green when left steering cylinder out solenoid is on

Steer Left Cylinder In Indicator

Green when left steering cylinder in solenoid is on

Steer Left Pushbutton

Moves left steering arm in and out when steering mode is in manual

Steer Right Cylinder Out Indicator

Green when right steering cylinder out solenoid is on

Steer Right Cylinder In Indicator

Green when right steering cylinder in solenoid is on

Steer Right Pushbutton

Moves right steering arm in and out when steering mode is in manual

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Description

Function

PTM2 Operations

PTM2 Options

Full view of PTM2 operators.

Cradle Position

Displays the raw count input from the cradle position transducer.

Trolley Position

Displays the raw count input from the trolley position transducer.

Cradle Shift Position

Displays the raw count input from the cradle shift position transducer.

Beams on the table

Displays the number of beams on the table. The program ramps the cradle movement up and down based on the number of beams on the table.

PTM2 Safe

Displays the current status of the PTM2. The PTM2 Safe light will be green as long as the cradle is in the up position.

Cradle Up Indicator

Turns green when the cradle is at the calibrated up position.

Cradle Down Indicator

Turns green when the cradle is at the calibrated down position.

Trolley In Indicator

Turns green when the trolley is at the calibrated in position.

Trolley Out Indicator

Turns green when the trolley is at the calibrated out position.

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Description

Function

PTM2 Operations, continued PTM2 push beam gripper status (located above clamp and unclamp icons)

Displays the current status of the PTM2 push beam grippers.

PTM2 push beam gripper release

Opens the PTM2 push beam grippers.

PTM2 close push beam gripper

Closes the PTM2 push beam grippers.

Cradle Up

Raises the PTM2 cradle. Motion is latched in when the miner is in auto mine. To stop motion press the cradle down pushbutton.

Trolley In

Moves the PTM2 trolley into the miner.

Cradle Shift Forward

Moves the PTM2 cradle towards the hose reel.

Cradle Down

Moves the PTM2 cradle down.

Trolley Out

Moves the PTM2 trolley out.

Cradle Shift Backward

Moves the PTM2 cradle towards the cab.

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Description

Function

Tram Operations Pump Rate

Default is 80% but can be adjusted according to operation.

Single Track selection

37.00 ° figure reports the angle of the track Selects each track for lifting, lowering, tram front, or tram rear.

Quad mode selection

Selects all four tracks to follow front right track steering motion.

Quad track selection

Selects all four tracks for “Quad” steering operations.

Quad mode selection

Tram Mode - Selects if the rear tracks are to go in the opposite direction from the front right track for quad steering.

Forward Tram

Available only in tram mode. All four tracks will tram when this button is pressed. To stop the forward tram function, press the reverse tram function.

Reverse Tram

Available only in tram mode. All four tracks will tram when this button is pressed. To stop the reverse tram function, press the forward tram function.

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Operation ________________________________________________________ Table 32 Symbol

Description

Function

Tram Operations, continued Front track selection

In Mine mode, front track selection.

Allows you to only select the front tracks for tramming.

Rear track selection

In Mine mode, rear track selection. Allows you to only select the rear tracks for tramming.

Left tram

In Mine mode, after track selection has been made. Allows you to tram selected tracks to the left

Right tram

In Mine mode, after track selection has been made. Allows you to tram selected tracks to the right.

Clockwise tram

In Mine mode, tram all four tracks in the clockwise direction.

Counter Clockwise tram

In Mine mode, tram all four tracks in the counter clockwise direction.

Tracks Lifting/Lowering Operations Lift tracks

Tracks to be lifted must be selected for this function.

Lower tracks

Tracks to be lowered must be selected for this function.

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________________________________________________________Operation Table 32 Symbol

Description

Function

Steering Operations Straight steering operation

Turns all tracks to the calibrated straight position when selected. To stop the movement, deselect the button.

Counter clockwise steering operation

Turns the selected tracks in the counter clockwise rotation when selected. To stop the movements deselect the button.

Clockwise Steering operation

Circle Steering operation

Turns the selected tracks in the clockwise rotation when selected. To stop the movements deselect the button.

In Mine mode, turns the tracks into a calibrated circle position.

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Operation ________________________________________________________

Auto Retract Page

Illustration 82

The Auto Retract Page contains the controls that configure Auto Retract Mode. Icons are populated on this page as selections are made on the Miner Configuration Page. Some of the controls that are displayed depending on miner configuration are tail swing belt functions, vertical auger, vertical conveyor functions, and PTM2 controls. Tram and Mine Mode change in response to selection on the Tram Page.

To prevent system overload, the system must be started in order, even when starting motors in Manual Mode. There is a three second delay after each motor starts before the next motor can be started.

The Automine and AutoRetract pages are very similar. The few differences between the pages are covered in Table 33.

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________________________________________________________Operation Table 33 Symbol

Description

Function

Power Head Operation Power Head Front Stop Override

Sometimes during a retract it becomes necessary to override the front stop setting in order to reach the string of beams that failed to stay in position. This button advances the powerhead in order to reach the next push beam to be removed.

Miscellaneous

Retract Time

Displays the total retract time. Timer starts when hole complete is selected and ends when beam count is zero.

Beam Retract

Displays the time retract a beam. The time starts when power head latches are latched and ends when power head reaches front position to latch power head again.

Auto Retract Message Auto Retract Message

Provides information on the current status of the miner in auto retract. Also prompts the operator for any input needed by the operator.

Not Categorized Hand\Auto

Turns auto retract on and off. Once auto retract is turned on the retract message box will prompt for any needed actions.

Resume Auto Retract

Re-starts the Auto Retract Sequence.

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Operation ________________________________________________________ (1) Shear Setup Navigation Interface Page 1

3

(2)

Setup

(3)

Navigation

(4)

Setup

(5)

Navigation Interface Options

(6)

Navigation Interface Page

The Navigation Interface Page (6) is only available if a Navigation interface is installed and selected.

To select a Navigation interface, select the Setup page (2) and the Shear Setup (1). In the Extended Options box press the button next to CM Rack (4).

This will bring up the Steering/Navigation Interface Options box (5), where the interface installed is selected. Once an interface is selected, the Navigation Box icon (3) will appear on the Operations navigation bar. Select the Navigation Box icon (3) to bring up the GPS Interface Page (6).

2

Table 34 describes the icons on the Navigation Interface Page (6).

4

5

6 Illustration 83

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________________________________________________________Operation Table 34 Symbol

Description

Function

Navigation Heading

Cutter head heading according to the Navigation unit.

CM roll left to right

Indicates the roll of the cutter module - right to left.

CM pitch front to back

Indicates the pitch of the cutter module – front to back.

Refresh

This does a refresh on the Navigation unit which causes the unit to regenerate the heading information.

Navigation Status Information Navigation Status Information

Information from the GPS unit such as latitude, longitude and heading information.

Actual Heading

Top number displays the actual CM Heading.

Heading Set Point

Second number displays the programmed heading set point.

Deviation from Centerline

Third number displays the cutter head deviation from centerline.

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Operation ________________________________________________________ Table 34 Symbol

Description

Function

Cutter Module Steering/Navigation Settings Cutter Module Steering/ Navigation Settings

Allows adjustment of how and when the steering works.

Mode Selection for Steering Operation

Allows selection of when steering correction takes place.

Heading Change Box

Allows selection of how much change is allowed before steering correction is necessary.

Correction Time Box

Allows selection of how much time is allowed for steering correction.

Steering Cylinder Limit

Allows control of how far the steering cylinder is allowed to extend.

Steering Left indicator

Indicates and manually performs a left steering cylinder extension.

Steering Right Indicator

Indicates and manually performs a right steering cylinder extension.

Steering Heading Set Point Box

Allows you to select a steering heading.

Contour Graph Page

Illustration 84

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________________________________________________________Operation Contour Graph Page The Contour Graph page gives a graphical representation of the contour of the hole being mined, as well as hole history.

Table 35 describes the icons on the Contour Graph page.

Table 35 Symbol

Description

Function

Current Hole Number

Displays number of hole currently being displayed.

Display Selector

Lets you select which hole you want to display.

1. Display current hole.

2. Display previous hole.

3. Display 2 holes ago.

4. Display 3 holes ago.

Top Contour Bottom Contour

Represents color for each contour displayed.

Left Contour Right Contour

Represents color for each contour displayed.

Top Scale

Adjusts top scale value of graph.

Bottom Scale

Adjusts bottom scale value of graph.

Scroll To Beginning

Scrolls to beginning of hole.

Scroll Backward

Scrolls toward beginning of hole.

Scroll Forward

Scrolls toward end of hole.

Cutter Module Steering Graph

Toggles between “top & bottom” and “left & right” contour graphs.

Zoom In

Allows you to “zoom in” on contour graph.

Zoom Out

Allows you to “zoom out” on contour graph.

Current Depth

Displays current depth of cutter module.

Record Number

Number of graph being displayed.

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Operation ________________________________________________________ Table 35 Symbol

Description

Function As a hole is mined the program calculates top and bottom hole contour positions from the start of the hole.

The arrow button advances forward through the data samples one sample at a time. New information will be displayed above the arrow buttons.

Previous Record

Next Record

As a hole is mined the program calculates top and bottom hole contour positions from the start of the hole.

The arrow button advances backward through the data samples one sample at a time. New information will be displayed above the arrow buttons.

Current Hole Top Contour

Displays top contour of current hole.

Bottom Contour

Displays bottom contour of current hole.

Hole Depth

Displays depth of current hole.

Total Depth

Displays total shift depth.

Tonnage

Displays tonnage from current hole.

Total Tonnage

Displays total shift tonnage.

Left Contour

Displays left contour of current hole.

Right Contour

Displays right contour of current hole.

Ribbing Error

Displays amount of ribbing error “deviation from heading set point” for current hole.

Hole History Number

Displays record number for history hole.

Top Contour

Displays top contour of history hole.

Bottom Contour

Displays bottom contour of history hole.

Hole Depth

Displays depth of history hole.

Total Depth

Displays total shift depth at time of record.

Tonnage

Displays tonnage of history hole.

Total Tonnage

Displays total shift tonnage at time of record.

Left Contour

Displays left contour of history hole.

Right Contour

Displays right contour of history hole.

Ribbing Error

Displays ribbing error for history hole.

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________________________________________________________Operation Cutter Head Steering Operation 1. On 2 Foot / 0.6096 Meter Sample As the power head moves forward the distance right or left of center is checked. If this is greater than the number entered in the Ribbing Delta box on the Miner Setup – GPS Interface page, corrections are made. The steering cylinders are retracted when the cutter head steering error is reduced to half of the value entered in the Ribbing Delta box on the Miner Setup – GPS Interface page.

2

Illustration 86 Illustration 85

(1)

System Status Icon

To use the steering system:

(2)

System Status Page

1. Activate the hardware.

The System Status Page (2) displays communication status with different nodes of operation. This page is accessed by pressing the System Status Icon (1).

2. Make sure this con is selected..

3. Wait 5 minutes for alignment to complete.

4. Select the desired steering mode.

System Status Page

The System Status Page (2) shows the status of the CPU and the communication status of the touch screens. Some nodes will not be used depending on selections made on the Setup page. The System Status Page (2) is helpful in communication troubleshooting.

Table 36 describes the icons on the System Status Page (2).

1

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Operation ________________________________________________________ Table 36 Symbol

Description

Function Displays the current status of the Service Fault indicator on the PLC.

SF

Indicates a hardware problem.

A red light will be on in the SF if a problem is detected within.

BF1

A red light will be on if a problem is detected in the diagnostic MPI/DP port network.

BF2

Buss Fault 2 – Indicates the current status of the buss fault 2 circuit on the PLC. The indicator would blink red when the PLC can’t communicate to a Profibus Node.

BF3

Buss Fault 3 – Indicates the current status of the buss fault 3 circuit on the PLC. The indicator would blink red when the PLC can’t communicate to a Profinet Node.

DC5V

PLC Power. Green when the power supply to the PLC is good and the PLC is functioning correctly.

FRCE

Indicates when something is forced internally in the PLC. FRCE will be indicated with a red light.

Indicates when the PLC is in Run mode.

RUN Run will be indicated with a green light.

Indicates when the PLC is in stop mode.

STOP Stop will be indicated with a amber light.

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________________________________________________________Operation Table 36 Symbol

Description

Function

IP Address/ Profinet Address

Lists the IP Address for the device.

PLC 192.168.1.2 Left 192.168.1.123 Right 192.168.1.124 Data Computer 192.168.1.125

Previous, Minimum, Maximum.

Lists the maximum, minimum, and previous and scan times of the PLC.

Node #: Component Profinet Status.

Red = Error Green = Good Grey = Simulator Active

Nodes 27 – 31

These are Variable Frequency Drive Nodes. The indicator shows node status. Red = Error, Green = Good. Node # is the profibus address assigned to each drive.

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Operation ________________________________________________________ Power Meter Page 1

2

3 Illustration 87 (1)

Power Meter

(2)

System Status

(3)

Power Meter Page

The Power Meter Page (3) displays information from the 995 Volt power meter. This page is accessed by pressing the System Status icon (2) and then the Power Meter icon (1).

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________________________________________________________Operation Table 37 Symbol

Description

Function

Kilowatts

Lists the wattage used by each phase and the total wattage used.

KVA

Lists the KVA total for each phase and the total KVA used.

Power Factor

Lists the power factor for each phase and the total power factor.

Voltage

Lists the Line to Neutral Voltage of each phase and the Line to Line Voltage of each phase.

Line Frequency

Lists the frequency of the 995 Voltage AC.

Current

Lists the current of each phase, the average of the three phases, and the maximum current recorded.

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Operation ________________________________________________________ VFD Controls Page

1

2

3

Illustration 88 (1)

VFD Controls

(2)

System Status

(3)

VFD Controls Page

The VFD Controls Page (3) is accessed by pressing the System Status icon (2) and then the VFD icon (1).

Table 38 describes the icons on the VFD Controls Page (3).

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________________________________________________________Operation Table 38 Symbol

Description

Function

VFD Selection Indication Box

Indicates which VFD the information is about.

VFD Selection Box

Allows you to select which VFD’s information is being displayed.

Status Box for the VFD selected

Indicates the status of the VFD selected.

Current Fault Information Box for VFD selected

Indicates the current fault conditions of selected VFD.

480V VFD Drive Page 1

3

2

4

Illustration 89 (1)

480V VFD Controls

(2)

System Status

(3)

480V VFD Controls Page

(4)

VFD Selection

The 480V VFD Controls Page (3) is accessed by pressing the System Status icon (2) and then the VFD icon (1).

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Operation ________________________________________________________ Table 39 describes the icons on the 480V VFD Controls Page (3).

Table 39 Key

Symbol

Description

Function

1

Ready

Green when drive is online

2

Running

Green when drive is running

3

Coast to Stop

On when drive receives coast to stop command

4

Quick Stop

On when drive receives emergency stop command

5

Direction Rotation

On when drive is running forward

6

Drive MSP

Green when 24 Volts from MSP is present

7

Motor Contactor

Green when 24 Volts from contactor auxiliary is present

8

Fault Present

Green when fault is present on drive

9

Warning Present

Green when warning fault is present on drive

10

Output Frequency

Displays the output frequency of the drive

11

Output Current

Displays the output current of the drive

Miner Status - Main Page

Illustration 103

Table 40 describes the icons on the Miner Status Page.

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________________________________________________________Operation Table 40 Symbol

Description

Function

Level

Hydraulic Oil Level

Displays the Hydraulic Oil Level in liters or gallons.

This is based on the metric or standard selection switch on the Miner Status Page.

Water Flow Horizontal Auger

Displays the water flow to the horizontal auger motors in liters per minute or gallons per minute. This is based on the metric or standard selection switch on the Miner Status Page.

Cutter Head

Displays the water flow to the cutter head motors in liters per minute or gallons per minute. This is based on the metric or standard selection switch on the Miner Status Page.

Temperatures Hydraulic Oil

Displays the hydraulic oil temperature in degrees Celsius or degrees Fahrenheit. This is based on the metric or standard selection switch on the Miner Status Page.

Cooling Water

Displays the cooling water temperature in degrees Celsius or degrees Fahrenheit. This is based on the metric or standard selection switch on the Miner Status Page.

Cutter Motor

Displays the cutter motor gear case temperature in degrees Celsius or degrees Fahrenheit. This is based on the metric or standard selection switch on the Miner Status Page.

Power Meter Voltages/Currents Line-Neutral A

Displays the line to neutral voltage of phase A.

Line-Neutral B

Displays the line to neutral voltage of phase B.

Line-Neutral C

Displays the line to neutral voltage of phase C.

Current A

Displays the line current of phase A.

Current B

Displays the line current of phase B.

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Operation ________________________________________________________ Down Time Flags Page

Illustration 90

The Down Time Flags Page contains controls to enable or disable down time flags.

Table 41 describes the icons on the Down Time Flags Page.

Table 41 Symbol

Description

Function

Level Time Entry

Enter Times in the format hours:minutes:seconds.

Enable/Disable

Enables Downtime Faults.

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________________________________________________________Operation Motor Amps/Pressure Page

Illustration 91

Table 42 describes the icons on the Motor Amps/Pressure Page.

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Operation ________________________________________________________ Table 42 Symbol

Description

Function

Cutter Motor Left

Displays Left Cuter Motor Amps.

Right

Displays Right Cutter Motor Amps.

Hydraulic Pump

Pump

Displays the BPM motor current.

BPM Pump Pressures Pump 1

Displays pressure for the Sump/Tram, P1, Pump in the BPM. Measurements can be displayed on metric or standard based on the selection switch on the Miner Setup page.

Pump 2

Displays pressure for the Extra Oil, P2, Pump in the BPM. Measurements can be displayed on metric or standard based on the selection switch on the Miner Setup page.

Pump 3

Displays pressure for the General Service, P3, Pump in the BPM. Measurements can be displayed on metric or standard based on the selection switch on the Miner Setup page.

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________________________________________________________Operation Table 42 Symbol

Description

Function

Shear Pressures Port A

Displays pressure at the A port on the shear valve.

Measurements can be displayed on metric or standard based on the selection switch on the Miner Setup page.

Port B

Displays pressure at the B port on the shear valve.

Measurements can be displayed on metric or standard based on the selection switch on the Miner Setup page.

Horizontal Motor Left

Displays Left Horizontal Auger Motor Amps.

Right

Displays Right Horizontal Auger Motor Amps.

Power Head Pressure G1 Blind Side

G1 Blind Side Pressure.

G2 Rod Side

G2 Rod Side Pressure.

G3 Pressure

Sump Manifold input pressure from Pump 1 and Pump 2.

G4 Tank

Outgoing tank pressure.

Chain Conveyor

Chain Conveyor

Displays Left Chain Conveyor Motor Amps.

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Operation ________________________________________________________ Table 42 Symbol

Description

Function

Gathering Motor Left

Displays Left Gathering Motor Amps.

Right

Displays Right Gathering Motor Amps.

Right Angle

Right Angle Amps

Displays Right Angel Conveyor Motor Amps.

Stacker Belt

Stacker Belt Amps

Displays Stacker Belt Motor Amps.

Water Spray Pump

Water Spray Pump Amps

Displays Water Spray Pump Amps.

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________________________________________________________Operation Motor Hours Page

Illustration 92

Table 43 describes the icons on the Motor Hours page.

Table 43 Symbol

Description

Function

Service Due Indicator

Turns red when motor and gearbox service is due.

Current

Current Motor Hours. Hours can be reset by clicking in the box and entering a password and then entering the desired hours.

Last Service

Hours recorded at the last motor service. Last Service hours can be reset by clicking in the box and entering a password and then entering the desired hours.

Reset Service Due

Resets the motor hours and service hours to 0.

Reset Service Hours

Press this button after servicing the motor and gearbox.

The last serviced hours will be set equal to the current motor hours.

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Operation ________________________________________________________

Motor Faults Page

Illustration 93

Table 44 describes the icons on the Motors Faults Page.

Table 44 Symbol

Description

Function

Number

Displays the fault number.

Time

Displays time the fault occurred.

Date

Displays date the fault occurred.

Status

Displays status of the fault.

1. C = Active Alarm 2. CA = Active Alarm Acknowledged 3. CAD = Alarm Cleared

Text

Displays description of the fault.

Alarm Group Code

Not Used.

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________________________________________________________Operation Table 44 Symbol

Description

Function

Info Text

Displays additional information.

Previous Page

Displays previous page.

Reset Faults

Resets faults that have been cleared.

Recorded Faults

Displays recorded faults.

Miner Warnings Page

Illustration 94

Table 45 describes the icons on the Miner Warnings Page.

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Operation ________________________________________________________ Table 45 Symbol

Description

Function

Number

Displays the warning number.

Time

Displays time the warning occurred.

Date

Displays date the warning occurred.

Status

Displays status of the warning.

1. C = Active Alarm 2. CA = Active Alarm Acknowledged 3. CAD = Alarm Cleared

Text

Displays description of the warning.

Alarm Group Code

Not Used.

Info Text

Displays additional information.

Previous Page

Displays previous page.

Reset Warnings

Resets warnings that have been cleared.

Recorded Warnings

Displays recorded warnings.

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________________________________________________________Operation

Force Page - Main Menu

I/O cards contained in each rack can be selected and individual force pages can be viewed using the icons described in Table 46.

Table 46 Symbol

Description

Function

I

Digital inputs.

Q

Digital outputs.

AI

Analog inputs.

AQ

Analog outputs.

If a force exists on any input or output then that card’s icon will change color to indicate an active force. Forces can be applied or removed and the status or value can be changed or monitored for each input/output from the individual force pages.

1

Table 47 describes the icons, located at the bottom of the page, that access the I/O rack.

Table 47 Symbol

Description ECM BPM Back Right Front Left Front Right Power Head

2 Illustration 95 (1)

Force Page #1

(2)

Force Page #2

PTM2 Cab Cutter Head Each card for a selected rack can be viewed from that location or can be directly accessed from the main menu.

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Operation ________________________________________________________ Table 48 describes IEC symbols used on the force pages to indicate the type of I/O being viewed.

Table 48

Symbol

Description Motor Starter.

Symbol

Description Ammeter.

Normally Closed Contact.

Circuit Breaker.

Normally Open Contact.

Coil.

Position Sensor.

Contactor.

Proportional Valve.

DC Power.

Proximity Sensor (Magnetic).

Direct Current.

Proximity Sensor.

E-Stop.

Fluid Actuator.

Short Circuit Sensor.

Siren.

Fluid Level.

Steering.

Frequency Meter.

Thermal Overload Relay.

Ground Fault.

Thermocouple.

Hydraulic Oil Pressure.

Thermostat.

Level Control.

Volt Meter.

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________________________________________________________Operation Analog Inputs & Outputs

Illustration 96

Individual force pages, like the Analog Input Force Page, shown, display various information about each input or output. Forces can be activated, deactivated, or monitored from these pages.

Table 49 describes the icons on a typical analog input force page.

Table 50 describes the icons on a typical analog output force page.

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Operation ________________________________________________________ Table 49 Symbol

Description

Function

Selected Rack

Displays the name of the rack that is being viewed.

Selected Page

Shortcut buttons to select between cards within a rack.

IEC Symbol

Displays the IEC Symbol the attached device. In this case, an active style thermocouple with 4-20mA output.

Indicator & I/O Description

Displays the current input raw counts at the physical input & the device which is connected to it.

Acceptable raw count range is 0 – 27,648.

Active Force Time

Displays the time an input has been forced. The time will be reset automatically when the force is removed and then forced again. Pressing the clock will reset the force time after the force is removed.

Internal PLC Address & Status

All analog inputs have two internal addresses. One is for metric units of measurements and the other is for standard units. This internal input displays scaled units where applicable. If the raw count is being used to display temperature one address will show degrees Fahrenheit and the other address will show Celsius.

Activate Force

Pressing this button activates the force.

Force On Raw count mode active

When forcing analog values you can force by entering scaled values or raw counts. When the grey arrow is present you will have to enter raw counts.

Force On Scaled value mode active

To force the input press the grey arrow. After it turns green enter the scaled value.

Reset Force Time

After the force is removed press the clock to reset the force time.

Force Value Entry

This is where you enter the forced value. The bottom box is for scaled units and the top box is for raw counts.

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________________________________________________________Operation Table 50 Symbol

Description

Function

Selected Rack

Displays the name of the rack that is being viewed.

Selected Page

Shortcut buttons to select between cards within a rack.

IEC Symbol

Displays the IEC Symbol the attached device. In this case, a proportional valve.

Indicator & I/O Description

Displays the current input raw counts at the physical input & the device which is connected to it.

Acceptable raw count range is 0 – 27,648.

Active Force Time

Displays the time an input has been forced. The time will be reset automatically when the force is removed and then forced again. Pressing the clock will reset the force time after the force is removed.

Internal PLC Address & Status

All analog inputs have two internal addresses. One is for metric units of measurements and the other is for standard units. This internal input displays scaled units where applicable. If the raw count is being used to display temperature one address will show degrees Fahrenheit and the other address will show Celsius.

Activate Force

Pressing this button activates the force.

Force On Raw count mode active

When forcing analog values you can force by entering scaled values or raw counts. When the grey arrow is present you will have to enter raw counts.

Force On Scaled value mode active

To force the input press the grey arrow. After it turns green enter the scaled value.

Reset Force Time

After the force is removed press the clock to reset the force time.

Force Value Entry

This is where you enter the forced value. The bottom box is for scaled units and the top box is for raw counts.

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Operation ________________________________________________________ Digital Inputs Individual force pages display various information about each input or out. Forces can be activated, deactivated, or monitored from these pages.

Illustration 97

Table 51 describes the icons on a typical digital input force page.

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________________________________________________________Operation Table 51 Symbol

Description

Function

Selected Rack

Displays the name of the rack that is being viewed.

Selected Page

Shortcut buttons to select between cards within a rack.

IEC Symbol

Displays the IEC Symbol the attached device. In this case, a normally open contact.

Indicator & I/O Description

Displays the current input raw counts at the physical input & the device which is connected to it.

Acceptable raw count range is 0 – 27,648.

Active Force Time

Displays the time an input has been forced. The time will be reset automatically when the force is removed and then forced again. Pressing the clock will reset the force time after the force is removed.

Internal PLC Address & Indicator

All analog inputs have two internal addresses. One is for metric units of measurements and the other is for standard units. This internal input displays scaled units where applicable. If the raw count is being used to display temperature one address will show degrees Fahrenheit and the other address will show Celsius.

Activate Force

Pressing this button activates the force.

Forced to Off

Forces the digital input to off, false, (0)

Forced to On

Forces the digital input to on, true, (1)

Reset Force Time

After the force is removed press the clock to reset the force time.

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Operation ________________________________________________________ Digital Outputs Individual force pages display information about each input or output. Forces can be activated, deactivated, or monitored.

Illustration 98

Table 52 describes the information found on a typical digital output force page.

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________________________________________________________Operation Table 52 Symbol

Description

Function

Selected Rack

Displays the name of the rack that is being viewed.

Selected Page

Shortcut buttons to select between cards within a rack.

IEC Symbol

Displays the IEC Symbol the attached device. In this case, a contactor.

Indicator & I/O Description

Displays the current input raw counts at the physical input & the device which is connected to it. Acceptable raw count range is 0 – 27,648.

Active Force Time

Displays the time an input has been forced. The time will be reset automatically when the force is removed and then forced again. Pressing the clock will reset the force time after the force is removed.

Internal PLC Address & Indicator

All analog inputs have two internal addresses.

One is for metric units of measurements and the other is for standard units. This internal input displays scaled units where applicable. If the raw count is being used to display temperature one address will show degrees Fahrenheit and the other address will show Celsius.

Activate Force

Pressing this button activates the force.

Force Off (When Inactive) Force On (When Active)

Reset Force Time

When forcing analog values you can force by entering scaled values or raw counts. When the grey arrow is present you will have to enter raw counts.

To force the input press the grey arrow. After it turns green enter the scaled value.

After the force is removed press the clock to reset the force time.

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Operation ________________________________________________________ Help Page

Illustration 99

Table 53 describes the icons found on the Help Page.

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________________________________________________________Operation Table 53 Symbol

Description

Function

Miner Version Miner Number

Displays miner number.

PLC

Displays PLC version number.

HMI

Displays HMI version number.

Step 7 Version Version

Displays Step 7 version number.

Service Pack

Displays Step 7 “service pack” number.

Hot Fix

Displays Step 7 “hot fix” number.

Debug

Push button to enter debug program simulator.

Simulator

Push button to use cab remote I/O with simulator.

WinCC Flexible Version Version

Displays version number of WinCC Flex that is installed.

Service Pack

Displays WinCC Flex “service pack” number.

Hot Fix

Displays WinCC “hot fix” number.

CE Version

Displays Windows CE version.

CE Build

Displays Windows CE build.

Advanced Diagnostics

Displays component information.

Host Name

Displays name of network host.

IP Address

Displays IP address of PLC.

Subnet Mask

Displays subnet mask.

MAC Address

Displays physical network address.

Data Logging Times Power Meter

Determines how often data is logged from power meter.

Universal

Determines how often other data is logged.

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Operation ________________________________________________________ Ground Man Controls

(1)

Ground Man Control Pendant

(2)

Jog #1 Motor

3

(3)

Jog #2 Motor

4

(4)

Cradle Up

(5)

Cradle Down

(6)

Trolley In

(7)

Trolley Out

(8)

Clamp

(9)

Release

2

5

1

6 7 8

(10) Cradle FWD

9

(11) Cradle REV

10

(12) Ground Man Display

The Ground Man Control Pendant (1) is used by the ground operator to load and unload push beams.

11

12

Illustration 100

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________________________________________________________Operation Operating Procedures

three points of contact while climbing. Use extra precautions during rainy or snowy conditions.

Before operating the machine, the operator must be fully trained. This training must include safety as well as operating procedures.

Start up

Failure to adhere to proper safety practices may result in serious injury or death.

1. Check all fluid levels (see Maintenance section of this chapter):

Safety

a. Left and right cutter head gear boxes

This section is not a comprehensive list of all safety regulations to be followed but, instead, lists typical considerations. Follow all regulatory agency and mine safety practices.

b. Gear oil in drum



Wear proper personal protective equipment.



If the machine is running, make radio and/or eye contact with the operator before mounting the machine.

c.

Left and right horizontal auger gear boxes

d. Chain conveyor gear box e. Right angle conveyor gear box. f.

Hydraulic oil level

g. Antifreeze level



Use caution when approaching the machine.

Terrain may be muddy and/or uneven.

2. Check all grease points (see Maintenance manual).



While approaching the miner, perform a visual inspection of the machine and work area. Look for:

a. Cutter head shear arms and pins



Damage to the machine that could cause injury.



Obstructions in the way of moving components.



Pay attention to mobile equipment working in the area.



Inspect the highwall for cracks, slips, or debris falling from the wall.



If following another crew (hot seating), obtain a shift report identifying problems, repairs, and mining conditions.

 



b. Power head grease block for power head augers. c.

d. Chain conveyor take-up shaft and drive shaft bearings e. Right angle conveyor take-up shaft and drive bearings f.

Communicate with the crew whenever power is to be turned on or off.

Communicate with the crew before starting any motor or any component is moved or put into operation.

Use caution when mounting, dismounting, or walking on the machine or push beams. Maintain

Hose reel grease block for reel bearing

PTM trolley wheels and cradle wheels

3. Make sure that all personnel are in the clear and are aware that machine power is be turned on.

4. Energize Power Source.

5. Energize the following breakers: a. Main (995 volt) breaker b. Right angle breaker c.

Chain conveyor breaker

d. Left and right horizontal auger breakers

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Operation ________________________________________________________ e. Main hydraulic pump breaker (BPM) f.

wall, how even the pit is, and whether or not the pit floor is even with the bottom of the seam.

Left and right cutter head breakers

g. Gathering breaker (if equipped) h. Stacker breaker (if equipped) 6. Communicate with the crew that power is now on the machine.

7. Check the computer screen in the operator’s cab for alarms. Address each alarm condition and clear alarms before continuing. a. Example: During extreme cold conditions the hydraulic oil may need to be preheated before operation. A prompt (fault) on the computer screen will indicate if this is necessary.

8. Move HW300 into mining position from the tram page . a. The operator should have a clear view of ground personnel as they must assist him in getting the machine lined up properly. Hand held radios are a good tool for crew communications.

11. Start a hole. a. Communication is key when starting a hole.

The operator must rely on the person designated to start him. b. It is important to observe the wall as debris commonly falls from the wall as the cutter head makes initial entry. c.

d. Push the power head forward until the cutter module is on the pad in manual mode, paying attention to the alignment of the cutter module. e. Push the cutter module forward to the mining stop point. If needed, add push beams and continue pushing until the cutter head is two to three feet from the wall. f.

b. Ground personnel should be aware of trailing cables during movement of the machine so they do not get in a position to be run over or pinched by the moving equipment.

9. Level the machine from the tram page. a. Side to side leveling is critical. Assuming the pit is fairly level, the entire machine can be lowered. The front should be slightly lower than the rear, and in contact with the ground to leave room for adjustment in beam alignment by raising or lowering the rear of the HW300.

10. Construct cutter module pad. a. The pad is a pile of coal placed directly in front of the cutter module. The pad acts as a ramp for the cutter module to make an easy, level transition from the miner to the pit floor. a level transition will insure proper beam alignment. The cutter module should be on the pit floor as it is ready to enter the coal seam (it is much easier to mine following the bottom of the seam). The amount of pad needed depends on the distance from the

With the operator and his designated starter communicating, turn on the main hydraulic pump.

If the beams are reasonable level and the cutter module is at the pit floor, begin mining.

If not, back the cutter module up and adjust the pad and/or raise/lower the machine as needed.

g. Once the position of the miner, beams, and cutter module are satisfactory, start the remainder of the components.

12. Start components. a. Communicate to the crew that all motors will be starting. b. Ensure that all personnel are clear. c.

Return the touch screen to the Mine page.

d. If equipped, start the stacker belt. There will be a delay as an alarm sounds, then the stacker belt will start. e. Start the right angle conveyor. f.

When the right angle conveyor amp gauges steady, start the chain conveyor.

g. When the chain conveyor amp gauge

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________________________________________________________Operation steadies, start the left horizontal auger motor. h. When the left horizontal auger motor amp gauge steadies, start the right horizontal auger motor. i.

When the right horizontal amp gauge steadies, start the cutter head motors.

There will be a delay as an alarm sounds, then the motors will start.

j.

Lower the power head forward speed to avoid stalling the cutter motors.

k.

Push the power head forward until the cutter contacts the face. When the cutter contacts the face, there will be an increase in the cutter motor amp gauges.

l.

At the prompt of the starter, shear the cutter head up manually until prompted to stop. This is the top set point.

m. Set the top set point on the Mine page. n. Depending on conditions, it may be necessary to do a few sumps manually to prevent wall failure or to fine tune the bottom and top set points. o. When it is safe and appropriate, the machine can be switched to Auto Mine mode.

13. Auto Mine mode: When in auto mine mode, the operator must monitor the computer screens and amp gauges in order to follow the coal seam. The machine will sump forward and shear down and then repeat until the end of the power head stroke. The operator must continue to pay attention to all motor amps and pressures while mining.

components shutoff automatically, the power head unlatches from the beam and returns to the full back position to allow the ground man to load another beam. While mining, the operator should maintain a constant observation of sump pressures. A rapid increase in sump pressure most likely means that a rock has fallen on top of the beams. If the pressure is too high, the string should be retracted and the debris removed.

14. Retracting a. Switch to the retract page on the touch screen. There are two speeds: high force/ medium speed or medium force/regen speed. High force/medium speed is for high pressure situations. When the pulling pressure is consistently below 1,300 psi (90 bar), the operator can switch to medium force/regen speed from the Mine Set page. b. Choose end hole or pause hole when prompted on the retract page. c.

Select Auto Retract. The power head will pull the string to the unlatching position.

d. The ground man now removes the push beam latch pins connecting the beams. e. The operator now pulls the power head back and unlatches from the beam and continues to move the power head until it is all the way back. f.

The ground man now removes the beam.

g. After the cradle up indicator comes on and it is verified that everyone is in a safe position, press the Resume Retract icon.

a. Sump Forward: Monitor sump pressure, cutter amps, and horizontal auger amps.

h. The power head will advance forward, latch to the string, and the cycle will be repeated.

b. Shear Up: Monitor cutter amps.

i.

c.

Shear Down: Monitor cutter amps and horizontal auger amps.

This process is repeated until the end of the power head stroke. At the end of the stroke, the machine goes into Clean Out mode. The length of clean out is determined and adjusted by the operator. At the end of clean out, the

Once the head is out of the mined entry, shut the cutter motor off for safety.

15. Shutdown: During retract, the only motors running are the main hydraulic pump and the cutter head motors. a. If any other motors are running, turn them off.

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Operation ________________________________________________________ b. Ensure all moving parts of the miner are in a safe position as hydraulic pressure could leak off after the pump is turned off, causing components to move. DO NOT LEAVE A BEAM HANGING. c.

Turn off the main hydraulic pump.

d. In the ECEM, de-energize the following.

1. Main 995V breaker 2. Right angle breaker 3. Chain conveyor breaker

Personal injury or death can result from machine movement.

Always lock out/tag out the machine, following all applicable laws and regulations, as indicated.

Important - All electrical work should be performed by a certified electrician.

1. Ensure the machine is positioned in a safe working area.

4. Left horizontal auger breaker 5. Right horizontal auger breaker 6. Main hydraulic pump breaker (BPM) 7. Left cutter head breaker 8. Right cutter head breaker 9. Gathering breaker, if equipped 10. Stacker breaker, if equipped

PTM II Trolley Positioning The following procedure is used to position the PTM II Trolley to load push beams on the left side or right side of the HW300 Highwall Miner.

Table 54 details the crew required to perform the operation.

Illustration 101

2. Instruct the machine operator to level the highwall miner using the front and rear super beam inclinometer.

3. Lower the handrail located on the PTM trolley by pulling the pins from the hinge point. Failure to do so could result in damage to the PTM trolley handrail and/or structure.

Table 54 Description, Skills Required Operator, Fork Wheel Loader Operator, HW300 Helper Technician, Electrical Technician, Mechanical Welder

Illustration 102

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________________________________________________________Operation 4. De-energize the machine by tripping the 1600 amp circuit breaker.

10. Energize the machine by resetting the 1600 amp circuit breaker.

5. Lock and tag out the 1600 amp circuit breaker.

11. Instruct the machine operator to start the hydraulic pump motor.

3

4

Illustration 105

Illustration 103

6. Center the PTM Trolley in the center of the machine.

7. Insert a 1 inch by 3 inch bolt into each trolley wheel scotch bolt hole (1) located on the front and rear trolley beams and secure with a 1 inch hex nut or equivalent. Tighten the bolts.

2

12. If moving from right to left, instruct the machine operator to energize the valve to retract the transfer cylinders using the icon (4) on the touch screen.

Note: The Type II Traverse Cylinder Bracket and Type II Cross Brace may catch or bind during movement. Communication with the operator is critical to prevent damage.

3

5

Illustration 106

Illustration 104

8. Remove the eight 1 inch nuts (2) and eight 1 inch bolts (3) retaining the Type II Traverse Cylinder Bracket to the front PTM structure trolley T-Beam and rear PTM structure trolley.

13. If moving from left to right, instruct the machine operator to energize the valve to extend the transfer cylinders using the icon (5) on the touch screen.

Note: The Type II Traverse Cylinder Bracket and Type II Cross Brace may catch or bind during movement. Communication with the operator is critical to prevent damage.

9. Remove the lock and tag from the 1600 amp circuit breaker.

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Operation ________________________________________________________ 18. Install the lock washers and nuts securing the Type II cylinder bracket to the front and rear PTM structure trolley beam. Torque 28.7 N-m to (680 lb·ft).

19. Remove the bolt or equivalent from the trolley scotch bolt hole located on front and rear trolley I-beams.

7

6

Illustration 107

8

14. Position the Type II traverse cylinder brackets (6) with the correct set of mounting holes on the front PTM structure trolley beam and the rear PTM structure trolley beam (7).

Illustration 109

20. Disconnect the cable from the proximity switches (8) located on the push beam indicator bracket.

9

Illustration 110 Illustration 108

21. Remove the two bolts (9) securing the push beam indicator bracket to beam table.

15. De-energize the machine by tripping the 1600 amp breaker.

16. Lock out and tag out the 1600 amp breaker.

17. Use pry bar to adjust the Type II traverse cylinder bracket for bolt hole alignment and install the bolts. (Note: The fork wheel loader or equivalent may be used to add additional support to the Type II cross brace to ease bolt hole alignment.)

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________________________________________________________Operation 25. Remove the two bolts (12) that secure the storage rack ladder to the BPM catwalk.

26. Place the storage rack ladder in a safe area.

10

13

Illustration 111

22. Disconnect the pneumatic line quick connect fitting (10) located under the storage rack.

Illustration 114

27. Remove the storage rack access ladders by lifting them out of their mounting brackets (13).

11

28. Place the storage rack ladders in a safe area.

14

Illustration 112

23. Disconnect the hydraulic line quick connect fittings (11) located under the skid.

24. Use the fork wheel loader or equivalent and straps to support the storage rack stairway to BPM catwalk.

Illustration 115

12

29. Use the fork wheel loader to remove the storage rack out of the stagger skid using the provided lifting points.

30. Move the storage rack with the fork wheel loader to the other side of the HW300 an in position.

Illustration 113

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Operation ________________________________________________________ 33. Relocate the push beam indicator bracket to the opposite side storage rack.

34. Connect the cable to the proximity switches located on the push beam indicator bracket.

35. Secure the storage rack stairway to the BPM catwalk with bolts.

10

36. Install the access ladders to the storage rack by placing them in their mounting brackets.

37. Remove lock and tag from the 1600 amp breaker.

Illustration 116

31. Connect the pneumatic line quick connect fitting (10) located under the storage rack.

38. Energize the HW300 by resetting the 1600 amp breaker.

39. Using the PTM set up page, select the correct side for loading push beams.

11

Illustration 119

40. Instruct the HW300 operator to calibrate the PTM II mechanism. Refer to Operations Manual for PTM II position calibration instructions.

Illustration 117

32. Connect the hydraulic line quick connect fittings (11) located under the skid.

15

Illustration 118

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_____________________________________________________ Maintenance Maintenance

Grease Recommendations

Fluid Recommendations

Table 56

General Information for Lubricants Your machine is designed to operate in a specific temperature range. If operated outside the design specified temperature range, please consult your Caterpillar dealer representative.

Type of Cat Grease for Highwall Miners Application Point

Grease Type

Cylinders Electric Motors

NLGI 2 NLGI 2 Cat High Speed Ball Bearing Grease

Selecting Viscosity In order to select the proper oil, refer to the “Lubricant Viscosity for Ambient Temperature” table. Use the oil type AND oil viscosity specified at the proper ambient temperature.

The proper oil viscosity grade is determined by the minimum ambient temperature (the air in the immediate vicinity of the machine). Measure the temperature when the machine is started and while the machine is operated. In order to determine the proper oil viscosity grade, refer to the “Min” column in the table. This information reflects the coldest ambient temperature condition for starting a cold machine and for operating a cold machine. Refer to the “Max” column in the table for operating the machine at the highest temperature that is anticipated. Unless specified otherwise in the “Lubricant Viscosities for Ambient Temperatures” tables, use the highest oil viscosity that is allowed for the ambient temperature.

Coolant Information The following coolant is permissible for use in the machine: 50% Glycol/50 % Water Mix Notice: Never use water alone as coolant. Water alone does not provide adequate protection against boiling or freezing.

Capacities (Refill) The refill capacities will vary depending on the service procedures and conditions.

Note: Observe all sight gauges and level indicators in order to ensure that the systems and/or compartments are refilled to the proper levels.

Notice: Not following the recommendations found in this manual can lead to reduced performance and component failure.

Hydraulic Oil Table 55 HW300 Highwall Miner Hydraulic Oil System

Oil Type

All Gear Boxes and Track CAT FDAO SYN Planetaries Hydraulic Tank

PLANTOFLUX AT/68-S

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Maintenance ______________________________________________________ Table 57

S·O·S Information Refill Capacities

Compartment or System

S·O·S Services is a highly recommended process for Cat customers to use in order to minimize owning and operating cost. Customers provide oil samples, coolant samples, and other machine information.

The dealer uses the data in order to provide the customer with recommendations for management of the equipment. In addition, S·O·S Services can help determine the cause of an existing product problem.

Liters

US Gallons

Air Compressor

0.95

0.25

BPM Coolant Tank

379

100

BPM Hydraulic Tank

3785

1000

Cutter Gearbox (XLSCM & LSCM)

34 (each side)

9 (each side)

Refer to Special Publication SEBU6250, “Caterpillar Machine Fluid Recommendations”, for detailed information concerning S·O·S Services.

Cutter Drum (CLSCM & LSCM)

22.75

6

Input Cutter Head Gear Case (MSCM & HSCM)

14.01

3.7

Refer to the Operating and Maintenance Manual, “Maintenance Interval Schedule”, for a specific sampling location and a service hour maintenance interval.

Reach Cutter Head Gear Case (MSCM & HSCM)

22.71

6

Final Cutter Head Gear Case

13.25

3.5

Power Head Auger Gear Case

28

7.5

Conveyor Gearbox

19

5

Track Planetaries

28

7.5

Consult your Cat dealer for complete information and assistance in establishing an S·O·S program for your equipment.

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_____________________________________________________ Maintenance System Pressure Release

Coolant Filter/Strainer Pressure Release

Hydraulic System

To relieve the pressure from the coolant filter/ strainer, turn the coolant system circulating pump motor off. Lock out and tag out the coolant system circulating pump motor to company specifications.

Turn off the coolant system valve located on the coolant tank. Allow the coolant in the filter/strainer to cool. Cautiously open the valve on the filter/strainer canister. Use catch mats and bucket to capture any leaking fluid. Allow pressure to bleed off until the valve can be completely opened.

Personal injury can result from hydraulic oil pressure and hot oil.

Hydraulic oil pressure can remain in the hydraulic system after the pump has been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic system.

Make sure all of the attachments have been lowered, oil is cool before removing any components or lines. Remove the oil filler cap only when the pump is stopped, and the filler cap is cool enough to touch with your bare hand.

Low Seam Cutter Module Shear Arms To relieve the pressure from the Low Seam Cutter Module shear arms, completely lower the head to the ground. Shut off the hydraulic pump electric motor.

Lock out and tag out the hydraulic pump electric motor to company specifications. Turn the shear line valves off located on the hose reel stand. Cautiously loosen the fittings on the A and B port of the shear cylinder. Use catch mats to capture any leaking fluid.

Allow pressure to bleed off until the line can be completely removed.

Coolant System Pressurized system: Hot coolant can cause serious burns. To disconnect lines, stop pump, wait until lines are cool. Then loosen lines slowly to relieve the pressure.

To relieve the pressure from the coolant system lines. Turn the coolant system circulating pump motor off. Lock out and tag out the coolant system circulating pump motor to company specifications.

Turn off the coolant system valve located on the coolant tank. Allow the coolant line to cool.

Cautiously loosen the fittings on the line. Use catch mats to capture any leaking fluid. Allow pressure to bleed off until the line can be completely removed.

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Maintenance ______________________________________________________ Prepare the Machine for Maintenance

Bodily contact with electrical potential can cause bodily injury or death.

To avoid the possibility of injury or death, ensure that the main power supply has been disconnected before performing any maintenance on the machine.

1. Position the machine in a safe working area suitable for performing maintenance (relatively level ground and a safe distance from the highwall.

2. Position cutter module, cutter module boom, power head, and PTM in suitable positions to perform planned maintenance.

3. If work is planned for raised loads, securely block loads to ensure personnel are not injured or trapped by unintended machine motion.

1 2

Welding on Machines and Engines with Electronic Controls Notice: Do NOT use electrical components (ECM or sensors) or electronic component grounding points for grounding the welder.

Do not weld on any protective structure. If it is necessary to repair a protective structure, contact your Caterpillar dealer.

Proper welding procedures are necessary in order to avoid damage to the electronic controls and to the bearings. When possible, remove the component that must be welded from the machine or the engine and then weld the component. If you must weld near an electronic control on the machine or the engine, temporarily remove the electronic control in order to prevent heat related damage. The following steps should be followed in order to weld on a machine or an engine with electronic controls.

1. Turn off the engine. Place the engine start switch in the OFF position.

2. If equipped, turn the battery disconnect switch to the OFF position. If there is no battery disconnect switch, remove the negative battery cable at the battery.

3. Clamp the ground cable from the welder to the component that will be welded. Place the clamp as close as possible to the weld. Make sure that the electrical path from the ground cable to the component does not go through any bearing.

Use this procedure in order to reduce the possibility of damage to the following components: Bearings, hydraulic components, electrical components, other components of the machine.

Illustration 120

4. Turn off the circuit breaker in the ECM. 5. Have a qualified individual verify that voltage is removed from the load side of the breaker (check all phases). Note: Voltage is still present on the line side of the breaker. If work is to be performed in this area, power must be removed from the source and verified.

4. Protect any wiring harnesses and components from the debris and the spatter which is created from welding.

5. Use standard welding procedures in order to weld the materials together.

6. Close cabinet door and attach a mechanical lock (1) and tag (2) to the main breaker lock device.

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_____________________________________________________ Maintenance Maintenance Interval Schedule

LSCM: Cutter Gear Box Mounting Bolts - Inspect

Ensure that all safety information, warnings, and instructions are read and understood before any operation or any maintenance procedures are performed.

LSCM: Cutter Gear Box Oil Level, Right and Left Check

The user is responsible for the performance of maintenance. All adjustments, the use of proper lubricants, fluids, filters, and the replacement of components due to normal wear and aging are included. Failure to adhere to proper maintenance intervals and procedures may result in diminished performance of the product and/or accelerated wear of components.

LSCM: Cutter Head Boom Pin, Right and Left, Grease NOTE: MSCM and HSCM maintenance procedures are identical MSCM: CLA Deck Bolts, Right and Left - Inspect MSCM: CLA Gear Box Oil Level, Right and Left Check

Use service hours, service shifts, or machine tonnage to determine the maintenance intervals.

Products that operate in severe operating conditions may require more frequent maintenance. Refer to the maintenance procedure for any other exceptions that may change maintenance intervals.

MSCM: Cutter Boom Pin, Right and Left - Grease

Note: Before each consecutive interval is performed, all maintenance from the previous interval must be performed.

MSCM: Gathering Head Cylinder Pin, Right and Left - Grease

Note: If Cat HYDO Advanced hydraulic oils are used, the hydraulic oil change interval is extended.

S·O·S service may extend the oil change even longer. Consult your Cat dealer for details.

After Every Entry Conveyor Bearings Right Angle Discharge, Belly Chain Conveyor: Bearings - Grease Right Angle Discharge, Conveyor: Bearings Grease Straight Discharge, Conveyor: Bearings Grease Straight Discharge, Belly Chain Conveyor, Tail Roller: Bearings - Grease Conveyor, Right Angle and Straight Discharge, Gear Box: Oil Level - Check NOTE: XLSCM and LSCM maintenance procedures are identical LSCM: Cutter Auger Bearing, Right and Left - Check Play and Grease

MSCM: Cutter Drum Bits and Bit Holders - Inspect MSCM: Cutter Drum Gear Box Oil Level, Right and Left - Check

MSCM: Conveyor Chain Tension - Check MSCM: Conveyor Chain Tail Roller - Grease MSCM: Steering Arm Hinge Pin, Right and Left Grease MSCM: Steering Arm Hinge Pin Retaining Bolts, Right and Left - Inspect Power Head: Auger Bearing, Right and Left - Grease Power Head: Auger Gear Box Oil Level, Right and Left - Check Push Beam: Auger Bearings - Grease Weekly Belly Chain Conveyor: Motor to Gear Box Coupling Inspect BPM: Coolant Tank Coolant Level - Check BPM: Hydraulic Motor to Pump Coupling - Inspect BPM: Hydraulic Pump Motor Bearings - Grease BPM: Hydraulic Oil Tank Oil Level - Check BPM Oil Cooler: Fan Motor (Radiator Mounted) Bearings - Grease

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Maintenance ______________________________________________________ BPM Oil Cooling: Radiator - Clean

Head - Check Torque

BPM: Pumps 1, 2, and 3 Pressure - Check

PTM II: Mounting Bolts - Check Torque

BPM: Water Cooling Fan Motor Bearings - Grease

Conveyor: Chain Tension - Check

Cab: Touch Screens - Clean

Conveyor: Drive Sprocket - Inspect

ECM and Cab: Ventilation Fan Air Flow - Check

Conveyor: Motor Bearings, Front and Rear - Grease

ECM: Air Conditioner Air Filter - Clean

Conveyor: Motor to Gear Box Coupling - Inspect

ECM: Lighting Battery (12V) Water Level - Check

Slip Ring: High and Low Voltage - Inspect

Hose Reel: Hydraulic System - Check for Leaks

Monthly

Hydraulic System: Valve Banks, All - Inspect

Air Compressor: Drive Belt Tension - Check

NOTE: XLSCM and LSCM maintenance procedures are identical

Air Compressor: Oil Level - Check Air Compressor: Water Trap - Drain

LSCM: Cutter Auger Pedestal Bolts, Front and Rear - Inspect

BPM: Hydraulic Hoses and Pipes - Inspect

LSCM: Cutter Head Auger Bearing Play - Check

ECM: Circuit Breakers (Conveyor Motors, Cutter Motor, Main, Power Head)- Test

LSCM: Cutter Motor Bearings, Right and Left Grease

ECM: Cutter Cables Earth Leakage Relay - Test

LSCM: Shear Cylinder Pin, Right and Left - Grease

ECM: Cutter Cables Ground Fault Monitor - Test

Lubrication: Bulk Grease and Oil Tanks Lubricant Levels - Check

ECM: Electrical Connections - Inspect

Miner: Plow Cylinder Pin - Grease NOTE: MSCM and HSCM maintenance procedures are identical MSCM: Cutter Head Auger Bearing Play - Check MSCM: Cutter Motor Bearings, Right and Left Grease MSCM: Cutter Motor Clutch - Inspect Power Head: Auger Coupling, Right and Left Inspect

Fire Extinguishers, All - Inspect Hose Reel: Brakes - Check Hose Reel: Bearings - Grease Hose Reel: Hose Retainers and Braces - Inspect Hose Reel: Mounting Bolts - Inspect NOTE: XLSCM and LSCM maintenance procedures are identical LSCM: Cutter Motor Mounting Bolts - Inspect LSCM: Motor to Gear Box Coupling Bolts - Inspect

Power Head: Auger Motor Bearings, Front and Rear, Right and Left - Grease

Power Head: Brass - Inspect

Power Head: Manifold - Check for Leaks

Super Beam: Base Frame Bolts, Front and Rear, Right and Left - Inspect

Power Head: Motor Mounting Bolts, Right and Left Inspect

Super Beam: Inspect

Power Head: Sump Cylinder Bolts, Rod and Power

Track Assembly: Gear Oil Level - Check

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_____________________________________________________ Maintenance Track Assembly: Hydraulic System - Check for Leaks Track Assembly: Steering Cylinder Clevis Pin Inspect Track Assembly: Track Lift Column - Grease Track Assembly: Track Pad Bolts - Inspect Track Assembly: Track Steering Collar Bolts - Inspect Track Assembly: Track Tension - Check Every 250 Hours Belly Chain Conveyor: Gear Box - S·O·S Oil Sample BPM: Hydraulic Oil Tank - S·O·S Oil Sample HSCM: Final Cutter Head Gear Case - S·O·S Oil Sample HSCM: Input Cutter Head Gear Case - S·O·S Oil Sample HSCM: Reach Cutter Head Gear Case - S·O·S Oil Sample LSCM: Cutter Drum - S·O·S Oil Sample LSCM: Cutter Gear Case - S·O·S Oil Sample MSCM: Final Cutter Head Gear Case - S·O·S Oil Sample MSCM: Input Cutter Head Gear Case - S·O·S Oil Sample MSCM: Reach Cutter Head Gear Case - S·O·S Oil Sample Power Head: Auger Gear Case - S·O·S Oil Sample Track Assembly: Planetaries - S·O·S Oil Sample XLSCM: Cutter Drum - S·O·S Oil Sample XLSCM: Cutter Gear Case - S·O·S Oil Sample

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Maintenance ______________________________________________________ After Every Entry Conveyor Bearings Right Angle Discharge: Belly Chain Conveyor: Bearing - Grease

1. Grease the right angle conveyor, drive-end, bearing through the Remote Grease Fittings (1) located on either side of the conveyor. Pump approximately 50 cubic centimeters (3 cubic inches) of grease into the fitting.

2. Grease the right angle conveyor, tail-end, bearing through the Remote Grease Fittings (2) located on either side of the conveyor. Pump approximately 50 cubic centimeters (3 cubic inches) of grease into the fitting.

Straight Discharge Conveyor: Bearing Grease

1 Illustration 121

1. Prepare the machine for maintenance. Refer to the Operation and Maintenance Manual, “Prepare the Machine for Maintenance”.

2. Grease the Belly Chain Conveyor, Drive-End, Bearing through the Grease Fittings (1). Pump grease approximately 50 cubic cm (3 cubic inch) of grease into the fitting.

Right Angle Conveyor: Bearings Grease

1 Illustration 123

1. Prepare the machine for maintenance. Refer to the Operation and Maintenance Manual, “Prepare the Machine for Maintenance”.

2. Grease the Belly Chain Conveyor, Drive-End, Bearing through the Grease Fittings (1). Pump grease approximately 50 cubic cm (3 cubic inch) of grease into the fitting.

1

2

Illustration 122

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_____________________________________________________ Maintenance Straight Discharge: Belly Chain Conveyor: Tail Roller Bearing - Grease

the Machine for Maintenance”.

2. Remove the Fill Cap/Dipstick (1). If required, add oil to the appropriate level.

3. Replace the Fill Cap/Dipstick (1).

LSCM: Cutter Auger Bearing, Right and Left - Check Play and Grease Prepare the machine for inspection. Refer to the Operation and Maintenance Manual, “Prepare the Machine for Maintenance”.

1

Illustration 124

1. Prepare the machine for maintenance. Refer to the Operation and Maintenance Manual, “Prepare the Machine for Maintenance”.

Note: In addition to the procedures listed in “Prepare the Machine for Maintenance”, the cutter motor breakers must be locked and tagged out prior to beginning the inspection procedure.

Inspect the right and left cutter auger bearings. If excessive play or visible wear is found, replace the bearing.

1

2. Grease the Belly Chain Conveyor, Tail-End, Bearing through the Grease Fittings (1). Pump grease approximately 50 cubic cm (3 cubic inch) of grease into the fitting. Same on both sides of base frame.

Conveyor: Gear Box Oil Level - Check (Right Angle and Straight Discharge) 1

2

1 Illustration 126 Illustration 125

1. Prepare the machine for inspection. Refer to the Operation and Maintenance Manual, “Prepare

Grease the right and left cutter auger bearings through the Front Grease Ports (1) and Rear Grease Ports (2) located on the left and right auger.

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Maintenance ______________________________________________________ LSCM: Cutter Drum Bits and Bit Holders - Inspect

2. De-energize the HW300 machine by tripping the 1600 amp breaker. Illustration

Prepare the machine for inspection. Refer to the Operation and Maintenance Manual, “Prepare the Machine for Maintenance”.

3. Lock out and tag out the 1600 amp breaker.

4. Remove the four cutter arm bolts (1) from both sides.

5. Loosen the shim retaining plate bolts (2) and slide retainer back to expose shims.

6. Place the hydraulic power pack in between the shear arm and cutter arm, and pump the jack until the slack of the chain is 4 inches (86mm).

7. Insert the desired amount of shim (3).

8. Release the hydraulic power pack.

9. Replace and tighten all four arm bolts (1).

1

2

10. Slide the shim cover back and tighten the bolts to the shear arm (2).

Illustration 127

Inspect the cutter head bits (1) to ensure that they rotate freely in the bit holders (2) and for damaged, excessively worn, or missing bits (1). Replace bits as necessary.

Inspect the bit holders (1) for damage, cracked welds, and for missing bit holders (2). Repair or replace as required.

11. Cross check the tension by measuring the slack 4 inches (86mm) (4).

12. Jog the cutter motors and verify the tension on the chain (4).

LSCM: Cutter Cylinder Pin, Right and Left - Grease

LSCM: Cutter Chain Tension - Check 2

1

3

Illustration 129

4

1

Illustration 128

Lubricate the right and left cutter head cylinder pins through the Remote Grease Fittings (1) located on the side of the cutter head. Pump approximately 50 cubic centimeters (3 cubic inches) of grease into the fitting.

1. Ensure HW300 & Cutter Module is positioned in a safe and dry working area.

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_____________________________________________________ Maintenance LSCM: Cutter Drum Drive Sprocket - Inspect Prepare the machine for maintenance. Refer to the Operation and Maintenance Manual, “Prepare the Machine for Maintenance”.

Inspect the Cutter Drum Sprocket Bolts (1), on the right and left sides of the cutter head, for damaged, loose, or missing bolts. Replace or tighten bolts as required.

LSCM: Cutter Gear Box Mounting Bolts Inspect Prepare the machine for maintenance. Refer to the Operation and Maintenance Manual, “Prepare the Machine for Maintenance”.

Illustration 132

Illustration 130

Visually inspect the sprocket for wear. If excessive wear is found, replace.

Inspect for loose or missing Cutter Gear Box Mounting Bolts. If required, torque the bolts as follows:

LSCM: Cutter Drum Sprocket Bolts Inspect

5/8 inch Bolts: 217 N m (160 lb-ft)

Prepare the machine for maintenance. Refer to the Operation and Maintenance Manual, “Prepare the Machine for Maintenance”.

1 inch Bolts: 895 N m (660 lb-ft)

LSCM: Cutter Gear Box Oil Level, Right and Left - Check 1. Prepare the machine for maintenance. Refer to the Operation and Maintenance Manual, “Prepare the Machine for Maintenance”.

1 Illustration 131

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Maintenance ______________________________________________________ Lubricate the cutter head boom pins through the Remote Grease Fittings (1) located on the side of the cutter head. Pump approximately 50 cubic centimeters (3 cubic inches) of grease into the fitting.

2

MSCM: CLA Deck Bolts, Right and Left Inspect Prepare the machine for maintenance. Refer to the Operation and Maintenance Manual, “Prepare the Machine for Maintenance”.

1

Raise the cutter head to height that allows access to the gathering pan. Lower the cutter head onto appropriate blocking.

3

Illustration 133

2. Level the cutter head.

3. Remove the oil check plug (1) and check the oil level: oil should just flow from the check hole when the plug is removed.

NOTE: Do NOT work under an unsupported cutter head. Do NOT use the load holding valves on the cutter head cylinders as a means of

4. If oil is needed, remove the fill plug (2) and add oil until the oil just begins to flow from the check hole (1). Note: The drain plug (3) can be removed to drain oil from the gear case.

5. Replace all plugs (1), (2), and (3).

LSCM: Cutter Head Boom Pins, Right and Left - Grease 1 1 Illustration 135

Inspect the CLA deck bolts (1) on the right and left side of the gathering pan. Inspect for damaged or missing bolts and bolt retainers. Check for correct bolt torque. (900 lb-ft ) (625 N-m)

Illustration 134

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_____________________________________________________ Maintenance MSCM: CLA Gear Box Oil Level, Right and Left - Check

MSCM: Cutter Boom Pin, Right and Left - Grease

1 2 3 4 1 Illustration 136 1)

Input Case Sight Glass

2)

CLA Head Pot Sight Glass

3)

Input Case Fill Plug

4)

CLA Head Pot Fill Plug

1. Level the miner and place the gathering head on the ground ensuring that the tip of the Gathering pan is on the same elevation or level with the bottom of cutter module frame.

Illustration 137

Grease the right and left Cutter Boom Pin (1) through the grease fitting located on each pin.

Pump grease into the fitting until grease comes out around the bearing.

MSCM: Cutter Drum Bits and Bit Holders - Inspect Prepare the machine for inspection. Refer to the Operation and Maintenance Manual, “Prepare the Machine for Maintenance”.

2. Position the cutter head to an appropriate working height and properly block/support. Do not rely on cylinder load holding valves to support the cutter head when performing work under the cutter head.

1

2

3. Check the oil level in the CLA Gear Boxes via the Input Case sight glass (1) and CLA Head Pot sight glass (2). Oil should be visible in both sight glasses.

4. If required, add oil through the Input Case fill port (3) and/or the CLA Head Pot fill port (4). To fill, remove the plug and add oil until oil is visible in the corresponding sight glass. Replace plug when done.

Illustration 138

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Maintenance ______________________________________________________ Inspect the cutter head bits (2) to ensure that they rotate freely in the bit holders (1) and for damaged, excessively worn, or missing bits (2). Replace bits as necessary.

1

2

Inspect the bit holders (1) for damage, cracked welds, and for missing bit holders (1). Repair or replace as required.

MSCM: Cutter Drum Gear Box Oil Level, Right and Left - Check 1. Prepare the machine for inspection. Refer to the Operation and Maintenance Manual, “Prepare the Machine for Maintenance”.

1 3

4

5

6

7

Illustration 139

2. Ensure that the cutter head boom is level.

Place bubble level on top of strut arm (1) to accurately gauge that cutter head boom is level.

(Cutter drums not shown for clarity)

8

9 Illustration 140

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_____________________________________________________ Maintenance 1)

Input Fill Plug

2)

Reach Fill Plug

3)

Input Sight Glass

4)

Reach Drain Plug

5)

Reach Sight glass

6)

Final Drive Fill Plug

7)

Final Drive Check Plug

8)

Final Drive Drain Plug

9)

Input Drain Plug

3. Check the oil level in the Input Sight Glass (3) and Reach Sight Glass (5). Oil should be visible in both sight glasses.

1

4. If oil is required, remove the appropriate fill plug, (1) and/or (2), and add oil.

Illustration 141

5. Replace plug and allow the oil to equalize throughout the gear case and then repeat steps 2 and 3.

6. If oil level is to high in either compartment remove needs to be drained remove appropriate drain plug (4( or (6).

Grease the right and left Gathering Head Cylinder Pin (2 places) (1) through the grease fitting located on each pin. Pump grease into the fitting until grease is visible around the bearing.

7. Check the oil level in the main cutter head gear case (final drive) by removing the Final Drive Check Plug (7). Oil should just flow from the hole.

8. If oil is required, remove the Final Drive Fill Plug (6) and add oil until oil just begins to flow from the Final Drive Check Plug hole (7). Replace plugs.

MSCM: Gathering Head Cylinder Pin, Right and Left - Grease Prepare the machine for maintenance. Refer to the Operation and Maintenance Manual, “Prepare the Machine for Maintenance”.

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Maintenance ______________________________________________________ MSCM: Conveyor Chain Tension - Check

a. If the chain is trailing above the sprocket, the chain tension needs adjusted. Reference the conveyor chain tension procedure. b. If, when the conveyor is rapidly started and stopped, the chain (1) tends to fold back on itself, the chain tension needs adjusted.

Reference the conveyor chain tension procedure.

3

5. Stop the conveyor.

6. Lower the cutter head until it is in the full down position.

7. Lock and tag out power to the HW300. Ensure that the power supply is removed from the machine.

1

2

8. Grasp the ends of a flight (3) with both hands and attempt to move it back and forth. The flight should not move more than 38 mm (1.5 inches) in either direction (no more than 76 mm (3 inches) total movement). If movement is greater than specified, the chain tension needs adjusted.

Reference the conveyor chain tension procedure.

MSCM: Conveyor Chain Tail Roller Grease

Illustration 142

1. Ensure conveyor chain is clean and free of any loose material.

2. Ensure that the tip of the Gathering pan is on the same elevation or level with the bottom of cutter module frame.

3. Stand to the side of the gathering pan and have the machine operator start the conveyor.

4. Observe the chain (1) flow as it comes through and over the foot shaft sprocket (1). There should be a smooth transition of the chain (1) as it comes over the sprocket (2).

1 Illustration 143

Grease the conveyor chain tail roller bearings through the Remote Grease Fittings (1) . Pump approximately 50 cubic centimeters (3 cubic inches) of grease into each fitting.

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_____________________________________________________ Maintenance MSCM: Steering Arm Hinge Pin, Right and Left - Grease

Power Head: Auger Bearing, Right and Left - Grease

1

1

Illustration 144

Grease the right and left Steering Arm Hinge Pin (1) through the grease fitting located on the end of each pin. Pump grease into the fitting until grease comes out around the pin.

MSCM: Steering Arm Hinge Pin and Retaining Bolts, Right and Left - Inspect 1

Illustration 146

Grease the power head auger bearings through the Remote Grease Fittings (1) . Pump approximately 50 cubic centimeters (3 cubic inches) of grease into each fitting.

Power Head: Auger Gear Box Oil Level, Right and Left - Check 1

Illustration 145

Inspect the Steering Arm Hinge Pin and Retaining Bolts (1). Look for damaged, loose, or missing pins or bolts. Tighten bolts as required.

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Maintenance ______________________________________________________ 2

Weekly Belly Chain Conveyor: Motor-Gear Box Coupling - Inspect

Illustration 147

Check the oil level in the Power Head Auger Gear Box by removing the check plug (1) on the side of the gear box. Oil should just flow from the hole with the plug is removed.

1

If oil is required, remove the breather (2) and add oil until it just flows from the check plug hole.

Replace the check plug (1) and the breather (2).

Push Beam: Auger Bearings - Grease

2 Illustration 149

1

1. Prepare the machine for maintenance. Refer to the Operation and Maintenance Manual, “Prepare the Machine for Maintenance”.

2. Remove the Coupling Access Cover (1).

Illustration 148

Grease the push beam auger bearings through the grease fittings (1) located at the front and rear of each push beam. Pump approximately 50 cubic centimeters (3 cubic inches) of grease into each fitting.

3. Inspect the Belly Chain Conveyor Motor to Gear Box Coupling (2). Check for loose or missing bolts, physical damage to the coupling, and signs of misalignment.

4. Replace the Coupling Access Cover (1).

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_____________________________________________________ Maintenance BPM: Coolant Tank Coolant Level Check

Personal injury can result from hot coolant, steam and alkali.

At operating temperature, coolant is hot and under pressure. All coolant lines contain hot coolant or steam. Any contact can cause severe burns.

2. If coolant is required, allow the system to cool and loosen filler cap slowly. Add premixed coolant in order to bring the coolant to the correct level.

BPM: Hydraulic Motor to Pump Coupling - Inspect Prepare the machine for maintenance. Refer to the Operation and Maintenance Manual, “Prepare the Machine for Maintenance”.

Do not attempt to tighten hose connections when the coolant is hot: the hose can come off, causing burns.

1

1 Illustration 151

1.

Remove the Coupling Access Cover (already shown removed).

2.

Inspect the coupling between the hydraulic motor and pump. Check for physical damage to the coupling, and signs of misalignment.

3. Replace the Coupling Access Cover (1).

BPM: Hydraulic Pump Motor Bearings Grease Illustration 150

Notice: If the machine is to be stored in, or shipped to, and area with freezing temperatures, the cooling system must be protected to the lowest outside (ambient) temperature.

Prepare the machine for maintenance. Refer to the Operation and Maintenance Manual, “Prepare the Machine for Maintenance”.

This machine was factory filled with a 50/50 mix of water and glycol.

If coolant needs to be added daily, check for leaks.

1. Use the coolant level gauge (1) in order to check the coolant level: level should fill three-fourths or more of the gauge. If equipped with a level check hose, coolant level should fill three-fourths or more of the hose.

1 Illustration 152

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Maintenance ______________________________________________________ Grease the Hydraulic System Pump Motor Bearings through the Grease Fittings (1). Pump approximately 16 cubic centimeters (1 cubic inch) into the Fitting (1). Note: Over greasing of the bearings or using incorrect grease will greatly effect bearing life.

BPM: Hydraulic Oil Tank Oil Level -

1

1 Illustration 154

NOTE: Do not over-lubricate the electric motors as this may cause premature bearing failure.

Pump approximately 8 cubic centimeters (.5 cubic inch) of grease into the grease fitting.

BPM Oil & Water Coolers (6 per machine): : Radiator - Clean

Illustration 153

The oil level in the BPM Hydraulic Oil Tank should be checked with Power Head at the forward stop point and HW300 sitting on the ground.

Use the sight gauge (1) on the BPM Hydraulic Oil Tank to check the hydraulic oil level. The sight glass should be nearly full to full.

If required, add hydraulic oil from ground level, pumped through return filter system.

BPM Oil & Water Coolers (6 per machine): Fan Motor (Radiator Mounted) Bearings - Grease

Illustration 155

Remove all trash and debris from around the radiator and inspect the radiator fins. If necessary, wash down the fins with a low pressure water jet.

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_____________________________________________________ Maintenance Note: Right side stairs and handrails not shown for clarity.

BPM: Pump 1, Pump 2, and Pump 3 Pressures - Check

1. Remove the end cap enclosing the filter. Note: Use care when handling the filter; accidental bumping will shake dirt loose inside the filter housing.

2. Clean the inside the housing. Use a clean, damp cloth to wipe every surface clean.

3. Ensure that the outlet tube sealing area is clean and undamaged.

4. Clean the gasket sealing surface. Make sure that all hardened dirt ridges are completely re-moved, both on the bottom and top of the air cleaner housing.

1

5. Inspect the new filter for damage before installing. Ensure the gasket is easily compressible.

6. Install the filter.

Illustration 156

7. Replace the end cap.

Check the pressure of BPM Pumps 1, 2, and 3 via the gauges (1) on each pump located inside the BPM enclosure or via the control system inside the operator’s compartment.

8. Replace element when deemed necessary.

CAB & ECM: Ventilation Fan Air Filter Clean

1

1 Illustration 157

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Maintenance ______________________________________________________ BPM: Water Cooling Pump Motor Bearings - Grease

1

ECM: Air Conditioner Air Filter - Clean 1. Remove the end cap enclosing the filter. Note: Use care when handling the filter; accidental bumping will shake dirt loose inside the filter housing.

2. Clean the inside the housing. Use a clean, damp cloth to wipe every surface clean.

3. Ensure that the outlet tube sealing area is clan and undamaged.

4. Clean the gasket sealing surface. Make sure that all hardened dirt ridges are completely removed, both on the bottom and top of the air cleaner housing.

5. Inspect the new filter for damage before installing. Ensure the gasket is easily compressible.

Air Compressor Air Filter: Clean

Illustration 158

Grease the BPM Water Cooling Pump Motor Bearings through the Grease Fittings (1). Pump approximately 8 cubic centimeters (.5 cubic inch) of grease into the fitting. Note: Over greasing of the bearings or using incorrect grease will greatly effect bearing life.

Cab: Touch Screens - Clean

Illustration 159

Clean the control system touch screens, located in the operator’s cab, using a damp, lint free cloth.

1. Unscrew and remove the wing nut (A) securing the filter housing (B) to it’s base (C) .

2. Remove the filter housing and withdraw the old filter element (D). Clean the element with a jet of air or vacuum.

3. Replace the filter element and housing, securing it in place with the wing nut previously removed.

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_____________________________________________________ Maintenance ECM: Lighting Battery (12V) Water Level - Check 1

1

Illustration 161 Illustration 160

1. Remove the battery cover.

2. Remove the battery fill caps.

3. Electrolyte level should reach the bottom of the fill opening. If level is low, add distilled water to raise the electrolyte level.

4. Replace battery fill caps and battery cover.

Hose Reel: Hydraulic System - Check for Leaks

Never use your hand to check for a hydraulic leak. Hydraulic fluid can be under pressure and can penetrate the skin. If hydraulic fluid penetrates the skin, seek immediate medical attention.

2. Groundman to check hoses in the hose chain as the hose reel is being paid out (1) during mining operations.

Hydraulic System: Valve Banks, All Inspect Inspect all valve banks for: 

Broken, damaged or missing handles (if applicable)



Correct function



Leaks at inlet ports, outlet ports, and/or between sections

LSCM: Cutter Auger Pedestal Bolts Inspect Prepare the machine for maintenance. Refer to the Operation and Maintenance Manual, “Prepare the Machine for Maintenance”.

1. Visually inspect all visible and accessible hydraulic hoses and fittings on the hose reel for leaks.

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Maintenance ______________________________________________________ 1

Visually inspect bearings (1). Replace if excessive play or wear is observed.

LSCM: Cutter Motor Bearings, Right and Left - Grease 1

Illustration 162

Check for missing, damaged, or loose Cutter Arm Bolts. Replace or torque as required.

If required, torque the bolts as follows: 5/8 inch Bolts: 217 N m (160 lb-ft) 1 inch Bolts: 895 N m (660 lb-ft)

LSCM: Cutter Head Auger Bearing Play Check Prepare the machine for maintenance. Refer to the Operation and Maintenance Manual, “Prepare the Machine for Maintenance”.

Illustration 164

NOTE: Do not over-lubricate the electric motors as this may cause premature bearing failure.

Clean the remote grease fittings (1) and pump 16 cubic centimeters (1 cubic inch) of grease into the fitting.

LSCM: Shear Cylinder Pin, Right and Left - Grease Prepare the machine for maintenance. Refer to the Operation and Maintenance Manual, “Prepare the Machine for Maintenance”.

1

Illustration 163

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_____________________________________________________ Maintenance Miner: Plow Cylinder - Grease

1

1

Illustration 167

Grease the plow cylinder through the Grease Fitting (1) located on the cylinder mounting eye. Pump grease into the fittings until grease comes out around the bushing.

Illustration 165

Grease the right and left Shear Cylinder Pins through the Grease Fittings (1) located on the pins. Pump approximately 50 cubic centimeters (3 cubic inches) of grease into each fitting.

Lubrication: Bulk Oil and Grease Tank Levels - Check

MSCM: Cutter Head Auger Bearing Play Check Prepare the machine for maintenance. Refer to the Operation and Maintenance Manual, “Prepare the Machine for Maintenance”.

1

1

2

Illustration 166

Check the bulk lubricant level in the Bulk Grease Tank (1) and Bulk Oil Tank (2). If required, add the appropriate lubricant to each tank.

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Maintenance ______________________________________________________ NOTE: Do not over-lubricate the electric motors as this may cause premature bearing failure.

1. Prepare the machine for maintenance. Refer to the Operation and Maintenance Manual, “Prepare the Machine for Maintenance”.

2. Open the cover (1) to access the motor or access the motor with grease access hole (optional) (2) at the top of the cutter head boom.

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

2 Illustration 168

Visually inspect bearings on conveyor (2) and cutter head (1) end of auger. Replace if excessive play or wear is observed.

MSCM: Cutter Motor Bearings, Right and Left - Grease

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.

4. Replace the plugs in the ports.

2

1

Note: Over greasing of the bearings or using incorrect grease will greatly effect bearing life.

MSCM: Cutter Motor Clutch - Inspect 1. Prepare the machine for maintenance. Refer to the Operation and Maintenance Manual, “Prepare the Machine for Maintenance”.

Illustration 169

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_____________________________________________________ Maintenance 2

2 1 Illustration 170 Illustration 172

2. Remove the end cover (1).

3. Visually inspect the wear tab/indicators on the clutch (2). Change clutch as indicated.

Power Head: Auger Coupling , Right and Left - Inspect

4. Replace the coupling cover (1).

Power Head: Auger Motor Bearings, Front and Rear, Right and Left - Grease

1. Prepare the machine for maintenance. Refer to the Operation and Maintenance Manual, “Prepare the Machine for Maintenance”.

1

Illustration 173

NOTE: Do not over-lubricate the electric motors as this may cause premature bearing failure.

Pump approximately 50 cubic centimeters (3 cubic inches) of grease into the grease fitting.

Illustration 171

2. Remove the coupling cover (1).

3. Inspect the coupling (2) for loose or missing bolts, physical damage to the coupling, and signs of misalignment. Replace or tighten bolts or replace coupling as required.

1. Energize the power head auger motor breaker.

2. Run the electric motor for 15 minutes with the grease plug removed to allow excess grease to purge.

3. De-energize the power head auger motor breaker.

4. Re-install grease outlet plug.

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Maintenance ______________________________________________________ Power Head: Manifold - Check for Leaks 1

Power Head: Sump Cylinder Bolts, Rod and Power Head - Inspect Prepare the machine for maintenance. Refer to the Operation and Maintenance Manual, “Prepare the Machine for Maintenance”.

Illustration 174

Visually inspect the power head manifold for leaks at all connections.

1

Power Head: Motor Mounting Bolts, Right and Left - Inspect

1 Illustration 176

Check the cylinder mounting bolts (1) and the rod mounting bolts (2). Check for damaged, loose, or missing bolts. Replace and tighten bolts as required.

Torque bolts as follows: (1) Power Head Bolts: 169 N-m (125 lb-ft) (2) Rod Bolts: 217 N-m (160 lb-ft)

PTM II: Mounting Bolts - Inspect 1 Illustration 175

Visually inspect the mounting bolts for the PTM II. Check for damaged, loose, or missing bolts.

Replace and tighten bolts as required.

Check the mounting bolts (1) for the right and left Power Head Motor. Check for damaged, loose, or missing bolts. Replace and tighten bolts as required.

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_____________________________________________________ Maintenance PTM II: Traverse Rail - Grease Prepare the machine for maintenance. Refer to the Operation and Maintenance Manual, “Prepare the Machine for Maintenance”.

Use a pry bar to check the tightness of the chain (1) in the center of the frame. The chain should not rotate more than 90 degrees at the link.

If chain rotates more than 90 degrees at the link, adjust the conveyor chain tension.

Conveyor Chain: Drive Sprocket Inspect

1 1

Illustration 177

Grease wheel bearings (1) on PTM II traverse rail as required.

Conveyor Chain: Chain Tension - Check Prepare the machine for maintenance. Refer to the Operation and Maintenance Manual, “Prepare the Machine for Maintenance”.

1

Illustration 179

1. Prepare the machine for maintenance. Refer to the Operation and Maintenance Manual, “Prepare the Machine for Maintenance”.

2. Remove the cover (1).

3. Visually inspect the sprocket for signs of wear or damage and replace as necessary.

4. Replace the cover (1).

Illustration 178

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Maintenance ______________________________________________________ Conveyor Motor Bearings, Front and Rear - Grease 1

1 Illustration 181

2. Remove the Coupling Access Cover (1).

Illustration 180

NOTE: Do not over-lubricate the electric motors as this may cause premature bearing failure.

1. De-energize the right angle conveyor motor breaker.

2. Clean the Grease Fitting (1).

3. Pump approximately 16 cubic centimeters (1 cubic inch) of grease into the fitting.

Conveyor Motors to Gear Box Coupling Inspect 1. Prepare the machine for maintenance. Refer to the Operation and Maintenance Manual, “Prepare the Machine for Maintenance”.

2 Illustration 182

3. Inspect the Right Angle Conveyor Motor to Gear Box Coupling (2). Check for loose or missing bolts, physical damage to the coupling, and signs of misalignment.

4. Replace the Coupling Access Cover (1).

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_____________________________________________________ Maintenance Slip Ring: High Voltage, Low Voltage Inspect 1. Prepare the machine for maintenance. Refer to the Operation and Maintenance Manual, “Prepare the Machine for Maintenance”.

Monthly Air Compressor: Drive Belt Tension Check With the air compressor running examine the slack side of the belt. When properly tensioned, there should be a slight box in the belt.

If necessary, adjust the belt: 1. Turn off the air compressor.

2. Lock and Tag-out Breaker.

3. Loosen the motor anchor screws.

1

4. Push the motor away from the pump.

Illustration 183

5. Tighten the motor anchor screws.

2. Remove the cover from the slip ring housing (1).

Turn the air compressor on and observe the belt to ensure proper tension has been achieved.

Air Compressor: Oil Level - Check Check the oil level and fill as needed.

Air Compressor: Water Trap - Drain Drain any accumulated water from the trap on the air compressor filter by opening the manual drain valve and collecting the condensate. Dispose of the condensate accordingly.

Illustration 184

3. Visually inspect the inside of the case: a. The collector for signs of overheating (color change or miss-coloring of braids, copper bars, or other parts) b. Damaged parts c.

Loose fasteners

d. Slip rings for dirt, moisture, or burn marks e. Carbon brushes for wear or overheating f.

BPM: Hydraulic Hoses and Pipes Inspect

Never use your hand to check for a hydraulic leak. Hydraulic fluid can be under pressure and can penetrate the skin. If hydraulic fluid penetrates the skin, seek immediate medical Inspect the BPM hydraulic hoses and pipes for damage, hoses that are rubbing or pinched, and leaks. Replace as necessary.

Cracked, burned or damaged isolators

4. Repair or replace parts as necessary and then replace the cover (1).

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Maintenance ______________________________________________________ ECM: Circuit Breakers (Belly Chain Motor, Cutter Motors, Main, Power Head Motors, Right Angle Conveyor Motor) Test Test each circuit breaker by: 1. Push the TEST or PUSH-TO-TRIP button located on each circuit breaker. The circuit breaker should trip.

2. Reset the circuit breaker by moving the circuit breaker handle past OFF to the reset position.

3. Move the circuit breaker handle back to the ON position.

1

ECM: Cutter Cables Earth Leakage Relay - Test

Illustration 185

Test the earth leakage relay by pressing the TEST button on the front of the relay. Reset by pressing the RESET button, also located on the front of the relay.



Check brake lines and fittings for leaks, chaffing, etc.



Check brake disc for wear or damage

ECM: Cutter Cables Ground Fault Monitor - Test



Check brake pad for wear or damage

Test the ground fault monitor by pressing the TEST button on the front of the monitor. Reset by pressing the RESET button, also located on the front of the monitor.

Visually inspect the brake:

Hose Reel: Bearings - Grease 1

1

ECM: Electrical Connections - Inspect Visual inspection for loose or broken wires, loose connections, or other signs of wear and damage.

Repair or replace as required.

Fire Extinguishers, All - Inspect Inspect all fire extinguishers as recommended on the instruction plates.

Hose Reel: Brakes - Check Prepare the machine for maintenance. Refer to the Operation and Maintenance Manual, “Prepare the Machine for Maintenance”.

Illustration 186

Grease the bearing (1) through the grease fitting located on each bearing. Pump approximately 50 cubic centimeters (3 cubic inches) of grease into each fitting.

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_____________________________________________________ Maintenance Hose Reel: Hose Retainers and Braces Inspect Visually Inspect all hose retainers, braces, and structure for loose fasteners, cracked welds, and physical damage. This should be done as the hose reel is being unwound out during mining.

3. Inspect the motor mounting bolts (1). Check for damaged or loose bolts. Replace or tighten as required.

4. Replace the covers.

Hose Reel: Mounting Bolts - Inspect

LSCM: Motor to Gear Box Coupling Bolts - Inspect

Check for missing, damaged, or loose Hose Reel Mounting Bolts. Replace bolts or tighten to a torque of 5/8 inch Bolts: 800 N m (590 lb-ft).

1. Prepare the machine for maintenance. Refer to the Operation and Maintenance Manual, “Prepare the Machine for Maintenance”.

LSCM: Cutter Motor Mounting Bolts Inspect 1. Prepare the machine for maintenance. Refer to the Operation and Maintenance Manual, “Prepare the Machine for Maintenance”.

1

2

1 Illustration 189

Illustration 187

2. Remove the coupling access cover (1).

2. Remove the motor cover (1) and coupling cover (2).

1

1

Illustration 188

Illustration 190

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Maintenance ______________________________________________________ 3. Inspect the motor to gear box coupling bolts (1).

Check for damaged or loose bolts. Replace or tighten as required.

Super Beam: Base Frame Bolts - Inspect

4. Replace the coupling access cover.

Power Head: Brass - Inspect Prepare the machine for maintenance. Refer to the Operation and Maintenance Manual, “Prepare the Machine for Maintenance”.

1

1

Illustration 192

Inspect the Super Beam Base Frame Bolts (1), front and rear, right and left sides. Inspect for damaged, missing, and loose bolts. Replace or tighten bolts as required.

Super Beam: Inspect Inspect the Super Beam for structural damage and cracked welds.

2 Illustration 191

Visually inspecting the power head brass (1). When the brass is worn even with the countersunk bolts (2), replace the brass.

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_____________________________________________________ Maintenance Track Assembly: Gear Oil Level - Check

Track Assembly: Steering Cylinder Clevis Pin - Inspect Prepare the machine for maintenance. Refer to the Operation and Maintenance Manual, “Prepare the Machine for Maintenance”.

1

2 1

Illustration 193

1. Tram the machine so that the and Drain Plug (2) is at the 6 O'clock position as shown.

2. Remove the Check Plug (1). Oil should just flow from the hole when the plug is removed.

3. Replace the Check Plug (1).

Track Assembly: Hydraulic System Check for Leaks

Illustration 194

Inspect the Track Assembly Steering Cylinder Clevis Pin (1) for loose or worn pins and retainers, oblong bores, and for the presence of grease.

Track Assembly: Track Lift Column Grease Prepare the machine for maintenance. Refer to the Operation and Maintenance Manual, “Prepare the Machine for Maintenance”.

Never use your hand to check for a hydraulic leak. Hydraulic fluid can be under pressure and can penetrate the skin. If hydraulic fluid penetrates the skin, seek immediate medical Check track assemblies hydraulic hoses and fittings for damages and leaks. Repair or replace leaking components.

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Maintenance ______________________________________________________ Track Assembly: Track Steering Collar Bolts - Inspect Prepare the machine for maintenance. Refer to the Operation and Maintenance Manual, “Prepare the Machine for Maintenance”.

1 Illustration 195

Apply a thin coat of grease to each track lift column.

Track Assembly: Track Pad Bolts Inspect Prepare the machine for maintenance. Refer to the Operation and Maintenance Manual, “Prepare the Machine for Maintenance”.

1 Illustration 197

Inspect the Track Steering Collar Bolts (1) for missing, damaged, or loose bolts. Replace or tighten as required.

Track Assembly: Track Tension - Check Prepare the machine for maintenance. Refer to the Operation and Maintenance Manual, “Prepare the Machine for Maintenance”.

2

1 Illustration 196

Inspect the Track Pad Bolts (1) for missing, damaged, or loose bolts. Replace or tighten as required.

1 Illustration 198

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_____________________________________________________ Maintenance 1. Prepare the machine for maintenance. Refer to the Operation and Maintenance Manual, “Prepare the Machine for Maintenance”.

1. Remove cap (1) in three places.

2. Place a straight edge across a length of track (L). L should be at least for track elements (approximately 1 to 1.5 m (3.28 to 4.92 ft)).

3. Remove bolts (2) that secure the three cover plates (4).

3. Measure the extent of the sag (f). Sag should be 2 to 3 cm (0.79 to 1.18 inches).

4. If sag is greater that allowed, the track tension must be adjusted

Every 250 Hours

2. Open valve (2) in three places

4. Remove the covers (3) taking care to not lose or damage the o-ring seals (6).

5. Remove the bypass valves (7) and place in a clean, suitable container.

6. Remove the filter elements (5).

7. Clean all dirt and debris from filter housing surfaces.

Hydraulic Oil Filter Change

8. Install new filters in the reverse order of removal.

S·O·S Oil Sampling and Oil Change Following standard Caterpillar recommended oil sampling procedures to sample oil in the following locations: Belly Chain Conveyor: Gear Case BPM: Hydraulic Oil Tank 4

3

HSCM: Final Cutter Head Gear Case HSCM: Input Cutter Head Gear Case HSCM: Reach Cutter Head Gear Case LSCM: Cutter Drum

1

2

LSCM: Cutter Gear Case MSCM: Final Cutter Head Gear Case MSCM: Input Cutter Head Gear Case MSCM: Reach Cutter Head Gear Case Power Head: Auger Gear Case Track Assembly: Planetaries XLSCM: Cutter Drum

5

XLSCM: Cutter Gear Case

7 6

Change oil as indicated by the results of the oil sampling.

Illustration 199

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