DOWNLOAD PDF : CAT 25M3 (CM240) Continuous Miner Operation and Maintenance Manual

BI016954-06 (EN-US) A6474X347 December 2014

Operation and Maintenance Manual 25M3 (CM240) Continuous Miner S/N 433612 S/N GEW00900

SAFETY.CAT.COM

BI016954-06 (EN-US)

__________________________________________________________

This manual is intended to provide GENERAL product information for the 25M3 (CM240) Continuous Miner. The illustrations, descriptions and procedures contained in this publication apply only to THIS machine. Caterpillar reserves the right to revise models and designs without prior notice.

This Continuous Miner was manufactured under the guidelines, procedures and requirements of the appropriate government regulatory agencies.

At the completion of the manufacturing process, this unit was issued the appropriate approval numbers and nameplates indicating it met the technical requirements of these regulatory agencies. Any change to the design or structure of this unit, without the consent of Caterpillar and these regulatory agencies, or any repair or replacement of parts contrary to the instructions, may invalidate these approvals and render this unit unsafe to operate.

Strict compliance with all Federal and State Mining laws, regulations and practices regarding the safe operation and maintenance of underground mining equipment and strict adherence to the instructions in this manual is necessary for the personal safety of those working on or around this unit.

While this manual attempts to anticipate the most important operations and maintenance needs for this unit, unforeseen circumstances may arise that have not been addressed in this manual. If any concerns or questions arise, please contact your service representative immediately.

This work contains information protected under trade secret and other intellectual property laws, and is protected under the U. S. Copyright Act of 1976, as amended. This work is provided under license and the license is non-transferable. Distribution and access is limited only to authorized personnel. Disclosure, reproduction, distribution or unauthorized use may be a violation of federal and state laws and may subject the unauthorized user to criminal liability.

© CATERPILLAR 2012 ALL RIGHTS RESERVED

BI016954-06 (EN-US)

________________________________________________ Table of contents

Table of contents 1. About this manual About this manual ................................................................... 1.3 Before starting to work ......................................................... 1.3 Who is this operating manual intended for?......................... 1.3 What is the purpose of this operating manual?.................... 1.4 Characters and symbols ...................................................... 1.5

2. Your safety Your safety ............................................................................... 2.3 Personnel ............................................................................. 2.4 Operation ......................................................................... 2.4 Installation and repair ...................................................... 2.4 Operating conditions ............................................................ 2.5 Intended use .................................................................... 2.5 Unauthorized use ............................................................ 2.5 Safety instructions ................................................................ 2.7 General rules: .................................................................. 2.7 Storage and transport...................................................... 2.8 Pre-start inspection ......................................................... 2.8 Installation and start-up ................................................... 2.9 Operation ......................................................................... 2.9 Stopping ........................................................................ 2.10 Maintenance and repair................................................. 2.10

3. Storage and transport Storage and transport............................................................. 3.3 Storage ................................................................................. 3.3 Storage of the machine and spare parts ......................... 3.3 Long-term storage of spare components ........................ 3.4 Transport .............................................................................. 3.5 Before transport ............................................................... 3.8

4. Installation Installation ............................................................................... 4.3 Points to observe prior to installation ................................... 4.3 Who is allowed to carry out installation? ......................... 4.3 Which tools are required for installation? ........................ 4.3 Notes on installation ........................................................ 4.4 Pre-installation check list ................................................. 4.5 Safety features ................................................................ 4.6

________________________________________________________________ A6474X347

REV 06

BI016954-06 (EN-US)

Table of contents _________________________________________________ 5. Operation Operation ................................................................................. 5.3 How to operate the Continuous Miner.................................. 5.3 Who is allowed to operate the Continuous Miner............ 5.3 When can operation be started? ..................................... 5.3 Controls and indicators......................................................... 5.4 Machine control system........................................................ 5.10 Red zone ............................................................................ 5.22 Safety precautions for underground operation ................... 5.27 Tramming safety rules ........................................................ 5.27 Starting procedure .............................................................. 5.28 Shutdown procedure .......................................................... 5.30 Tramming the miner ........................................................... 5.31 Cutter head operation......................................................... 5.33 Conveyor operation ............................................................ 5.34 Scrubber motor operation .................................................. 5.35 Area and headlight operation ............................................. 5.36 Fire suppression in radio remote operation ....................... 5.37 Shear up/down in radio remote operation .......................... 5.38 Gathering head raise/float in radio remote operation......... 5.38 Stabilizer cylinder raise/lower in radio remote operation ... 5.38 Conveyor raise/lower/left/right in radio remote operation .. 5.38 Breaker on/off in radio remote operation ........................... 5.40 Typical cutting sequence .................................................... 5.41 Mechanical assemblies ...................................................... 5.43 Hydraulic system ................................................................ 5.49 Water system ..................................................................... 5.84 Electrical system ................................................................ 5.94 Instructions on the maintenance ................................... 5.125 Important notes ................................................................. 5.125 Before maintenance .......................................................... 5.125 Torque values.................................................................... 5.127 Specific lubrication and maintenance instructions ..... 5.131 Every shift ..................................................................... 5.131 Every third shift (daily) .................................................. 5.133 Weekly .......................................................................... 5.139 Monthly ......................................................................... 5.142 Every three months ...................................................... 5.148 Every six months .......................................................... 5.152 Instructions on the adjustment procedures ................. 5.158 Pilot/auxiliary pump circuit relief ................................... 5.160 Main control valve ........................................................ 5.162 Tram track .................................................................... 5.165 Tail shim ....................................................................... 5.170 Chain tension................................................................ 5.173 Mechanical ........................................................... 5.173 Grease take-up..................................................... 5.175 Hydraulic .............................................................. 5.177 Cutter motor feedback .................................................. 5.178

________________________________________________________________ 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

________________________________________________ Table of contents Replacement of wear parts ............................................ 5.181 Cutter head (boom) assembly ...................................... 5.181 Boom pivot pin .............................................................. 5.185 Center cutter drum ....................................................... 5.190 End cutter drum ............................................................ 5.194 Drum drive motor .......................................................... 5.198 Drum drive torque limiting clutch .................................. 5.204 Drum drive gear case ................................................... 5.209 Gathering head assembly ............................................ 5.215 Gathering head drive motor.......................................... 5.219 Gathering head gear case ............................................ 5.224 Gathering head foot shaft ............................................. 5.230 CLA............................................................................... 5.233 CLA tip replacement ..................................................... 5.236 Tram motor ................................................................... 5.237 Tram primary planetary gear ........................................ 5.242 Tram brake ................................................................... 5.245 Tram secondary planetary gear ................................... 5.252 Tram case..................................................................... 5.255 Tram reach gear set ..................................................... 5.260 Tram sprocket .............................................................. 5.268 Tram track front idler .................................................... 5.275 Front idler take-up cylinder ........................................... 5.279 Hydraulic pump ............................................................ 5.281 Hydraulic pump motor .................................................. 5.284 Scrubber fan/motor....................................................... 5.287 Swivel pin assembly ..................................................... 5.290 Tail roller ....................................................................... 5.292 Chain replacement ....................................................... 5.294 Troubleshooting procedures .................................... 5.295 Typical hydraulic problems ........................................... 5.296 Contaminants in hydraulic systems .............................. 5.297 Specific hydraulic circuits ............................................. 5.298 Multi-function failure ............................................. 5.298 Oil tank fill ............................................................. 5.299 Cutter head raise .................................................. 5.299 Cutter head lower ................................................. 5.299 Gathering head raise............................................ 5.300 Gathering head float............................................. 5.300 Conveyor raise ..................................................... 5.300 Conveyor lower .................................................... 5.301 Conveyor swing .................................................... 5.301 Stabilizer up.......................................................... 5.301 Stabilizer down ..................................................... 5.301 General safety procedures for shutdown ..................... 5.302 Excessive noise ............................................................ 5.303 Excessive heat ............................................................. 5.304 Incorrect flow ................................................................ 5.305 Incorrect pressure ........................................................ 5.306 Faulty operation ............................................................ 5.307 Restarting checklist ...................................................... 5.308 Water system ............................................................... 5.309 Electrical system .......................................................... 5.311 Bearings ....................................................................... 5.315

________________________________________________________________ A6474X347

REV 06

BI016954-06 (EN-US)

Table of contents _________________________________________________

________________________________________________________________ 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

_______________________________________________________________

1

About this manual

________________________________________________________________

BI016954-06 (EN-US)

_______________________________________________________________

________________________________________________________________

BI016954-06 (EN-US)

___________________________________________ Before starting to work

About this manual This chapter provides important information making it easier for you to use this manual. You will also be given information on the structure of the manual and the symbols and characters used.

Before starting to work applicable operating manual machine type

Take care to ensure that the operating manual available to you is applicable for the type of equipment or machine used.

This operating manual is intended for: 25M3 (CM240) Continuous Miner Serial No.: N/A and is only permitted to be used for equipment of this type.

new operation manual

The operating manual must be accessible at all times to all persons working on or with the machine. It should, if possible, always be available at the place of operation.

Send for a new operation manual immediately if the present manual is no longer complete or has become illegible.

Who is this operating manual intended for?

This operating manual is intended for those persons who work with or on the machine. Every person working on the face or in the intersection between face and entry or in the entry must read this operating manual.

This includes persons who: ■

are in charge of transport

■

perform assembly / disassembly work

■

operate the machine

■

find/fix faults

■

perform daily routine work on the face or in the entry

■

perform maintenance work

■

perform repair work

supervisory personnel who: ■

initiate and/or supervise the activities just indicated.

______________________________________________________________ A6474X347 REV 06 1.3

BI016954-06 (EN-US)

Before starting to work ____________________________________________ What is the purpose of this operating manual? cost-effectiveness

This operating manual is intended to help you work efficiently and safely with our product. It contains important information on all the activities related to the machine.

Read this operating manual completely and at ease. Pay special attention to the safety instructions. Try to memorize the appearance and the meaning of the safety and instruction symbols.

service

If any details are not clearly understood, please contact our service department. Our service address is given in the chapter titled “For your information”.

safety

Read the chapter “For your safety” with special attention. The chapter contains important information indicating possible hazards. Observe the information given and follow the procedural instructions.

________________________________________________________________ 1.4 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

___________________________________________ Before starting to work Characters and symbols used The following characters and symbols are used for safety instructions and important information in the operating manual.

Try to memorize the symbols and their meanings.

DANGER! Points in the text marked with this symbol draw your attention to immediately impending danger. Possible consequences are: very serious injury or even death.

WARNING! These points contain information on dangerous situations. Possible consequences are: very serious injury or even death.

CAUTION! This symbol draws attention to dangerous situations. Possible consequences are: light to moderately serious injuries and machine damage.

NOTICE! Points in the text marked with this symbol draw attention to harmful situations. Possible consequences are: damage to the machine or damage in the immediate vicinity.

IMPORTANT! Points in the text marked with this symbol contain useful tips and information intended to facilitate work for you. They do not warn about harmful or dangerous situations.

■

Items in lists are marked with bullets.

–

Points in sub-lists are marked with a long dash at the start of the line.

 Points in text marked in this way describe individual operations.

Follow these instructions step by step. They will help you carry out your work faster and more importantly, safer.

______________________________________________________________ A6474X347 REV 06 1.5

BI016954-06 (EN-US)

Before starting to work ____________________________________________

________________________________________________________________ 1.6 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

_______________________________________________________________

2

Your safety

________________________________________________________________

BI016954-06 (EN-US)

_______________________________________________________________

________________________________________________________________

BI016954-06 (EN-US)

______________________________________________________ Personnel

Your safety This chapter provides vital information for your safety. Pay special attention to this chapter. The safety instructions and rules of procedure will help you to avoid hazardous situations and to perform the necessary work as safely as possible. state of the art

The machine has been manufactured in accordance with the state of the art and generally recognized safety standards and regulations.

You and others can, nevertheless, be exposed to dangerous situations e.g. as a result of environmental influences, machine damage or operator errors.

Do not make any alterations or modifications which could impair the safety of the machine. All modifications and changes must be approved.

Use only original spare parts. Note that the use of parts from other manufacturers will void the warranty.

In addition to this operating manual be sure to also observe the respective legal provisions and regulations in your country.

Observe the safety and accident prevention regulations

further operating manuals

■

of the mine,

■

of the mine inspector, and

■

of the mining supervisory authorities.

Read the operating manuals of the components required for operation, e.g. of gearboxes, electric motors, radio remotes, etc., carefully and thoroughly. Clarify any questions before starting work.

______________________________________________________________ A6474X347 REV 06 2.3

BI016954-06 (EN-US)

Personnel _______________________________________________________ Personnel Operation training

The machine may only be operated by qualified, trained personnel.

The machine is only allowed to be operated by qualified personnel who can provide proof of having been trained on this unit.

Reading of the operation manual, especially the chapter on safety, shall constitute a part of this training.

You must have adequate knowledge of the ■

mechanics,

■

hydraulics, and

■

control engineering

and must be able to prove this knowledge.

Installation and repair As a fundamental rule, installation and repair work may only be carried out by personnel who have been adequately trained for these particular requirements.

Installation and repair work on: ■

safety components (pressure relief valves, extinguishers, etc.)

■

the electrics (motors, controllers, etc.)

■

the hydraulics (controls, cylinders, etc.)

may only be carried out by service engineers or by specially qualified personnel of the mine.

________________________________________________________________ 2.4 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

____________________________________________ Operating conditions Operating conditions Intended use The Continuous Miner has been designed and manufactured for specific uses. Intended uses include: ■

extraction of coal, phosphate, potash, salt, trona, and other medium hardness minerals

■

loading the materials listed above onto a haulage system or shuttle car, or dumping it onto the ground for loading at a later time

■

operation on grades of less than 10 degrees

Unauthorized use Applications not expressly listed as intended uses are unauthorized uses and are not allowed to be performed with the machine.

■

the transport of persons

■

stone development or extraction

The manufacturer accepts no liability for any damage resulting from any such unauthorized use.

______________________________________________________________ A6474X347 REV 06 2.5

BI016954-06 (EN-US)

Operating conditions _____________________________________________

________________________________________________________________ 2.6 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

______________________________________________ Safety instructions Safety instructions General rules general

Always work with full concentration.

Familiarize yourself with your working environment.

noise emissions

Always wear your personal protective equipment. This also includes ear protectors as the noise emitted by other equipment in the area may at times exceed 85 db(A).

Inform your colleagues of

safety equipment

■

your exact location,

■

the work you are performing, and

■

the time that you will probably require.

Start the machine only when it is in a good and safe operating condition and all protective devices, e.g. EMERGENCY STOP devices, cover plates, etc. are correctly installed.

Observe the acoustic and optical start-up warnings of the machine.

symbol plates

Observe the symbol plates on the machine.

emergency stop

Press the EMERGENCY STOP button immediately in the event of fault or irregularities in operation. Report any irregularities to your superior so that necessary measures can be taken immediately.

lock-out and tag

Disconnect, lock-out, and tag the power system while performing: ■

maintenance work

■

inspection work

■

repair work

Follow all mine, state, and Federal regulations regarding lock-out/tag out procedures. cordon off working area moving parts

Cordon off your working area widely for the machine.

Never allow parts of your body to come between parts which could move, such as e.g.: ■

chains, flights, and chain sprockets

■

pivot points

■

cutter head and loading head

■

crawler assemblies and conveyors

■

cutter and gathering head assemblies

______________________________________________________________ A6474X347 REV 06 2.7

BI016954-06 (EN-US)

Safety instructions _______________________________________________ Storage and transport Maintain the prescribed storage periods and observe the instructions for storage.

Do not store materials or parts in the travel way or in your working area.

Inform the persons involved about the intended transport route and the anticipated duration of the transport. transport safety device

Ensure that the transport safety devices are correctly fitted.

Fix all moving parts with transport locks.

Never stand under unsupported parts or suspended loads.

means of attachment

Connect the lifting equipment only to the points of attachment provided for that purpose. Observe the different load limits of the attachment points. Also observe the instructions on the transport sheet.

Only use means of attachment which are in good condition and have been designed for the loads to be handled.

For round components use transport straps, only. Never use chains or steel cables for this purpose.

Do not damage the treated or polished surfaces of shafts, sealing surfaces, etc.

mobile handling equipment

When using mobile handling systems for transport make sure that the center of gravity is as low as possible.

Pre-start inspection operation

Read this entire manual before attempting to operate this machine.

inspection

Inspect the machine and have any malfunctioning, broken or missing parts corrected or replaced before use.

maintenance instruction and safety tags operator’s compartment (optional) cab/canopy (optional)

Verify that all maintenance has been performed.

Verify that all instruction and safety tags are in place and readable.

These are as important as any other equipment on the machine.

Clean any foreign material from the operator’s compartment.

This machine may be shipped from the factory equipped with a protective cab/canopy. The cab/canopy must be securely in place before operating the unit.

________________________________________________________________ 2.8 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

______________________________________________ Safety instructions Installation and start-up inclined face environmental acceptability

On inclined faces secure all component parts by chains, e.g. to the support.

When working with oils, greases and other chemical substances, observe the safety regulations applicable to the product. Safety regulations can be found on the container or on the Material Safety Data Sheet (MSDS) for the product.

Dispose of cleaning rags, etc. which have been soiled with oil, grease or other chemical substances in an environmentally safe manner.

controls

When starting up machine, do not operate any controls located inside the operator’s compartment (optional) from outside the compartment.

starting procedures

Follow the starting procedure instructions in the operations manual.

red zone

Do not operate any levers, pedals or controls if anyone is in the red zone. (See Red Zone in Chapter 5 of this manual)

Operation training

Operate the machine only if you have a profound knowledge of the control elements and their functions. It is necessary that you have been task trained on the respective Continuous Miner.

before start-up

Before start-up, ensure that there are no persons or obstructions in your line of travel or in the articulation area when steering the unit.

protective devices

Check that all protective devices are installed on the machine and function properly.

operator’s compartment (optional)

Clean the operator’s compartment at regular intervals. Ensure that the operating symbols are legible in order to avoid any operator errors and resulting accidents.

Never climb onto, or climb out of the machine while it is in motion.

Do not operate the machine with any part of your body outside of the operator’s compartment in order to prevent body parts from being crushed between the machine and outside objects .

traveling

Use extreme caution when traveling in close quarters or in congested or blind-travel areas.

passengers

Never carry passengers. Passengers may be thrown off the machine or crushed between the machine and outside objects.

safety rules

Always follow all safety rules of each particular mine when operating the machine.

problems and malfunctions

If problems or malfunctions are encountered while operating the unit, it must be properly shutdown and the problem corrected immediately.

______________________________________________________________ A6474X347 REV 06 2.9

BI016954-06 (EN-US)

Safety instructions _______________________________________________ Stopping operator’s compartment (optional)

Do not leave the operator’s compartment with the unit running. Always properly shutdown the unit before leaving the operator’s compartment.

parking

Always park the unit on solid, level ground. If this is not possible, park the unit at a right angle to the slope to prevent accidental movement of the machine.

Use proper flags, warnings or barriers when parking in areas of traffic.

radio

There is a unique code switch setup which permits each operator to activate only his designated miner, allowing several remote-controlled miners to operate in the same area without getting their radio signals crossed. In addition, an improperly decoded radio signal will automatically shut-off the miner. Follow the general safety notices and safety recommendations listed in the remote control system troubleshooting guide.

Maintenance and repair Be sure to observe the prescribed maintenance and inspection intervals.

Inform the supervisory personnel and the face crew of any maintenance and repair operations. Give them information on the intended operations and the anticipated duration. trailing cable uncoupled and locked and tagged out

securing

Before attempting any repairs, a DANGER sign must be attached to the appropriate circuit at the power distribution box. It is mandatory under the United States Federal Law that the trailing cable be uncoupled, tagged and locked-out from the power source to provide visual evidence that the miner is de-energized.

Secure your working area over a wide range, in order to avoid endangering other persons.

Disconnect the power from the machine to prevent unauthorized and unintentional restarting.

Protect your work area against falling rocks.

original parts methane monitoring

Pass defective components removed on for servicing without delay in order to prevent these parts being reinstalled elsewhere.

Use only spare parts which satisfy the specified technical requirements.

This is only ensured with original spare parts.

Please refer to the spare parts lists for the order numbers.

Before attempting any repairs or maintenance, methane air monitoring must be completed before and during the repair and maintenance.

________________________________________________________________ 2.10 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

______________________________________________ Safety instructions lifting

handling of hydraulic fluids

For raising the Continuous Miner use only: ■

crib blocks with adequate load-holding capacity.

■

hoists, jacks or cranes with adequate load-carrying capacity.

Avoid direct contact between the skin and hydraulic fluids. Hydraulic fluid can penetrate the skin and cause serious infection.

Never use hydraulic fluid for rinsing or cleaning. Hydraulic fluid represents a very serious danger to health.

maintenance, repair

Only persons who have and can demonstrate a special knowledge of hydraulics are allowed to work on the hydraulic system.

Avoid, whenever possible, servicing, cleaning or examining the machine in congested areas.

Avoid, whenever possible, servicing or providing maintenance to the unit unless the appropriate safety devices are placed where recommended to prevent accidental movement of the unit.

Do not alter the electrical or hydraulic settings from that indicated in this manual or as set at the factory.

Always replace damaged or lost decals and metal instruction plates.

Disconnect the power when working with the electrical system, or when welding on the unit to prevent electrical shock.

Always follow all safety procedures of each particular mine when performing maintenance.

It is important that any procedure not specifically recommended in this guide be thoroughly evaluated from the standpoint of safety before it is implemented.

______________________________________________________________ A6474X347 REV 06 2.11

BI016954-06 (EN-US)

Safety instructions _______________________________________________ Some illustrations in this manual show guards or cover panels removed for purposes of clarity. Never operate unit without guards or cover panels in place.

Carry out a visual inspection of all the hydraulic components at regular intervals. In particular check that: ■

the hoses are not pinched or trapped.

■

the hoses have no bubbles or blisters.

■

the hose or outer sheathes of the hose are not abnormally rigid or hard.

■

the outer sheath of the hoses is not damaged.

■

the connectors are securely inserted into the sockets.

■

the connections are leak-tight.

Ensure that no dirt enters the hydraulic system during repair work. Dirt in the hydraulic system can cause serious damage in the whole system!

Flush out the hydraulic lines thoroughly before connecting. permissible hoses

If hydraulic hose couplers are difficult to disconnect or cannot be disconnected, the hydraulic line may still be pressurized. Be sure to depressurize the line before disconnecting couplers.

Secure the connectors of the hydraulic elements only with the proper coupling clamps. Always fasten the clamps completely and with both sides. Never use nails, wire or similar materials for securing.

After finishing repair work, check all connectors and connections for leaks before pressurizing the system again.

Use only hydraulic hoses approved for the prevailing pressures.

Do not use any hydraulic hoses with damaged connectors or worn orings.

Replace hydraulic hoses only with hoses of the same or a higher quality.

Never try to hold a jumping hydraulic hose. Depressurize the line in question immediately.

Never try to repair damaged hydraulic hoses.

Replace hydraulic hoses at the first suspicion of damage.

________________________________________________________________ 2.12 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

______________________________________________ Safety instructions installing hydraulic hoses

Install the hydraulic hoses properly behind the brackets and clamps provided for them.

Always install hydraulic hoses so they: ■

always have a little slack.

Fig. 1: Installing hydraulic hoses, slack Right

■

Wrong

are not twisted.

Fig. 2: Installing hydraulic hoses, twisting Right

■

Wrong

are not bent directly behind the connections. (distance min. 1.5 x nominal diameter).

Fig. 3: Installing hydraulic hoses, bending Right

Wrong

______________________________________________________________ A6474X347 REV 06 2.13

BI016954-06 (EN-US)

Safety instructions _______________________________________________ ■

always have a little slack.

■

are not kinked.

■

do not have to withstand tensile strains.

■

are protected against thermal radiation.

■

are accessible at all times.

Screw hydraulic hoses into the sockets only by hand and finger tighten.

Never try to drive the hydraulic hoses in with a tool as this will damage the connections. Use the appropriate amount of torque to ensure a proper hose fit.

When installing the hydraulic hoses, ensure that they cannot be: ■

torn out,

■

kinked,

■

crushed,

■

driven over or

■

twisted by movement of the machine.

Fig. 4: Installing hydraulic hoses, connections on moving parts Right

Wrong

________________________________________________________________ 2.14 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

_______________________________________________________________

3

Storage and transport

________________________________________________________________

BI016954-06 (EN-US)

_______________________________________________________________

________________________________________________________________

BI016954-06 (EN-US)

____________________________________________ Storage and transport

Storage and transport This chapter contains important information on the correct storage and transport of the Continuous Miner. Storage procedures are general.

For specific procedures for your environment, contact Engineering.

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

Storage corrosion protection

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

Before delivery, the hydraulic functions are tested and the hydraulic pressures are preset to OEM specifications.

Storage of the machine and spare parts no direct exposure to sunlight dirt and moisture

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

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

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

short-term storage

During short-term storage (approximately 4 weeks) of equipment outdoors, but at temperatures above freezing, electrical components need not be removed. Such components must be particularly protected against excessive temperatures, dirt, and moisture.

long-term storage

If the equipment is to be stored more than six months, the following lubrication and corrosion inhibiting procedures must be followed: ■ ■ ■ ■ ■

■

If the cylinder rods are exposed, the rods must be coated with a corrosion inhibiting fluid.

Completely fill the hydraulic oil tank with oil.

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

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

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

______________________________________________________________ A6474X347 REV 06 3.3

BI016954-06 (EN-US)

Storage and transport _____________________________________________ machine electrical components

Forced Potato electronic components have the following storage requirements: ■ ■ ■

traction drives

Graphic displays must be stored at temperatures above 14 °F (-10 °C) Power supplies (part number 295275) must be stored at temperatures above -3 °F (-20 °C) Other components must be stored at temperatures above -13 °F (-25 °C)

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

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

random sample inspection

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

On request, the inspection can be carried out.

natural aging

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

HFA fluids

Instructions on the storage of concentrates for hydraulic fluids can be found, if required, in chapter 6 in this operating manual.

IMPORTANT! Take care to insure that new maintenance supplies are stored separately from existing stock and that removal takes place on the “first in, first out” principle.

Long-term storage of spare components hydraulic components

miscellaneous components

motors fan assembly

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

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

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

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

plastic deformation

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

3.4

25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

____________________________________________ Storage and transport Transport Load units: dimensions and weights Observe the transport sheets for the machine and spare parts. They contain information on: ■

dimensions,

■

weights,

■

lifting points, etc.

Additional information on the dimensions and weights can be found in chapter 6 and in the lifting weight guide (Table 1) in this operating section. Fig. 5 illustrates the position of lifting eyes on the miner.

WARNING! Use only load handling devices complying with the technical and legal regulations for the transport of loads. You could be seriously injured or even killed by falling loads. Use only suitable load handling devices.

Table 1: Lifting weights of individual assemblies

removal and installation of heavy components

Description

Approximate Weight

Complete Machine

160,000 lbs.

Tractor Frame Assembly

75,000 lbs.

Gathering Head Assembly

23,000 lbs.

Conveyor Assembly

17,000 lbs.

Cutter Head Assembly

45,000 lbs.

Whenever possible, all removals should be accomplished using an adjustable lifting beam. All supporting members (chains and cables) should be parallel to each other and as nearly perpendicular as possible to the top of the object being lifted.

When it is necessary to remove a component on an angle, remember that the capacity of an eyebolt diminishes as the angle between the supporting members and the object increases. Eyebolts and brackets should never be bent.

When an eyebolt is provided to lift a component, use it to lift only that component.

WARNING! You could be seriously injured or killed as a result of falling loads.

Do not use the eyebolt to lift the component and its related assemblies.

______________________________________________________________ A6474X347 REV 06 3.5

BI016954-06 (EN-US)

Storage and transport _____________________________________________ Fig. 5: Lifting points Lifting eye (15 ton)

Lifting eye (15 ton)

Cutting head

Lifting eye (4.5 ton)

Lifting eye (4.5 ton)

Lifting eye (4.5 ton)

Lifting eye (4.5 ton) Conveyor

________________________________________________________________ 3.6 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

____________________________________________ Storage and transport Fig. 5 (continued): Lifting points

Lifting eye (4.5 ton)

Lifting eye (4.5 ton)

Lifting eye (10 ton)

Lifting eye (10 ton)

Gathering head

Lifting eye (2) (30 ton)

Lifting eye (2) (30 ton) Frame

______________________________________________________________ A6474X347 REV 06 3.7

BI016954-06 (EN-US)

Storage and transport _____________________________________________ Before transport temperatures below freezing

Before transporting the equipment at temperatures below freezing, all hydraulic components operated with emulsion (HFAE or HFAS) must be completely drained and then filled with a corrosion inhibitor/frostproofing fluid (e.g. CV 50).

Transport of equipment at temperatures between -6° F (-21° C) and 40° F (-40° C) is only permissible when certain measures were taken to meet these conditions at the design and manufacture stages. Nevertheless, the individual parts and devices of this equipment must not be subjected to sudden impact loads at such low temperatures and may only be loaded statically or quasi-statically.

During transport of this equipment with floor-mounted vehicles at such low temperatures, measures must also be taken to ensure that the parts and devices are not subjected to sudden impact loads. At very low temperatures and on poor roads, the transport vehicle speed must therefore be limited to a maximum of 15 mph (25 kph) for truck transport.

electronic components

Electrical and electronic components must be protected against harmful environmental influences by a suitable packaging.

The electrical cables remain in the equipment. They must be carefully protected against transport damage and soiling of the connections.

________________________________________________________________ 3.8 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

_______________________________________________________________

4

Installation

________________________________________________________________

BI016954-06 (EN-US)

_______________________________________________________________

________________________________________________________________

BI016954-06 (EN-US)

_____________________________________________________ Installation

Installation Points to observe prior to installation Who is allowed to carry out installation?

Installation is only allowed to be carried out by personnel having received adequate training to perform this task.

Work on: ■

the safety components (pressure relief valves, fire extinguishing equipment etc.)

■

the electrical equipment (control units, signaling devices, etc.)

■

the hydraulic equipment (cylinders, directional control valves, hoses etc.)

should only be carried out by service engineers or by specially trained personnel.

Which tools are required for installation? tool box

No special tools are required to put the Continuous Miner into service.

Various items of auxiliary equipment and machines may be required at the point of installation.

These include: ■

hoists with adequate lifting capacity

■

means of attachment with adequate lifting capacity

■

unloading dock and crib blocks

■

jacks with adequate lifting capacity

■

995V, 50 Hz to attach temporarily to SHD-G 2/0 shielded cable

■

impact wrenches, including accessories

______________________________________________________________ A6474X347 REV 06 4.3

BI016954-06 (EN-US)

Installation ______________________________________________________ Notes on installation CAUTION! Serious damage can be caused to the Continuous Miner as a result of incorrect installation. The unit should therefore only be installed under the instruction of specialists. installation plan

Continuous Miners are shipped to the customer site per customer preference. The Continuous Miner can be shipped to the customer site as a complete machine or in component sections. This depends on mine conditions, transportation weight restrictions/requirements, or size/ weight restrictions at the mine.

IMPORTANT! The sequence of operations during installation must be adapted to the individual conditions prevailing at the site. Before starting the work a detailed list of steps to be taken with respect to transport and assembly should be prepared and a corresponding plan established.

reassembly instructions

When assembly is required after shipment of the machine, the assistance of specialists from is recommended. This will insure that the correct installation, safety and maintenance procedures are followed.

________________________________________________________________ 4.4 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

_____________________________________________________ Installation Pre-installation check list NOTICE! The machine was inspected prior to shipment from the factory to ensure proper functioning and installation of all components.

However, to ensure that no transit damage has occurred, the following pre-startup checks should be performed: ■

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

■

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

■

Check the full length of the trailing cable for damage.

■

Ensure that the trailing cable is properly suspended across inter sections and that the trailing cable clamp at the Continuous Miner is secure.

■

Clean any foreign material from the optional operator’s compartment, conveyor, and gathering pan.

■

Start up the machine and check for correct operation of all stop switches.

■

Perform daily maintenance.

■

Visually inspect all hydraulic hoses and electrical cables for damage.

■

Check safety provisions for operational condition on fire suppression system.

■

Start up the machine and check for correct operation of E-stop buttons.

■

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

■

Check that all tags and instruction labels are in place and secure.

■

Check that operator’s canopy (optional) is secure and in place.

■

Start the machine and allow the hydraulic system to warm up for five (5) to ten (10) minutes.

■

Check hydraulic system pressures (refer to the hydraulic schematic supplied for your particular machine for pressure settings).

■

Check and operate all control handles and remote switches to ensure all machine functions are operating properly and are in neutral position.

■

Check the tension of the conveyor chain and crawler chain.

______________________________________________________________ A6474X347 REV 06 4.5

BI016954-06 (EN-US)

Installation ______________________________________________________ Safety features NOTICE! The operator must become familiar with all the safety features and their location on the machine prior to installation or operation.

Safety features include: (Reference Fig. 6) machine stop buttons

The machine is equipped with two machine stop buttons, one on each side of the machine. The machine stop is used to break the control circuit only in emergency situations, stopping all motors. Striking with a small amount of force will actuate the machine stop.

radio remote E-stop button

There is an E-stop located on the radio remote, which when pressed, directs the processor module to send a control message to the power supply. This will drive the pilot relay output and trip the main power supply to the machine.

canopy/cab (optional)

The machine may be shipped from the factory with a protective canopy/ cab (optional). Ensure that the canopy/cab is in place and secure at all times to protect the operator from falling debris.

fire suppression

The machine may be equipped with fire suppression (remote) actuators. If equipped, the location may vary. This particular suppression system is pneumatically actuated and extinguishes with dry chemicals.

To actuate the system from the actuators, pull the safety pin and strike downward on the plunger. Immediately after the plunger is struck, dry chemical will be dispensed throughout the machine. The fire suppression system must be completely recharged with dry chemicals and expellants after it has been actuated.

WARNING! If either of the fire suppression actuators is actuated, the system must be completely recharged with dry chemicals and expellants.

fire sprays

Water can be directed to the fire spray nozzles manually from the fire spray valve above the switch box in the operator's compartment or by the fire spray valve on the left hand side of the machine.

On radio units, an electronically actuated solenoid is used to actuate the fire spray system from the remote position.

IMPORTANT! The fire spray valve must be manually set to the normal position before the dust suppression water spray system can be operated.

CAUTION! The mine supply water pressure at the machine should not exceed 500 psi and should supply 20 gpm minimum for cooling.

The remote fire spray actuator located on the main feed behind the miner is used to activate the fire spray when there is a fire and power has been turned off. Simply turning the valve allows 'pilot' oil to feed into the small hose secured within the valve assembly and through the main feed line into the miner, where it contacts a s olenoid that activates the fire spray system.

________________________________________________________________ 4.6 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

_____________________________________________________ Installation scrubber/dust suppression (optional)

The Continuous Miner may be equipped with an optional dust suppression package (scrubber). The dust suppressor allows the Miner operator to use fan induced ventilation at the face. The fan suction draws in the dust and liberated methane from the intake duct(s). The dust laden air is then drawn through the scrubber screen, which is constantly flooded with water spray. The dirty water is then removed from the air stream by a de-mister which is located directly behind the scrubber screen. The dirty water flows down to a sump tank where a water powered jet pump empties the sump and dumps the dirty water onto the conveyor. The clean, dry air exits the de-mister and is discharged into the mine atmosphere at the rear of the miner, diffused downward and towards the rib to prevent coal fines from being blown on the offside shuttle car operator.

guards and covers

The machine is equipped with guards and covers to reduce the possibility of personnel coming in contact with rotating or moving parts. All guards and covers must be installed and securely fastened during operation.

DANGER! Do not operate the machine with any of the guards or covers removed. You or other personnel could be seriously injured from moving or rotating parts.

cutter boom safety supports

There are two cutter boom safety supports, one on each side of the cutter boom. The supports are used to block up the cutter boom during maintenance operations.

conveyor safety supports

There are two conveyor safety supports, one on each side of the conveyor. The supports are used to block up the conveyor during maintenance operations.

start switch safety covers

Every switch on the operator’s controller case that engages a function (pump start, cutter start, etc.) is protected from accidental activation by a cover.

methane monitor

The machine is equipped with a methane monitor that detects the presence of methane in the mine atmosphere. When the miner is being powered up, the monitor looks for methane before any other function is energized. If the methane monitor detects a level of methane within a preset tolerance, the methane monitor relay will close and power will be supplied to the other functions on the machine.

______________________________________________________________ A6474X347 REV 06 4.7

BI016954-06 (EN-US)

Installation ______________________________________________________ Fig. 6: Safety features on the Continuous Miner

Methane monitor display

Manual circuit breaker reset (optional) (location

Machine stop

Safety covers

Machine stop (location typical)

________________________________________________________________ 4.8 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

_____________________________________________________ Installation Fig. 6 (continued): Safety features on the Continuous Miner

Cutter boom safety support (2)

Conveyor safety support (2)

______________________________________________________________ A6474X347 REV 06 4.9

BI016954-06 (EN-US)

Installation ______________________________________________________ Fig. 7: Overview of the Continuous Miner Cutter boom

Conveyor boom

Operator’s station

Crawler assembly

Scrubber intake

Gathering head assem-

________________________________________________________________ 4.10 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

_______________________________________________________________

5

Operation

________________________________________________________________

BI016954-06 (EN-US)

_______________________________________________________________

________________________________________________________________

BI016954-06 (EN-US)

______________________________________________________ Operation

Operation This chapter contains important information on the operation and maintenance of the machine. It also includes instructions on the replacement of wear parts.

Read this chapter carefully and thoroughly. In particular, observe the safety instructions in chapter 2 “Your safety”.

How to operate the continuous miner DANGER! Incorrect operation endangers yourself and others! Incorrect operation of the machine is often the cause of very serious accidents! Operate the unit only when you have been sufficiently trained on the machine and have read and understood this operating manual. Should anything be unclear, please contact your immediate supervisor.

Who is allowed to operate the continuous miner?

The Continuous Miner is only allowed to be operated by persons with adequate knowledge of the complete machine.

This includes: ■

what safety devices are installed on the machine.

■

where these safety devices are located.

■

how these safety devices are to be operated.

When can operation be started?

Operation must not be started until the safe condition and proper function of the complete machine has been checked and the daily maintenance operations have been carried out.

NOTICE! Before beginning cutting operations, carefully unload the trailing cable providing enough slack and placing it where it allows adequate clearance for safe maneuverability of the miner.

The 25M3 (CM240) Continuous Miner is an electrically powered, drum type, radio remote controlled miner.

The Miner is mounted on crawler tracks that provide full mobility and a sharp turning radius in both room and pillar and longwall development mining plans. The ranging cutter head mines material from the solid face using a chainless rotating drum, and a CLA-type gathering head with high speed conveyor efficiently moves mined material to a haulage system behind the Miner.

______________________________________________________________ A6474X347 REV 06 5.3

BI016954-06 (EN-US)

Operation _______________________________________________________ Controls and indicators Operator’s station WARNING! The Continuous Miner is typically radio remote controlled. Manual operation is not allowed for production operation unless the miner has an operator’s pit and canopy. Manual operation is generally for troubleshooting and maintenance under roof support. Operating the Continuous Miner manually from the Operator’s station may result in serious injury or death.

The primary controls for the machine are normally located at the operator’s station (Fig. 8) on the right hand side of the machine near the rear bumper, or in the optional operator’s compartment.

The operator’s station houses the controls and indicators used in the normal operation of the machine. Mounted inside the case are the main circuit breaker, auxiliary circuit breaker, control transformer, electrical metering package, control breakers, radio/manual switches and manual start/stop switches. All control breakers are located within this case, behind the small access cover located above the trailing cable entrance. The trailing cable enters into this enclosure at the bottom left corner facing the case. The machine stop is mounted on the enclosure and operates the pump stop switch to shut the machine down. The operator's station has been built and designed as explosion-proof, and must be maintained as such at all times.

The manual circuit breaker reset levers (optional) are located at the bottom of the case.

“MACHINE STOP”

“EARTH LEAKAGE”

Pressing “MACHINE STOP” will shutdown the pump, causing the miner to shutdown. To restart the machine after striking the machine stop, follow normal pump startup procedure (see Startup procedure in this chapter).

The “EARTH LEAKAGE” operation selector switch is located to the right of the “MACHINE STOP” button. The selector switch has four positions: ■

“120V GND CHK” - Placing the operation switch in the 120V ground check position should cause the mine power center to trip, thereby shutting down all power to the miner.

■

“RUN MODE” - During normal mining operations, the switch should be in the “RUN MODE” position.

■

“RESET” - Placing the operation switch in the reset position allows the operator to reset the earth leakage monitor.

■

“270V GND CHK” - Placing the operation switch in the 270V ground check position should cause the mine power center to trip, thereby shutting down all power to the miner.

________________________________________________________________ 5.4 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

______________________________________________________ Operation “MINER”

The “MINER” operation selector switch is located to the right of the “EARTH LEAKAGE” button. The selector switch has three positions: ■

“E-TRAM” - Turning the switch to this position allows the miner to be trammed from the pendant controls. “E-TRAM” is used in the event that the operator loses his radio link with the miner.

■

“REMOTE” - During normal mining operations, the switch should be in the “REMOTE” position. This allows the miner to be controlled by the radio remote system.

■

“GND CHK” - Placing the operation switch in the ground check position should cause the mine power center to trip, thereby shutting down all power to the miner.

control breaker switches

There are sixteen control breaker reset buttons located across the top of the operator’s case. The button will pop out when the circuit breaker trips. To reset a circuit breaker, push the button in.

“CONVEYOR HOUR METER”

The “CONVEYOR HOUR METER” indicates the hours of running time for the conveyor motors.

“CUTTER HEAD HOUR METER”

The “CUTTER HEAD HOUR METER” indicates the hours of running time for the cutter head motors.

Fig. 8: Operator’s station

Control breakers

“CUTTER HEAD HOUR METER”

“MACHINE STOP”

“EARTH LEAKAGE” switch

“MINER” mode

“CONVEYOR HOUR METER”

______________________________________________________________ A6474X347 REV 06 5.5

BI016954-06 (EN-US)

Operation _______________________________________________________ Gauge panel Six (6) pressure gauges (Fig. 9) located to the right of the operator’s station are used to monitor water pressure throughout the miner.

“MACHINE WATER PRESSURE”

The “MACHINE WATER PRESSURE” gauge monitors the pressure at the main distribution manifold for the water system on the miner. The “MACHINE WATER PRESSURE” should be at a minimum of 250 psi.

When the difference between the “MINE WATER PRESSURE” and the “MACHINE WATER PRESSURE” gauges is greater than 75 psi, it is an indication that the strainer and/or filter need changed. If the “MACHINE WATER PRESSURE” gauge reads below 250 psi, shutdown the machine (see Shutdown procedure in this chapter) and call maintenance.

“MINE WATER PRESSURE”

The “MINE WATER PRESSURE” gauge monitors the pressure of the supply water coming into the water system from the mine. The “MINE WATER PRESSURE” has to be at a minimum of 250 psi under dynamic conditions. This pressure should not exceed 500 psi. If the pressure exceeds 500 psi, immediately adjust the supply water pressure or shutdown the machine (see Shutdown procedure in this chapter).

“LEFT HAND CUTTER HEAD SPRAY PRESSURE”

The “LEFT HAND CUTTER HEAD SPRAY PRESSURE” gauge monitors the water pressure at the left hand cutter head spray manifold in the dust suppression system. The gauge readings are dependent on the individual mine requirements. Consult the schematic in the parts manual supplied with your machine.

“LEFT HAND CENTER CUTTER HEAD SPRAY PRESSURE”

The “LEFT HAND CENTER CUTTER HEAD SPRAY PRESSURE” gauge monitors the water pressure at the left hand center cutter head spray manifold in the dust suppression system. The gauge readings are dependent on the individual mine requirements. Consult the schematic in the parts manual supplied with your machine.

“RIGHT HAND CENTER CUTTER HEAD SPRAY PRESSURE”

The “RIGHT HAND CENTER CUTTER HEAD SPRAY PRESSURE” gauge monitors the water pressure at the right hand center cutter head spray manifold in the dust suppression system. The gauge readings are dependent on the individual mine requirements. Consult the schematic in the parts manual supplied with your machine.

“RIGHT HAND CUTTER HEAD SPRAY PRESSURE”

The “RIGHT HAND CUTTER HEAD SPRAY PRESSURE” gauge monitors the water pressure at the right hand cutter head spray manifold in the dust suppression system. The gauge readings are dependent on the individual mine requirements. Consult the schematic in the parts manual supplied with your machine.

________________________________________________________________ 5.6 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

______________________________________________________ Operation Fig. 9: Gauge panel “MINE WATER PRESSURE”

“MACHINE WATER PRESSURE” “LEFT HAND CUTTER HEAD SPRAY PRESSURE”

“RIGHT HAND CENTER CUTTER HEAD SPRAY PRESSURE”

circuit breaker

“LEFT HAND CENTER CUTTER HEAD SPRAY PRESSURE” “RIGHT HAND CUTTER HEAD SPRAY

The circuit breaker is the main circuit breaker for the machine. The circuit breaker has three (3) positions: "OFF," to de-energize the machine's electrical systems and "ON," for normal operation, and “TRIPPED” when the circuit breaker has tripped. The circuit breaker should be in the "OFF" position before the machine is serviced or shutdown.

WARNING! The machine circuit breaker de-energizes the electrical controller and motors. However, electrical power is still present inside the connection box to the circuit breaker. If the circuit breaker inside the connection box requires service, the trailing cable should be disconnected from the power center.

manual circuit breaker reset (optional)

The manual circuit breaker reset levers are located below the electrical switches at the operator’s control station. The circuit breaker trips when the electrical system is overloaded or shorted.

WARNING! Once the breaker has tripped, it will not stay in the “ON” position without first being moved to the "RESET" position, and then to "ON".

To reset the circuit breaker manually proceed as follows:  Move the selector to “RESET” position and move the circuit breaker to full “OFF” position.  Move the selector to the “ON” position for normal operation.

______________________________________________________________ A6474X347 REV 06 5.7

BI016954-06 (EN-US)

Operation _______________________________________________________ machine stop

The Continuous Miner is equipped with an machine stop button (Fig. 10) located off the side of the machine. The machine stop button is used to break the control circuit in emergency situations, stopping all motors. Striking with a small amount of force will actuate the emergency stop.

WARNING! Be prepared for a sudden stop when the machine stop is actuated during normal tramming of the machine.

Fig. 10: Machine stop

Machine stop (location typical)

methane monitor (typical)

The machine is equipped with a methane monitoring system (Fig. 11) which, when energized, maintains a continuous check on methane gas concentration. This machine has a LED indicator display which shows the percentage of methane gas in larger numerals.

Consult the manufacturer’s manual and literature in the parts book for your machine for the setup, operation, and maintenance of the methane monitoring system.

Fig. 11: Methane monitor display (typical)

Methane monitor display

________________________________________________________________ 5.8 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

______________________________________________________ Operation radio remote control (optional)

When operated by a radio (Fig. 12), a portable wireless remote with a unique code feature sends radio commands to a controller in the switch console via a whip antenna setup. The small whip antennae intercept the radio signals which the controller translates into electrical commands to various electrical circuits to perform the function selected. These circuits energize solenoids which actuate pilot-valves, switches, or relays controlling a specific mechanical, hydraulic, or electrical function.

There are eight selectable frequencies which permits each operator to activate only his designated miner, allowing several remote-controlled miners to operate in the same area without getting their radio signals crossed. In addition, an improperly decoded radio signal will automatically shutdown the miner.

IMPORTANT! Refer to the radio remote control operation manual supplied with your machine for information regarding the operation of your specific remote control.

Fig. 12: Radio remote control (typical)

______________________________________________________________ A6474X347 REV 06 5.9

BI016954-06 (EN-US)

Operation _______________________________________________________ Machine control system A multi-component system is used to control and monitor the functions of the machine. This system consists of the following main components: ■

Machine controller

■

Power supply

■

Input/Output (I/O) modules

■

Radio remote

■

Graphics display

The following information is presented as a general guide to the capabilities and functions of the control system. Before attempting to operate, service, or troubleshoot the continuous miner, training must be completed. machine controller

power supply

input/output modules

The machine controller is the main control unit of the system. It includes the radio data controller which is used to receive and decode commands from the radio remote.

The control system has its own power supply, with the option of having battery backup for the power supply, which provides power to the machine controller and I/O modules.

Input/Output modules are used to read data from and/or send commands to the following machine functions: ■

Cutter motors (left and right)

■

Gathering head motors (left and right)

■

Traction motors (left and right)

■

Pump motor

■

Hydraulic oil level

■

Methane monitoring

Based on the parameter settings and the input received from different components, the control systems has the ability to issue error messages, fault messages, and/or shutdown the machine.

________________________________________________________________ 5.10 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

______________________________________________________ Operation radio remote

The radio remote (Fig. 13) is a battery powered remote used to control the continuous miner during normal operations.

WARNING! Radio remote control systems are dangerous. The continuous miner operator cannot operate a remote system until he is properly trained in the operation of the system. Remote control systems sometimes have automatic features of which untrained operators and workers may not be aware.

Fig. 13: Radio remote (typical)

The radio remote shown may vary from the radio remote that shipped with your machine.

IMPORTANT! Refer to the radio remote control operation manual supplied with your machine for information regarding the operation of your specific remote control.

______________________________________________________________ A6474X347 REV 06 5.11

BI016954-06 (EN-US)

Operation _______________________________________________________ There is a graphics display located at the operator’s case located near the back right hand side of the machine (Fig. 14). This screen is used to display diagnostic information on the miner.

Fig. 14: Control system display locations (typical)

Graphics display

displays

The graphics display, located on the operator’s case, is used to monitor machine operating parameters, for diagnosing error and fault codes, and for input of operating parameters.

There are different screens that can be displayed: production monitoring, function monitoring, diagnostic, motor hours, and fault pages. A system halt message can appear as a pop-up dialog box in the middle of any screen. A message will appear when a critical conditions has occurred that prevents continued operation of the machine in a safe manner. The message box cannot be cleared and it is necessary to recycle power to the control system to restore machine operation.

Normal display pages The main diagnostic screen (Fig. 15) is displayed during normal remote control operation of the machine. The screen presents real time diagnostic and performance information.

________________________________________________________________ 5.12 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

______________________________________________________ Operation Fig. 15: Main page, example

Graphics display

______________________________________________________________ A6474X347 REV 06 5.13

BI016954-06 (EN-US)

Operation _______________________________________________________ System Menu The control system provides information, diagnostic, and setup screens that are grouped together in the system menu (Fig. 16). The system menu is accessed by using either display module and a remote control handset.

To access and navigate the system menu using the radio remote:  Press the SHIFT and MENU key to access the system menu screen.

IMPORTANT! All functions and motors are shut down and disable when the system menu is selected.  Press CONV UP or CONV DOWN to move the cursor up and down the list.  Press SHIFT and MENU to select the highlighted item  To leave the menu and return to remote mode, press SHIFT and REMOTE. Fig. 16: System menu, example

________________________________________________________________ 5.14 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

______________________________________________________ Operation Diagnostic Mode Diagnostic mode allows a large number of monitoring screens to be selected and displayed while the machine is operating. Each screen provides helpful troubleshooting information such as machine information, software revision, and machine configuration. It also provides the status of the motors, digital and analog inputs, etc. Diagnostic mode is for informational purposes only. No configuration changes can be made within this mode.

To navigate through the screens, hold the SHIFT switch while pressing a conveyor switch. To return to the main menu, press SHIFT and MENU. Graphics diagnostics includes the following pages: ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■

Main monitor Production monitor Pump monitor Cutter monitor Conveyor monitor I/O monitor - relay outputs I/O monitor - digital inputs I/O monitor - analog outputs Solenoid modules Thermistor monitor Motor mate network monitor

See Fig. 17 for example screen shots of various diagnostic pages.

______________________________________________________________ A6474X347 REV 06 5.15

BI016954-06 (EN-US)

Operation _______________________________________________________ Fig. 17: Graphics display diagnostic pages, examples

________________________________________________________________ 5.16 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

______________________________________________________ Operation Fig. 17: Graphics display diagnostic pages, examples, continued

______________________________________________________________ A6474X347 REV 06 5.17

BI016954-06 (EN-US)

Operation _______________________________________________________ Fault log The fault log (Fig. 18) allows the user to view the last 100 faults that have occurred since the log was last cleared.

To navigate the fault log page:  Press the CONV UP or CONV DOWN key to move the cursor up or down the page.  Press SHIFT and CONV UP or CONV DOWN move up or down one page.

It is possible to clear the fault log under the Engineering Setup Menu, which is password protected.

IMPORTANT! It is not recommended that the fault log be cleared unless the machine controller has been replaced. Retaining the faults is very helpful in troubleshooting a problem when a controller is sent for service. Faults cannot be retrieved once they have been cleared.

Use caution and only clear the log if it is absolutely necessary.

Once a fault has been selected, the SHIFT and MENU keys can be used to access more information on the fault (Fig. 19).

Fig 18: Fault log, example

________________________________________________________________ 5.18 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

______________________________________________________ Operation Once a fault has been selected, the SHIFT and MENU keys can be used to access more information on the fault (Fig. 19).

Fig. 19: Fault detailed information, example

For a complete list of faults, see the troubleshooting section of this chapter.

______________________________________________________________ A6474X347 REV 06 5.19

BI016954-06 (EN-US)

Operation _______________________________________________________ Hour meters Selecting hour meters (Fig. 20) from the Main Menu will display runtime for the following motors: pump, fan, left cutter, right cutter, and conveyor. Time is displayed in hours:minutes:seconds format. This runtime only reflects accumulated time since the controller has been installed or since the counter was last reset. The hour meters can be cleared under the Engineering Setup Menu, which is password protected.

IMPORTANT! The hours meters should only be cleared when a motor is replaced or when the machine controller is installed. To keep an accurate log of a motor’s total hours, the information should be recorded anytime data is cleared.

Fig. 20: Hour meters, examples

________________________________________________________________ 5.20 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

______________________________________________________ Operation Tram pendant

The machine can be operated using a pendant control (Fig. 21) connected to the miner by an umbilical cable. This control is used in the event that the operator loses radio link with the mine to safely recover the miner from the face to an area under supported roof for troubleshooting and maintenance.

The pendant controller allows limited operation of the machine: tramming and pump motor activation to provide hydraulic power to raise or lower the cutting head.

In order to use the pendant, it must be connected to the machine via a pigtail. After plugging in the umbilical cord, the “MACHINE” mode of operation switch must be rotated to the “E-TRAM”.

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

Fig. 21: Tram pendant

______________________________________________________________ A6474X347 REV 06 5.21

BI016954-06 (EN-US)

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

Most significantly, the operator’s greatest danger is from his Continuous Miner, especially when he is maneuvering it during mining operations.

The miner is capable of slewing when turning, especially when the crawlers are split. The discharge conveyor can also swing. In each of these cases, the miner operator is in danger of being hit, or worse yet, run over by his own machine. Equally dangerous is the possibility of the operator being pinned against the rib by his own miner.

Miner operator danger areas, or Red zones Some typical situations dangerous to the miner operator are illustrated on the following pages. The danger area, or red zone (Fig. 22) is indicated by alternating red and white diagonal stripes.

Fig. 22: Red zone

________________________________________________________________ 5.22 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

______________________________________________________ Operation Tramming the miner (Fig. 23) from one place to another, especially maneuvering around intersections. This illustrates that the operator should not place himself between his miner and the rib.

Beginning the first sump (Fig. 23) in a new cut. The miner is against the left rib and the discharge conveyor is swung toward the center of the entry ready for the haulage car. The operator must stay clear of the discharge conveyor and the rear of the miner.

Fig. 23: Red zones

Tramming the miner red zone

Beginning 1st sump red zone

Sumping in the left hand side of the cut (Fig. 24). As the miner penetrates the face, new unsupported roof is being exposed, and the operator now has an additional constraint to his movements. He must also stay clear of the haulage vehicle at the rear of the miner as it approaches the miner and while it is loading.

Repositioning the miner for the right hand cut (Fig. 24). Because the miner is backing out and turning in close quarters, the operator must stay behind the miner to be safe.

Sumping in the right hand cut (Fig. 24). Again, the operator must stay away from the face where the newly-exposed roof is unsupported, as well as staying clear of the haulage vehicle while it approaches and loads.

______________________________________________________________ A6474X347 REV 06 5.23

BI016954-06 (EN-US)

Operation _______________________________________________________

Fig. 24: Red zones

Sumping on the left hand side red zone

Repositioning miner for right hand cut red zone

Sumping in the right hand cut red zone

________________________________________________________________ 5.24 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

______________________________________________________ Operation Crosscut red zones (Fig. 25). Beginning and completing crosscuts requires a lot of maneuvering of the miner and loading the haulage vehicle while at awkward positions. Crosscuts also result in newlyexposed unsupported roof. Respecting a red danger zone is important to operator safety in these conditions.

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

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

Fig. 25: Crosscut red zones

Beginning a right hand crosscut red zone

Right hand crosscut development

______________________________________________________________ A6474X347 REV 06 5.25

BI016954-06 (EN-US)

Operation _______________________________________________________ Pillaring red zones (Fig. 26) Remote control offers a significant safety advantage in partial or complete removal of the pillars in retreat mining because it places the operator further away from potential collapsing roof.

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

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

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

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

Fig. 26: Pillaring red zones

Pillaring in a left hand cut red zone

Pillaring in a end cut red zone

Pillaring in a right hand cut red zone

________________________________________________________________ 5.26 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

______________________________________________________ Operation Safety precautions for underground operation In addition to the preceding instructions for operating the Continuous Miner, observe the following special precautions after the Continuous Miner is taken underground.

■

Communication is a key element in maintaining safety. Exact instructions and warnings should be given to, and thoroughly understood by each workman. Good communications between the entire crew must be maintained throughout the shift.

■

Check the condition of the trailing cable before turning power on at the power source.

■

This machine must be maintained in a permissible condition, following all state and federal laws.

■

Make a visual check of the Continuous Miner before energizing.

Look for loose bolts, covers, locking devices, damaged parts, and cracked or broken lenses. Any part of the machine which does not function properly is a hazard. Report it immediately to your immediate supervisor or their designee.

■

Prior to operation, make sure the working area is safe. Make a visual inspection of roof and ribs and take all steps necessary to insure safety.

Tramming safety rules ■

Communicate your intentions to the workmen affected by the movement of the Continuous Miner.

■

Check the position of the water hose and trailing cable to be sure there is sufficient slack to finish the operation.

■

Note the condition of the roadways and physical surroundings of the route.

■

Position the cutter and gathering head for tramming.

■

Position the stabilizer shoe and booms for tramming.

■

Position your body completely inside the operator's compartment (optional), facing the intended direction of travel.

■

Position the Continuous Miner in the center of the road way to allow maximum safe clearance. Consistently maintain clearance, which is critical to the safe movement of the Continuous Miner.

______________________________________________________________ A6474X347 REV 06 5.27

BI016954-06 (EN-US)

Operation _______________________________________________________ Starting procedure WARNING! Failure to read and understand all operating instructions before starting the Continuous Miner could result in serious injury or death to the operator or persons around the machine or cause damage to the machine.

WARNING! Read all instructions carefully before attempting to start or operate machine.

WARNING! Understand the functions of all controls before starting the Continuous Miner. Read and follow the instructions on all warning tags on the machine, observe all regulations and safety precautions .

WARNING! Never operate a Continuous Miner which has been damaged or is not operating properly. Any part of the Continuous Miner which does not function properly can be a hazard. Report it immediately to your supervisor or their designee.

WARNING! Before starting the Continuous Miner, make sure that no one is in the red zone (Fig. 22 through Fig. 26).

NOTICE! In extremely cold weather, allow motors and gear cases to idle.

This will warm the hydraulic oils and lubricants. Still oils and greases could immobilize the machine.

IMPORTANT! A pump “growl” means not enough oil is reaching the pumps through the suction lines. Ensure the pump gets primed before continuing operation. Always check the oil level.

DANGER! Improper position could result in injury or death to the operator by crushing him against the rib or roof supports. It may also cause him to run over the trailing cable or dislodge the roof supports.

WARNING! Turning on the water sprays prior to cutting prevents the accumulation of dust and the generation of excessive heat which could cause an ignition or explosion.

________________________________________________________________ 5.28 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

______________________________________________________ Operation After reading the previous descriptions and locating each control, the operator is ready to operate the Continuous Miner. An experienced operator should monitor a new operator’s indoctrination to the starting procedure.

The Continuous Miner is typically operated by radio remote control.

Manual operation is not allowed for production operation unless the miner has an operator’s pit and canopy. Manual operation generally is for troubleshooting and maintenance under roof support.

WARNING! The Continuous Miner is typically operated by radio remote control. Manual operation is not allowed for production operation unless the miner has an operator’s pit and canopy. Manual operation generally is for troubleshooting and maintenance under roof support.

The operating procedures listed in the following sections are for radio operation.

IMPORTANT! Before start-up, check that daily maintenance has been performed on the machine.

WARNING! Visually check for other personnel and verbally shout a warning before starting this machine. Make sure all personnel are completely clear of the machine and it’s components and check that any loose material, tools, oil cans or other objects are clear from the area before starting the machine.  Turn the main circuit breaker to the “ON” position.  Turn the operator switch to remote mode.  Turn the power switch on the radio remote to the on position.  Press “SHIFT” and wait 1/4 second.  While pressing “SHIFT”, press “PUMP ON”. Hold both keys in until the pump starts.  Release the “PUMP ON” key.

IMPORTANT! The “PUMP ON” key must be released before “SHIFT”. If “SHIFT” is released first, the pump motor will shut off.  Release the “SHIFT” key.

______________________________________________________________ A6474X347 REV 06 5.29

BI016954-06 (EN-US)

Operation _______________________________________________________ Shutdown procedure The Continuous Miner must be properly shutdown before leaving the area or before performing any maintenance or service. Some maintenance or service procedures may require additional steps to insure the safety of the maintenance personnel working on or around the machine and will be listed in the maintenance section of this guide.  Back the miner about one foot from the face providing sufficient clearance and shut off the cutter head motors (see Cutter operation in this section).  Tram the miner to an area of well supported roof. Park the machine in its designated parking area out of traffic, on flat, solid ground. If it is not possible to park the machine on flat ground, park the machine at a right angle to the slope.

WARNING! After turning off the power to the machine, never walk away and leave the remote turned on. Failure to turn the remote off could result in an accident causing serious injury or loss of life.  Empty the conveyor and shut it off (see Conveyor operation in this chapter).  Lower the cutter head to the floor.  Lower the conveyor and gathering head.  Press and hold the “PUMP OFF” key. The pump motor should shutdown immediately.  Release the “PUMP OFF” key.  Turn off the water sprays.  Position all levers and controls to Neutral or Off.  Shut off the main power supply.  Shut off the mine water supply.

________________________________________________________________ 5.30 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

______________________________________________________ Operation Tramming the miner Tramming requires cooling water to prevent damage.

NOTICE! The Continuous Miner has skid type steering: it is capable of turning within its own limits.

WARNING! Tramming requires cooling water to the tram motors. Failure to cool the motors will result in motor damage and premature failure.  Ensure that the stabilizer shoe is away from the mine floor.  Raise cutter boom to best possible position to allow clearance from roof, ribs, and floor.  Raise gathering head away from the mine floor.  Adjust conveyor boom to best possible position to allow clearance from roof, walls, and floor.

WARNING! Adjust conveyor boom to allow clearance from roof, walls, and floor. Failure to do so will result in damage to the conveyor boom.  Ensure adequate clearance at all times while tramming machine.

Be award of people, equipment, and cables.

Remote control - tram enable  To enable machine tramming, press and release the “TRAM 2-3” key.  Once enabled, the tram levers can be used to drive left and right tramming tracks forwards and backwards. If the tram levers are released for a continuous period of five (5) seconds, the tram becomes disabled.  To re-enable the tram function, press and release the “TRAM 2-3” key.

Remote control - tram track console  Press the “LEFT FWD” tram key to turn the left tramming track forward.  Press the “LEFT REV” tram key to turn the left tramming track backwards.  Press the “RIGHT FWD” tram key to turn the right tramming track forward.  Press the “RIGHT REV” tram key to turn the right tramming track backwards.

______________________________________________________________ A6474X347 REV 06 5.31

BI016954-06 (EN-US)

Operation _______________________________________________________ Remote console - tram speed control The system allows the tramming to be driven in three discrete speeds (SPEED 1, SPEED 2, and SPEED 3). SPEED 1 is the default tramming speed.

To advance a speed:  Press the tram levers and “TRAM 2-3” keys together to move from SPEED 1 to SPEED 2.  Once in SPEED 2, press the tram levers and “TRAM 2-3” together to move from SPEED 2 to SPEED 3.

The following tramming configurations are enforced by the control system for safety reasons: ■

Spilt track tramming is limited to SPEED 1.

■

Single track tramming is normally limited to SPEED 1.

■

It is possible to speed up a single track from SPEED 1 to SPEED 2 providing that tramming is started in SPEED 1.

■

Tramming is limited to SPEED 1 while the cutters are on.

■

While the cutters are running, reverse speed can be incremented even while the forward tram keys are being pressed. Note that this option is used when the miner is retreating or pillar mining.

________________________________________________________________ 5.32 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

______________________________________________________ Operation Cutter head operation To start the cutter motors  Ensure that the cutter head is not in contact with anything. Cutter head motors must never be started under a load.

WARNING! Never start cutter head motors under a load. Starting motors under load may result in motor damage or premature failure.  Warn “ALL CLEAR” before starting the cutter head.

WARNING! Warn “ALL CLEAR” before starting the cutter head. Failure to do so may result in serious injury or death.  Ensure that the pump motor is running. The cutter motors will not run if the pump motor is not running.  Press “SHIFT” and wait 1/4 second.  While holding in “SHIFT”, press “CUTTER ON”. Continue to hold both keys in until the cutter motors turn on.

IMPORTANT! Both cutter motors do not start at the same time. There is a preset timed delay between the left cutter motor starting and the right cutter motor starting.  Release the “CUTTER ON” key.

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

To stop the cutter motors  Press and hold the “CUTTER OFF” key. The cutter motors should shutdown immediately.  Release the “CUTTER OFF” key.

______________________________________________________________ A6474X347 REV 06 5.33

BI016954-06 (EN-US)

Operation _______________________________________________________ Conveyor operation To start the conveyor motors in forward  Place conveyor boom in desired position.  Warn “ALL CLEAR” before starting the conveyor.

WARNING! Warn “ALL CLEAR” before starting the conveyor. Failure to do so may result in serious injury or death.  Ensure that the pump motor is running. The conveyor motors will not start if the pump motor is not running.  Press “SHIFT” and wait 1/4 second.  While holding in “SHIFT”, press “CONV ON”. Continue to hold until the conveyor motor turns on and the conveyor starts to run forward.  Release the “CONV ON” key.

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

To stop the conveyor motors - conveyor forward  Press and hold the “CONV OFF” key. The conveyor motors should shutdown immediately.

To start the conveyor motors in reverse (momentary only)  Place conveyor boom in desired position.  Warn “ALL CLEAR” before starting the conveyor.

WARNING! Warn “ALL CLEAR” before starting the conveyor. Failure to do so may result in serious injury or death.  Ensure that the pump motor is running. The conveyor motors will not start if the pump motor is not running.  Press “SHIFT” and wait 1/4 second.  While holding in “SHIFT”, press “CONV REV”. Continue to hold until the conveyor motor turns on and the conveyor starts to run in reverse.  The conveyor will continue to run in reverse until the “CONV REV” or the “SHIFT” key is released.

________________________________________________________________ 5.34 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

______________________________________________________ Operation Scrubber motor To start the scrubber fan motor  Ensure that the pump motor is running. The scrubber motor will not start if the pump motor is not running.  Press “SHIFT” and wait 1/4 second.  While holding shift, press “FAN ON”. Continue to hold until the scrubber fan motor turns on.  Release the “FAN ON” key.

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

To stop the scrubber fan motor  Press and hold the “FAN OFF” key. The fan motor will shutdown immediately.  Release the “FAN OFF” key.

______________________________________________________________ A6474X347 REV 06 5.35

BI016954-06 (EN-US)

Operation _______________________________________________________ Control headlights and area lights The light switch has three positions: manual, off & radio. When the power is turned on to the continuous miner, the methane monitor relay is closed and the light switch is off. When the light switch is turned to the manual position, the headlights and the area lights will come on.

When the light switch is turned to the radio position, the headlights only (not the area lights) can be turned on and off with the radio.

The headlights can be turned off and on from the remote console at any time that the light switch is in remote position and the remote console is on by:  Press the “SHIFT” and “LIGHTS” keys together to turn the lights on.  Press the “SHIFT” and “LIGHTS” keys together to turn the lights off.

See the operation manual for the radio remote that shipped with your machine for options.

________________________________________________________________ 5.36 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

______________________________________________________ Operation Fire suppression in radio remote The control system uses a solenoid output to drive the fire suppression system on the continuous miner. The fire suppression can be activated at any time from the remote control console. If the machine is fitted with the battery backup version of the power supply, the fire suppression can also be activated in battery standby mode. The system will remain in battery standby mode for at least ten minutes after loss of main power to the machine.

When in radio mode, the fire suppression can be activated from the radio as follows:  Press the “SHIFT” and “FIRE” keys at the same time and hold for two (2) full seconds.  After two seconds, the fire suppression system will activate. At this time, the “SHIFT” and “FIRE” keys can be released.

See the operation manual for the radio remote that shipped with your machine for options.

______________________________________________________________ A6474X347 REV 06 5.37

BI016954-06 (EN-US)

Operation _______________________________________________________ Shear up/down in radio remote The pump motor must be running in order to raise or lower the cutter head.  Press “SHEAR UP” to move the cutter head up. The shear up solenoid remains energized until the key is released (unless height limiting is in force).  Press “SHEAR DOWN” to move the cutter head down. The shear down solenoid remains energized until the key is released.

See the operation manual for the radio remote that shipped with your machine for options.

Gathering head raise/float in radio remote The pump motor must be running in order to raise or lower the gathering head.  Press “PAN UP” to lift the gathering head. The pan up solenoid remains energized until the key is released.  Press “PAN FLOAT” to “float” the head down.

See the operation manual for the radio remote that shipped with your machine for options.

Stabilizer (stab) cylinder raise/lower in radio remote The pump motor must be running in order to raise or lower the stabilizer cylinder.  Press “STAB UP” to raise the stabilizer cylinder. The stabilizer cylinder solenoid remains energized until the key is released.  Press “STAB DOWN” to lower the stabilizer cylinder. The stabilizer cylinder down solenoid remains on until the key is released.

See the operation manual for the radio remote that shipped with your machine for options.

________________________________________________________________ 5.38 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

______________________________________________________ Operation Conveyor raise/lower and left/right in radio remote The pump motor must be running in order to control the conveyor raise, lower, and swing left/right.

To control the conveyor from the radio remote:  Press the “CONVEYOR LEFT” key then the “CONVEYOR OFF” key to the left to swing the conveyor tail to the left. The solenoid controlling the left conveyor swing will remain energized until the key is released.  Press the “CONVEYOR RIGHT” key then the “CONVEYOR OFF” key to the right to swing the conveyor tail to the left. The solenoid controlling the right conveyor swing will remain energized until the key is released.  Press the “CONVEYOR DWN” key then the “CONVEYOR OFF” key to lower the conveyor boom. The solenoid controlling the conveyor lower function will remain energized until the key is released.  Press the “CONVEYOR UP” key then the “CONVEYOR OFF” key to raise the conveyor boom. The solenoid controlling the conveyor raise function will remain energized until the key is released.

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

______________________________________________________________ A6474X347 REV 06 5.39

BI016954-06 (EN-US)

Operation _______________________________________________________ Breaker “ON”/”OFF” in radio remote The control system allows the main circuit breaker on the miner to be turned on and off using the radio remote control console. This normally requires that a battery backup version of the power supply be installed on the machine.

To turn the breaker off  Press and hold the “SHIFT” and “C.B. OFF” keys together for two (2) seconds. After two (2) seconds, the breaker off solenoid will energize, turning off the machine circuit breaker.

To turn the breaker on It is essential that a battery backup version of the control system power supply be installed for this function to be available. Typically, a hydraulic valve provides the mechanical force for the breaker mechanism. To allow this valve to be operated after loss of power, a hydraulic accumulator is charged by the pump motor during normal “powered” operation of the machine. If the hydraulic accumulator is discharged, then it will not be possible for the breaker to be turned on from the remote control.  Press and hold the “SHIFT” and “C.B. ON” keys together for two (2) seconds. After two (2) seconds, the breaker on solenoid will energize, turning on the machine circuit breaker.

See the operation manual for the radio remote that shipped with your machine for options.

IMPORTANT! The backup accumulator must maintain a minimum pressure of 500 psi for 12 minutes after the pump has been de-energized.

________________________________________________________________ 5.40 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

______________________________________________________ Operation Typical cutting sequence CAUTION! Always ensure operator safety while operating the machine.

CAUTION! Always be alert to hazardous conditions and take corrective action as necessary.

IMPORTANT! Care should be taken not to stall cutters on conveyor during cutting operations. Severe damage to motors and gear boxes could occur if cutters or conveyor are repeatedly stalled.  Place gathering head in the float position.  Position conveyor so it doesn't hit the roof, walls, other equipment or any other obstacle. Never operate the conveyor in its fully limited position, right left, up, or down. If in the fully limited position and contacting any obstacle, damage could occur.  Start the gathering head and conveyor. Do not start machine in face or with excessive material in the gathering head.  Engage tram and adjust for speed and direction.  Start cutter head prior to contacting area to cut.  Raise cutter head to desired mining height.  Lower the rear stabilizer to the floor to provide stability if necessary.

Do not lower the shoe enough to raise the rear of the machine. If the shoe is lowered too far the machine will not sump into the face properly.  Engage tram in the forward position.

IMPORTANT! Tram is limited in the forward direction while the cutters are running with the cutter head feedback circuit. As the cutter head begins to cut the material from the face, the sump speed will automatically slow the tram down to prevent over sumping the machine.  Continue to sump until the machine stops tramming. The depth of the sump will depend on the type of material being cut, the diameter of the cutter drum, and bit lacing.  Release tram levers.  Shear down (lower cutter head). The shear down rate is controlled by a shear down relief valve to limit the hydraulic pressure being applied to the cylinders. This is an adjustable feature and can be easily changed as mining conditions change.

______________________________________________________________ A6474X347 REV 06 5.41

BI016954-06 (EN-US)

Operation _______________________________________________________  To maintain smooth level floor conditions, it may be necessary to tram the machine backward approximately 36 in., thus trimming ridges and smoothing the floor. This may or may not be necessary each cut sequence depending on mine conditions.  Repeat this procedure to desired depth of cut.  Turning crosscuts is accomplished by making a series of partial ] cuts (sumps) until the machine can be turned to the desired angle.

Relocating the miner  Ensure rear stabilizer is raised from the floor.  Position cutter boom so as to prevent it from hitting roof, ribs, or floor.  Raise gathering head.  Lower conveyor boom down and position so it will not hit roof, ribs, floor or any other equipment or obstacles.  Ensure that trailing cable out of the path of travel.  Ensure there is enough clearance when relocating to avoid damage to machine and ensure operator safety.  Be alert to any people, obstacles, or other machines.  Know the position of fellow workers.  Engage tram in desired direction.

________________________________________________________________ 5.42 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

___________________________________________ Mechanical assemblies Mechanical assemblies The following pages contain a brief description of the major mechanical assemblies that are on the Continuous Miner.

WARNING! This section is intended to familiarize the user with the major mechanical assemblies of the Continuous Miner. All mechanical maintenance should be performed by a qualified technician with the knowledge of the function of the assemblies involved.

Cutter head The Continuous Miner has a rotary, drum type cutter head with bit blocks arranged spirally on a set of cylindrical drums (Fig. 28) that direct the cut material to the center of the gathering head mechanism.

The cutter head has a heavy-duty gear-drive cutting system. There are no cutting chains on the cutter head assemblies.

With the bits installed, the cutter head has a cutting diameter that varies per specification. The width of the cutter head and cutter motor horse power varies per model specification. The AC electric motors are mounted on each side of the cutter head support frame. A torque shaft through the center of the motor drives an input gear case that is mounted to the support frame. From the input gear case, a shaft is gear driven to the cutter head gear case in the drum. This main gear case on each side of center is driven by the cutter head shaft and removes material from the face to provide clearance for the cutter head gear case on that side of the miner.

Cutting power is transferred through a series of bevel gears. A torque shaft from the clutch (through the center of the motor) drives an input gear case that is mounted to the support frame.

The operator controls the height of the cutter head by controlling two double-acting cylinders through hydraulic control valves. Cutter head height reach and speed of cutter head rotation varies per model specification (See Technical Data Chapter 6 for specifications).

The fixed-drum cutter head hinges directly to the machine chassis at its own pivot point at the back of the cutter boom frame.

______________________________________________________________ A6474X347 REV 06 5.43

BI016954-06 (EN-US)

Mechanical assemblies ____________________________________________ Fig. 27: Cutter head (without bits installed)

Carbide bits and bit blocks The carbide-tipped cutter bits are mounted into holders called bit blocks (Fig. 28). While a variety of bit and bit block designs are available to meet light, tough, or average mining conditions, all are designed to absorb vibration to maintain cutter efficiency. The conical bits also rotate as they cut to produce a self-sharpening effect. The bits and blocks may be deployed around the drum in different bit lacing patterns to give the best performance under different conditions.

IMPORTANT! Inspection of the bits and bit blocks before the start of each shift will reduce later problems. Mining with dull, bent or broken bit blocks increases dust and noise levels, as well as putting excesFig. 28: Cutter bit and bit blocks

Bit block

Cutter bit

________________________________________________________________ 5.44 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

___________________________________________ Mechanical assemblies Conveyor chain The miner is equipped with a conveyor chain assembly that runs through the center of the miner and transports the mined material from the gathering head to the rear of the miner for haulage at a high loading rate compatible with the miner’s cutting output. The conveyor chain (Fig. 29) is made up of one basic chain assembly which repeats sequentially along the entire chain loop (see Maintenance section in this chapter for Conveyor chain maintenance).

Fig. 29: Conveyor chain

Conveyor tail section The conveyor pivots on the main frame behind and just below the cutter head pivot. Two single acting hydraulic cylinders permit the operator to raise the conveyor discharge end to a maximum height and clearance varying per machine or to lower the discharge end of the conveyor to a specific ground clearance.

A double-acting hydraulic cylinder on the left side of the conveyor (right for attached haulage) permits the discharge end to swing 45 degrees left or right of the conveyor centerline. The range in height and swing of the conveyor with an overhang permits the conveyor to accommodate any haulage vehicle.

Two AC electric motors drive through the gathering head gear cases to a foot shaft sprocket to propel the conveyor chain.

Fig. 30: Conveyor tail section

Conveyor tail section

______________________________________________________________ A6474X347 REV 06 5.45

BI016954-06 (EN-US)

Mechanical assemblies ____________________________________________ gathering head and continuous loading arms (CLAs)

The gathering head (Fig. 31) loads the material that is mined by the cutter head assembly onto the conveyor for transport to the rear of the machine. The gathering head assembly consists of a gathering pan and two continuous loading arms (CLAs), each driven by a bevel gear case (or pot). Each CLA has 3 to 6 fingers, or blade fan-type rotating assemblies. The CLA’s are driven by rotary drive shafts in their respective gear cases. The CLA’s gather and force the cut material into the conveyor throat and onto the moving conveyor flights.

The AC motors that drive both the conveyor and the gathering head are located on each side of the gathering head assembly. Through each motor lies a specially-constructed torque shaft that extends across the rear of the gathering head frame into a heavy duty input gear case on that side driving the bevel gear input shaft to it.

The input gear cases contain bevel and helical gears that drive each main gear case (pot). These in turn drive the CLAs and the foot shaft at the base of the conveyor. The foot shaft extends across the gathering pan from the right gear case to the left gear case and has a sturdy 4 or 5 tooth sprocket at its center to drive the conveyor chain. The left gear case drives the left CLA and the right gear case drives the right CLA. Together, they both drive the foot shaft.

The gathering head pivot is below and in front of the cutter head pivot.

Two hydraulic cylinders raise and lower the gathering head in response to the operator’s controls.

Fig 31: Gathering head and continuous loading arms (CLA’s)

Conveyor Gathering head cylinder (2) (located behind cover) CLA (2)

________________________________________________________________ 5.46 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

___________________________________________ Mechanical assemblies Traction system The Continuous Miner is trammed by two individually controlled traction systems (Fig. 32). Each traction assembly has an electric motor connected to a tram drive gear case. The gear case encloses a bevel gear that drives a planetary sun gear. The gear case reduces the rotation speed, increases torque, and provides a right-angle drive to the drive sprocket.

The drive sprocket is directly connected to a tram drive planetary gear case. This gear case reduces the rotation speed, increases torque, and drives the track belt. (See the Maintenance section in this chapter for track belt adjustment procedures and Traction assembly maintenance procedures.)

There are three (3) tram speeds: 1st, 2nd, and 3rd. The speeds are selected from the radio remote.

Fig. 32: Traction system

Traction case

Track belt

______________________________________________________________ A6474X347 REV 06 5.47

BI016954-06 (EN-US)

Mechanical assemblies ____________________________________________ tractor frame/chassis tractor (main frame)

The tractor frame (Fig. 33) is a rectangular structure of high-strength steel weldments that supports major operating assemblies such as the cutter head frame, gathering head frame, conveyor and traction units. It houses supporting assemblies, the crawler and take-up mechanisms and planetary gear cases. It anchors the pivots for the conveyor, the gathering head, and the cutter head frame. The clevises for the hydraulic cylinders actuating these assemblies are also on the main/tractor frame. The frame also provides a platform for electrical and hydraulic control modules, all water controls and plumbing and the optional operator’s control compartment. Integral within the frame is the hydraulic reservoir or oil tank.

Fig. 33: Main frame/tractor frame

stabilizer shoe

A stabilizer shoe (Fig. 34), located beneath and at the rear of the tractor frame, may be lowered to anchor the back end of the machine and provides a greater downward thrust of the cutter head for hard-cutting while preventing backward creep of the miner. The stabilizer shoe is raised and lowered hydraulically by a double acting cylinder that moves the shoe bracket up or down.

Fig. 34: Stabilizer shoe

Stabilizer shoe

________________________________________________________________ 5.48 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

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

Figure 35 gives a layout overview of hydraulic cylinders located on the 25M3 (CM240) Continuous Miner. Figure 36 shows the location of other hydraulic components.

This section gives general descriptions of the hydraulic components used on the miner along with typical schematics for hydraulic functions.

The schematics in this section are general; always refer to the hydraulic schematic in the parts manual supplied with your machine.

Operation considerations In order for a hydraulic system to function correctly, it must be properly maintained. Maintenance of the hydraulic system includes: ■

maintaining atmospheric pressure in the tank by keeping the breather clean and free of obstructions;

■

maintaining a sufficient oil level in the tank;

■

maintaining tight, leak-proof pump suction lines to prohibit air being pumped through the system; and

■

changing filters and fluids at prescribed intervals.

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

For complete maintenance procedures, see the Maintenance section in this chapter.

______________________________________________________________ A6474X347 REV 06 5.49

BI016954-06 (EN-US)

Hydraulic _______________________________________________________ Fig. 35: Cylinder locations

Cutter head raise cylinder

Gathering head raise cylinder

Conveyor lift cylinder

Stabilizer shoe cylinder

Cutter head raise cylinder

Gathering head raise cylinder

Gathering head cylinder

Cutter head raise cylinder

Conveyor lift cylinder

Stabilizer shoe cylinder

Conveyor lift cylinder

Stabilizer shoe cylinder

Conveyor swing cylinder

Conveyor chain take-up cylinder (optional)

Conveyor swing cylinder Conveyor chain take-up cylinder (optional)

Conveyor chain take-up cylinder (optional)

________________________________________________________________ 5.50 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

______________________________________________________ Hydraulic Fig. 36: Hydraulic component location

Pilot pressure reducing valve Pressure gauge, 0-4000 Anti-chatter/maintenance valve 3/4” flow control valve

Main control valve

1” jet pump 1/2” ball valve

Accumulator/brake Circuit sequence valve 3-way brake valves 3/8” check valve Pilot pressure manifold Brake release solenoids Breaker reset solenoids

Multi-gauge manifold Conveyor chain take-up valve Gathering head float valve Relief valve Pilot pressure filter Return filter (3 and 10 micron replacement elements) Main auxiliary breaker cylinder 2 unit valve solenoid 3 unit valve solenoid

Hydraulic pump Accumulator SAE-6 control valve

______________________________________________________________ A6474X347 REV 06 5.51

BI016954-06 (EN-US)

Hydraulic _______________________________________________________ Hydraulic system schematics Abbreviations and Symbols Troubleshooting is easier when you can readily read and understand the diagrams and blueprints of a hydraulic network. To do this, you need to know hydraulic symbols.

Graphic symbols denote the type of function a component performs but do not necessarily sh ow i ts s hap e or c ons tr ucti on . T hes e schematic symbols are used to trace the system flow from the reservoir to the actual work being performed and then back to the reservoir.

The symbols used are shown individually with a functional description where needed. The study of these symbols helps in understanding the system and thereby aids in troubleshooting the system.

In a hydraulic schematic, components are represented on a schematic diagram by symbols. Using the hydraulic symbols to trace a circuit will help to define the relationships of the components and circuits. The component symbols are linked together by lines, which represent the hydraulic hoses and pipes on the miner.

A schematic diagram is an illustration which shows the hydraulic relationship of the various components in the circuits. A schematic diagram does not show the physical location of the components.

IMPORTANT! Schematics may vary from one unit to the next. Consult the parts manual for the correct schematic for your machine.

________________________________________________________________ 5.52 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

______________________________________________________ Hydraulic Main Control Valve (MCV) The Main Control Valve (MCV) consists of a series of directional control valves assembled in a row. This row of valves is commonly referred to as a valve bank. The MCV directs fluid flow to perform a specific function of work that transforms hydraulic energy into mechanical energy.

Control may be initiated manually or electrically (through the solenoid pilot valve).

The MCV (Fig. 37) is typically located on the right side of the machine.

Each working section on a control valve has a uniquely designed internal spool. Typically, there are (5) five working sections. Spools may be spring-loaded to return the spool to a preset position (usually neutral) when not held in the required position. When more than one function is activated, those functions will slow down in comparison to operating a single function.

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

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

If the valve sections are separated for any reason, make sure that all reassembled parts are in their proper location and that all mating surfaces are free of burrs and foreign items (paint, dirt, etc.). Assembly stud nuts or screws should be tightened to specified torques. The presence of foreign items between sections or incorrect torqueing of assembly hardware can result in improper operation of the valve due to warping or distortion of the sections. This can cause machine malfunction.

Periodic inspection of spool operation, oil condition, and pressure connections saves time-consuming breakdowns and unnecessary parts replacement.

■

All hydraulic connections must be tight. Loose connections not only allow leakage, but also permit air to be drawn into the system, resulting in noisy and erratic operation.

■

Spools not detented should return to neutral automatically when the control is released. The standard centering spring force is about 12-14 pounds at the handle. If more force is necessary, the spool may be binding, or else control linkage may be faulty.

______________________________________________________________ A6474X347 REV 06 5.53

BI016954-06 (EN-US)

Hydraulic _______________________________________________________ Fig. 37: Main control valve

________________________________________________________________ 5.54 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

______________________________________________________ Hydraulic How to read a hydraulic schematic All valves are shown in the neutral position on the hydraulic schematics.

To follow oil flow through a system, visually imagine the valve spool shifting as shown in Fig. 38.

Fig. 38: Oil flow through a spool

MAIN PRESSURE

PILOT PRESSURE

SOLENOID A

SOLENOID B PORT A IS ACTIVATED BY ENERGIZING SOLENOID A. THE SOLENOID WILL SHIFT THE 3-WAY PILOT VALVE WHICH WILL HYDRAULICALLY SHIFT THE MAIN SPOOL ALLOWING FLOW TO PORT A. SEE FIGURE 2

A (RAISE)

PORT B IS ACTIVATED BY ENERGIZING SOLENOID B. THE SOLENOID WILL SHIFT THE 3-WAY PILOT VALVE WHICH WILL HYDRAULICALLY SHIFT THE MAIN SPOOL ALLOWING FLOW TO PORT A. SEE FIGURE 3

B (LOWER)

TO TANK

FIGURE 1 STABLIZER RAISE/LOWER SECTION OF TYPICAL MAIN CONTROL VALVE. CURRENTLY SHOWN IN NEUTRAL POSITION.

MAIN PRESSURE

PILOT PRESSURE

MAIN PRESSURE

PILOT PRESSURE

SOLENOID A

SOLENOID B

TO TANK

A (RAISE)

A (RAISE)

B (LOWER)

B (LOWER)

TO TANK

FIGURE 2

FIGURE 3

PORT A ACTIVATED

PORT B ACTIVATED

______________________________________________________________ A6474X347 REV 06 5.55

BI016954-06 (EN-US)

Hydraulic _______________________________________________________ accumulator

A bladder accumulator is essentially a fluid pressure storage chamber in which the potential energy of a fluid under pressure can be stored against a compressible force of a gas to do useful work. This stored fluid is readily available to perform a given task when called upon by the requirements of the system in which it is used.

breather

A breather (Fig. 39) permits air to move in and out of the oil tank reservoir to maintain atmospheric pressure.

cylinders

Cylinders (Fig. 39) are bored and honed steel tubes enclosing a piston connected to a rod that extends out the end of the cylinder.

Working surfaces are ground and finely finished, with seals and gaskets incorporated to prevent leakage. Fig. 36 illustrates the location of the hydraulic cylinders on the miner.

A cylinder with pressure applied in only one direction is a single-acting cylinder (e.g. some elevation functions; the weight of the unit maintains pressure on the return). A double-acting cylinder receives input pressure on each side of the piston alternately.

Fig. 39: Accumulator and cylinder hydraulic symbols

Accumulator

Cylinder, single acting with external spring

Breather

Cylinder, single acting

Cylinder, double acting

Cylinder, single acting with dry pocket

Cylinder, double acting with load holding valve with integral atmosphere relief

________________________________________________________________ 5.56 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

______________________________________________________ Hydraulic filters

Filters and strainers are designed to protect a hydraulic oil system from harmful levels of particulate contamination. High levels of contaminants accelerate wear of components, cause improper functioning, and add to system sluggishness. Other problems such as seizure of parts, higher temperatures due to increased fluid friction, leakage, and loss of control may occur. Contamination also contributes to oxidation and chemical breakdown of the fluid.

The primary cause of hydraulic component failure is system contamination. Please see the troubleshooting section in this chapter to better learn how to prevent contamination.

WARNING! Never run the machine without the proper filter elements in place.

Running the machine with incorrect or no filters may result in hydraulic system contamination, machine failure, erratic operation, and injury.

Fig. 40: Filter hydraulic symbols

Filter, bypassing

Filter, non-bypassing

______________________________________________________________ A6474X347 REV 06 5.57

BI016954-06 (EN-US)

Hydraulic _______________________________________________________ flow meter orifice

A flow meter (Fig. 41) is a visual device which indicates the volume of fluid passing through it per unit of time.

An orifice (Fig. 41) is a device that restricts flow.

pressure/return manifold

A pressure manifold (Fig. 41) has one inlet port and many outlet ports to supply flow to many circuits. A return manifold has many inlet ports and only one outlet port for flow to return to tank. Note: You can have the same part number for a pressure or return manifold.

pressure gauge

A pressure gauge (Fig. 41) is a visual device used to indicate the pressure in a hydraulic or water circuit.

pump

The purpose of a pump (Fig. 41) is to produce flow; it does not produce pressure, which is caused by a resistance to flow. All system components have some resistance to flow. The miner is equipped with a multi -section gear-type fixed displacement hydraulic pump assembly. Each section consists of two closely-meshed gears inside a tightly-fitted housing.

pump, jet (Venturi)

The miner may be equipped with optional Venturi jet pumps. These pumps have no moving parts. They are made from a metal tube that narrows over its full length. When liquid passes through the narrowing tube, a vacuum is formed according to the “Venturi” principle. This vacuum is used to draw liquid into or out of reservoirs. See detailed circuit descriptions for more information.

hand pump

The hand valve is a manual, rotary handle pump that moves oil through the hydraulic system.

Fig. 41: Hydraulic symbols

Flow meter

Orifice

Pressure gauge

Pump, hydraulic two stage

Pump, jet

Hand pump

Pressure/return manifold

________________________________________________________________ 5.58 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

______________________________________________________ Hydraulic valves ball valve check valve directional control valve

The hydraulic symbols for the different types of valves are given in Fig. 42.

A valve that checks flow by the seating of a ball. Ball valves are typically operated by hand.

A valve that allows fluid flow in one direction only.

A directional control valve is typically solenoid operated and is used to extend/retract a cylinder.

flow control valve

A valve with a primary function of controlling flow rate.

flow control valve with internal check

A valve with a primary function of controlling flow rate in one direction and allow free flow in opposite direction.

load holding valve

The purpose of the load holding valve is to prevent the accidental lowering of a hydraulic cylinder, whether by sudden or gradual circuit depressurization, either during operation or maintenance. The load holding valve (also called a "load locking valve") may be a pilot-operated check valve, a counterbalance valve, or an overcenter valve.

A load holding valve locks a load in any position without allowing drift. It may provide static overload relief and thermal expansion relief with open-center control valves, as are on the cutter head raise circuit, or be combined with an atmospheric relief, as on the conveyor raise circuit of the miner. Cartridge style valves allow installation directly into the cylinder.

In the event of hydraulic system failure or a deliberate system shutdown (as during maintenance), the absence of pilot pressure to the spring-loaded valve automatically closes off the return line and prevents fluid from leaving the cylinder (and thereby stops the piston from moving). The load holding valve is used on the miner, in conjunction with mechanical blocking, when the cutter head or conveyor must be elevated for extended periods of time so that repairs can be effected beneath.

WARNING! Do not rely on the load holding valve when working under the cutter head or the conveyor. Always block the conveyor or the cutter head if it must be elevated. Serious injury or death may result from not mechanically blocking the load.

An load holding valve is merely a counterbalance valve with a pilot override on the relief valve section. The load raises by free oil flow through the bypass check section. With the control valve centered in NEUTRAL, the load is locked (the relief must be set at least 1.3 times higher than the maximum load induced pressure or system pressure).

______________________________________________________________ A6474X347 REV 06 5.59

BI016954-06 (EN-US)

Hydraulic _______________________________________________________ There is a pilot-operated check valve incorporated in the load holding valve in each conveyor raise/lower cylinder, and a pilot load holding valve attached to each cutter head raise/lower cylinder (for a total of four holding valves). Each one prevents its respective cylinder from lowering its load in the absence of a specific pilot pressure. Pilot pressure is induced only when the LOWER control of that particular function is engaged.

The load holding valves for the conveyor and cutter head incorporate a relief function which bypasses the pilot-operation whenever the pressure setting is exceeded.

There are no adjustments required on the load holding valves.

WARNING! The load holding valves on the cutter head and conveyor cylinders are preset and DO NOT require adjustment. Adjustment of these valve may result in very serious injury or even death.

It is often difficult without actual pressure testing using a gauge to determine failure of any of the four holding valves. When both holding valves in either function fail, be it the conveyor or cutter head raise circuit, the load measurably drifts down over a short period of time when the power to the unit is off. Sometimes this drift down is fast enough to be detected visually.

This drift down can be indicative of other hydraulic problems, especially damaged or worn cylinder packing. If, however, the load holding valves are at fault, do not attempt to adjust the valve (s). Replace the valves while the cutter head or conveyor raise cylinders are completely retracted and the cutter head or conveyor is fully lowered. pressure reducing valve (pressure regulator)

Pressure reducing valves are normally open and are used to maintain reduced pressure in the down stream circuit. Normally actuated by pressure sensed in the down stream circuit, the valve closes as pressure reaches the valve setting, preventing further pressure buildup.

relief valve

A properly set relief valve is a protection device that maintains the safe limit of system pressure in the hydraulic circuit to which it is installed.

When the system pressure rises to the set limit, the relief valve opens, providing a return to the tank until the system pressure returns to the adjusted setting.

________________________________________________________________ 5.60 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

______________________________________________________ Hydraulic There are a number of relief valves in the hydraulic system that are set for individual sub-circuit protection (conveyor elevation, gathering head, etc.). Each pump section also has a main relief valve for protection against over-pressurization. For relief valve adjustment procedures, see the Adjustment section of this chapter. shuttle valve

A shuttle valve has two inlets and one outlet, which allows it to operate a function from either of two sources (never at the same time). For example, a function may be operated from a manual control or by radio control via solenoid.

sequence valve

A sequence valve is used to control the order of operation of two or more hydraulic actuators. The sequence valve pressure is set higher than the first actuator pressure. Once the first actuator has finished its cycle, the second actuator is allowed to move once the sequence valve opens.

needle valve

The needle valve allows uncompensated adjustable flow control through the hydraulic system. The valve serves as a fixed orifice in the hydraulic circuit, and the flow is shutoff when the needle valve is fully closed.

solenoid pilot valve, main control valve (with radio option)

Each section of the main control valve is piloted by a solenoid valve that is mounted on top of that particular section. Reduced pilot pressure is supplied to these 2-way normally closed valves to control the main spool inside the larger working section of the directional control valve. Energizing the solenoid opens the pilot valve to allow the pilot pressure to move the spool in the proper direction to achieve the desired function of the directional control valve.

These 2-way normally closed valves are used to supply reduced pilot pressure that controls a number of functions on the machine. These functions include the control of hydraulically piloted water valves for the Dust/Cooling, Fire, and Scrubber spray system circuits. They are also used to control the Breaker On/ Breaker Off function.

water valve, hydraulic piloted

A valve that is piloted open with hydraulic pressure to allow water to pass through it.

water valve, hydraulic piloted detented

A valve that is piloted open with hydraulic pressure to allow water to pass through it and stays open until manually closed.

______________________________________________________________ A6474X347 REV 06 5.61

BI016954-06 (EN-US)

Hydraulic _______________________________________________________ Fig. 42: Valve hydraulic symbols

Check valve

Ball valve

Conveyor chain take -up valve Directional control valve

Anti-chatter/maintenance valve

Flow control valve with internal check

Gathering head float valve

Out

Pressure reducing valve

In Shuttle valve

Needle valve

Pressure regulator valve

Sequence valve

Relief valve

Solenoid valve 2-unit

Water valve, detent hydraulic operated

Water valve hydraulically piloted

________________________________________________________________ 5.62 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

______________________________________________________ Hydraulic Abbreviations and terms Cavitation: Briefly, cavitation means that air bubbles are forming in the liquid that is being pumped. These bubbles are usually formed in the suction line of a pump when an obstruction causes the suction pressure (which is a vacuum) to go significantly below atmospheric pressure. The actually pressure at which these bubbles forms is dependent on the rank fluid level and the integrity of the seal on the suction line components. When these air bubbles are compressed in the pump gears, they can cause surface pitting, corrosion, and/or erosion.

These bubbles can also coalesce to create erratic operation or water hammer problems.

Closed center circuit: A circuit in which flow through the system is blocked in neutral and pressure at the pump outlet is maintained at the maximum pressure control setting by a relief. Example: the pilot circuit.

Contamination: Any material foreign to hydraulic fluid that has a harmful effect on its performance in a system.

Differential pressure: Pressure measured as the absolute difference between the inlet and outlet pressure of a device.

Fixed displacement pump: A pump in which the displacement per cycle cannot be varied.

GPM (gpm): Gallons per minute (unit of flow per unit of time).

Micron: 1/1000th of a millimeter (0.00003937 inches). The measure used to determine the particle size of contaminants in a fluid system.

Micron rating: The size, in microns, of particles a filter will remove.

PSI (psi): Pounds per square inch (unit of pressure) Open center circuit: A circuit in which flow through the system and back to the oil tank reservoir is open in neutral. Example: the main flow-primary pressure circuit.

______________________________________________________________ A6474X347 REV 06 5.63

BI016954-06 (EN-US)

Hydraulic _______________________________________________________ Hydraulic pump assembly circuit Hydraulic power for all of the hydraulically actuated functions originates with the pump assembly (Fig. 43). This pump assembly is made up of single-stage pump with a piggy-back hydraulic pump or 2-section tandem pump. The pump assembly is typically mounted on the left side of the machine frame.

Oil is supplied from the oil tank reservoir to the suction side of pump through a 2 inch suction line.

Fig. 43: Hydraulic pump circuit

________________________________________________________________ 5.64 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

______________________________________________________ Hydraulic Main flow - primary pressure circuit The main flow-primary pressure circuit is powered by the hydraulic pump. The system is an open-center circuit and it supplies oil flow to the main control valve. The main control valve operates the cutter head, conveyor raise and swing, gathering head, and stabilizer shoe cylinders, along with oil tank fill. After passing through the pump, oil enters a 10 micron by-passing pressure filter (tri-filter manifold) and continues to the main control valve, whose relief is set at 3,000 psi. On the return side of the system, oil exits the main control valve. There is a tee to allow external filling of the reservoir (see conveyor raise/lower circuit). Oil enters a 10 micron by-passing return filter (tri-filter manifold) before entering the oil reservoir. Once in the reservoir, the oil is forced to flow through and around baffle plates for cooling and de-aerating before re-entering the suction line. Also, located in the reservoir are floor magnets which will trap ferrous metal particles.

The schematic shown in Fig. 44 is a typical primary pressure circuit.

Always refer to the schematic in the parts book for your machine.

Fig. 44: Main flow-primary pressure circuit

______________________________________________________________ A6474X347 REV 06 5.65

BI016954-06 (EN-US)

Hydraulic _______________________________________________________ Pilot pressure circuit The pilot hydraulic section is a closed-center system powered by gear section 8. It supplies oil flow to the following: ■

hydraulic tension conveyor chain take-up (optional)

■

all solenoid valves, which control –

the scrubber

–

dust sprays

–

fire sprays

–

tram breaker on and off

–

traction brake

–

all main control valve functions

After passing through the pump, oil enters a 10-micron by-passing pressure filter and circuit relief valve set at 2800 psi. Oil then flows to a 3-micron non by-passing pressure filter (tri-filter), and continues to the hydraulic tension conveyor chain take-up (optional) and all solenoid valves.

The schematic shown is Fig. 45 is typical for a pilot pump circuit. Always refer to the schematic in the parts book for your machine.

Fig. 45: Pilot pressure circuit

________________________________________________________________ 5.66 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

______________________________________________________ Hydraulic Tank Ports Return oil from hydraulic system components connect to a 10-port pressure manifold. Oil flows from the pressure manifold to the oil tank reservoir. The oil tank reservoir includes the oil level float switch, a dipstick and two tank breathers.

The schematic shown is Fig. 46 is typical for tank port connections.

Always refer to the schematic in the parts book for your machine.

Fig. 46: Tank port connections

______________________________________________________________ A6474X347 REV 06 5.67

BI016954-06 (EN-US)

Hydraulic _______________________________________________________ Cutter head cylinder circuit DANGER! The area under and around the raised cutter head is dangerous.

Securely block the head before performing maintenance on or below it. Failure to block the raised cutter head could result in serious injury or even death.

Oil is supplied by the hydraulic pump through a 10-micron bypassing pressure filter (tri-filter) to the cutter head working section of the main control valve. By manual or remote solenoid control, the spool allows oil to enter the cutter head cylinder circuit. The cutter head cylinder is a double acting cylinder with load holding cartridge. there are two (2) cutter head cylinders, one on each side of the machine.

There are two (2) port reliefs in the working section on the main control valve. Both port reliefs are set at 2,800 psi. To raise the cutter head (extend cylinders), pull the handle. Oil goes to port “P2” of the antichatter/maintenance valve, free flowing through the check valve out of port “P1”, and continues to the extend port of the cylinders free flowing through the check valve of the load holding cartridge.

To lower the cutter head (retract cylinders), push the handle. Oil goes to the retraction port of the cylinders and also pilots open the load holding cartridge, allowing oil to exit the extend ports on the cylinders. The oil continues to the anti-chatter/maintenance valve block, where it passes through a counterbalance valve which is set to relief at 1,200 psi, then through the main control valve and a 10-micron bypassing return filter (tri-filter) into the oil tank.

The shear down/anti-chatter manifold has three primary functions: shear down/maintenance valve (anti-chatter)

1. It provides back pressure against the shear cylinder pistons when shearing down to prevent the machine from climbing the face (raising the machine off of the ground).

2. It provides back pressure against the shear cylinder pistons when lowering the cutter head without shearing. This allows for a smooth downward motion without allowing the load of the cutter head to run uncontrollably.

3. It allows for bypassing of the counterbalance valve to eliminate the back pressure against the shear cylinder pistons. This provides the maximum pressure differential between the two sides of the shear cylinders which allows the machine to be raised off the ground (jack-knifed). To jack-knife the miner, the stabilizer shoe is first lowered and then the cutter head is lowered with the bypass opened. At this point, the machine can be inspected, adjustments can be made to the crawler tracks, and the tram voltage can be adjusted.

This counterbalance valve may need to be adjusted during installation (see Adjustment Procedures section).

________________________________________________________________ 5.68 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

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

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

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

This schematic shown is Fig. 47 is a typical cutter head cylinder circuit.

Always refer to the schematic in the parts book for your machine.

______________________________________________________________ A6474X347 REV 06 5.69

BI016954-06 (EN-US)

Hydraulic _______________________________________________________ Fig. 47: Cutter head raise circuit

Note:

Solenoid designations are CHD (cutter head down – rear solenoid and CHU (cutter head up – front solenoid).

________________________________________________________________ 5.70 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

______________________________________________________ Hydraulic Conveyor raise/lower circuit - oil tank fill Reference Fig. 48. conveyor raise/lower

Oil is supplied by the hydraulic pump through a 10-micron bypassing pressure filter (tri-filter) to the conveyor raise/lower working section on the main valve control. By manual or remote solenoid control, the spool allows oil to enter the conveyor raise/lower cylinder circuit. The conveyor raise/lower cylinder is a single-acting cylinder with a load holding cartridge. There are two (2) conveyor raise/lower cylinders. There are two (2) port reliefs in the working section on the main control valve. The front port relief for raising the conveyor is set at 2,700 psi and the rear port relief for lowering the conveyor is set at 1,400 psi. Pull the handle to extend the cylinders and raise the conveyor. Oil free flows through the flow control check valve to the extend port of the cylinders free flowing through the check valve of the load holding cartridge to extend the cylinders. Push the handle to retract the cylinders and lower the conveyor. Oil goes to the retract port of the cylinders and pilots open the load holding cartridge, allowing oil to exit the cylinders. Oil then travels thru a 10-micron bypassing return filter (tri-filter) to tank.

oil tank fill

The oil tank fill operates from the conveyor lower circuit. Oil goes to lower the conveyor and tees off to a ball valve that is closed. With the conveyor in the down position, the ball valve is manually opened. By manual or remote solenoid control, the spool allows oil to enter the conveyor lower cylinder circuit and runs the oil tank fill. Oil passes thru the ball valve to a jet pump, which creates a venturi (vacuum) effect, pulling oil from the clean oil reservoir through a check valve joining the return oil going thru 10-micron bypassing return filter (tri-filter) to tank. Manual fill is controlled by a hand pump.

IMPORTANT! Ensure that the suction hose is tightly plugged to prevent dirt and contaminants from entering the hydraulic system when not in used.

IMPORTANT! The power fill is activated by engaging conveyor down function and opening the ball valve.

When referring to Fig. 48, note that solenoid designations are CD (conveyor down) and CU (conveyor up).

The schematic is typical conveyor raise/lower circuit. Always refer to the schematic in the parts book for your machine.

______________________________________________________________ A6474X347 REV 06 5.71

BI016954-06 (EN-US)

Hydraulic _______________________________________________________ Fig. 48: Conveyor raise/lower - oil tank fill circuit

________________________________________________________________ 5.72 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

______________________________________________________ Hydraulic Conveyor swing circuit Oil is supplied by the hydraulic pump through a 10-micron bypassing pressure filter (tri-filter) to the conveyor swing working section on the main control valve. By manual or remote solenoid control, the spool allows oil to enter the swing circuit. The swing cylinder is a doubleacting cylinder. The range on the cylinder will allow the conveyor tail to move 45 degrees off the centerline of machine in both directions. There are two (2) port reliefs in the working section on the main control valve both of which are set at 1,800 psi. The purpose of the port reliefs is to protect the swing cylinder from damage in either right or left direction in the event of an excessive external load due to the impact of the conveyor tail with the rib, haulage vehicle, or some other object.

Push the handle and the left hand cylinder will retract, moving the conveyor tail to left. Pull the handle out and the cylinder will extend, moving the discharge conveyor to the right. The left and right movement is based off standing at the rear of machine looking forward to the cutter head.

An optional right hand cylinder may be required for attaching haulage.

The flow output to the two cylinders powers each in the opposite direction. The right hand cylinder retracts as the left hand cylinder extends and vice-versa.

The schematic shown is Fig. 49 is a typical conveyor swing cylinder circuit. Always refer to the schematic in the parts book for your machine.

______________________________________________________________ A6474X347 REV 06 5.73

BI016954-06 (EN-US)

Hydraulic _______________________________________________________ Fig. 49: Conveyor swing cylinder circuit

Note: Solenoid designations are CSL (conveyor swing left) and CSR (conveyor swing right).

________________________________________________________________ 5.74 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

______________________________________________________ Hydraulic Gathering head raise/hold/float-lower circuit Oil is supplied by the hydraulic pump through a 10 micron by-passing pressure filter to the gathering head working section on the main control valve. By manual or remote solenoid control, the spool allows oil to enter the gathering head raise circuit. When raising the gathering head pan, oil free flows through the gathering head float valve (check valve) and splits to both cylinders. At any time during raising the gathering head, the operator can stop the gathering head pan and the pan will hold in position.

The gathering head lower function is controlled through the working section of the main control valve and through the gathering head float valve block. The spool in the main control valve is open to tank, which allows control of the gathering head lower to be controlled by the gathering head float valve block. The counterbalance valve stamped “VR” is set to relieve at 1,200 psi to allow the gathering head to drift down at a controlled rate of speed. This valve is adjustable and the rate of retract speed for the cylinders can be increased by decreasing the pressure setting of the valve. Conversely, the retract speed for the cylinders can be decreased by increasing the pressure setting of the valve. the oil from the gathering head cylinders returns to the gathering head working section of the main control valve then through a 10 micron bypassing return filter to tank.

The counterbalance valve that is stamped “CR” is set to relieve at 1,800 psi. This fixed setting will relieve pressure directly to the tank in the event of a forced movement of the gathering head to grade level. This can occur if the cutter head is lowered onto a raised gathering pan or by some other external force.

The gathering head raise cylinders are single acting. Each has a dry pocket providing additional stoke beyond its pressure-extend limit in the event that the gathering head is trammed into an obstruction forcing it to raise beyond its normal travel limit. When in the float condition, the cylinders carry some of the gathering head pan weight to prevent the gathering head leading edge from digging into the soft bottom of the mine and moves the machine’s center of gravity forward when mining.

When the pan goes over a roll, it may raise quickly, extend the gathering head cylinders, and create a vacuum in the pilot oil supply. In extreme cases, the pilot pressure may decrease to the point where the solenoid controlled main control valve may not have sufficient pilot pressure to shift. It is, therefore, possible to experience a momentary loss of radio control to the machine.

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

______________________________________________________________ A6474X347 REV 06 5.75

BI016954-06 (EN-US)

Hydraulic _______________________________________________________ The schematic shown in Fig. 50 is a typical gathering head circuit. Always refer to the schematic in the parts book for your machine.

Fig. 50: Gathering head circuit

Note: Solenoid designations are GHD (gathering head down) and GHU (gathering head up.

________________________________________________________________ 5.76 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

______________________________________________________ Hydraulic Stabilizer shoe cylinders circuit Oil is supplied by the hydraulic pump through a 10-micron bypassing pressure filter (tri-filter) to the stabilizer shoe working section on the main control valve. By manual or remote solenoid control, the spool allows oil to enter the stabilizer shoe circuit. The stabilizer shoe cylinder is a double-acting cylinder. There are two stabilizer shoe cylinders.

There are two port reliefs in the working section on the main control valve. Port relief to lower the stabilizer shoe is set at 2500 psi. Port relief to raise the stabilizer shoe is sat at 1400 psi. Push the handle it extends the cylinders and lowers the stabilizer shoe. Pull the handle it retracts the cylinders and raise the stabilizer shoe. Solenoid designations are SSU (stabilizer shoe up) and SSD (stabilizer shoe down).

The schematic shown is Fig. 51 is a typical stabilizer shoe cylinder circuit. Always refer to the schematic in the parts book for your machine.

Fig. 51: Stabilizer shoe circuit

______________________________________________________________ A6474X347 REV 06 5.77

BI016954-06 (EN-US)

Hydraulic _______________________________________________________ Conveyor chain take-up circuit (optional) The pilot-auxiliary hydraulic pressure circuit is powered by the hydraulic pump. From the pump, oil passes through a 10 micron by-passing pressure filter and continues to the pilot pressure filter (tri-filter).

The oil continues to the sequence valve and then to the conveyor chain take-up valve to (2) two conveyor chain take-up cylinder assemblies.

From the sequence valve, oil also passes to a relief valve and a modified solenoid valve before terminating in the tank. The conveyor chain take-up valve consists of a check valve to hold pressure in the circuit, a pressure reducing/relieving cartridge to reduce the pilot pressure to 200 psi for conveyor chain tension and relieves pressure build up above 200 psi. A needle valve cartridge relieves pressure from the circuit for maintenance.

The conveyor chain take-up cylinder assemblies consist of the cylinder with a removable rod with wear rings and a spring. The oil pressure keeps tension on conveyor chain and the spring takes up the dither when the conveyor chain is running.

The conveyor chain take-up circuit described below (Fig. 52) is for typical. Always refer to the schematic in the parts book for your machine.

________________________________________________________________ 5.78 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

______________________________________________________ Hydraulic Fig. 52: Conveyor chain take-up circuit

______________________________________________________________ A6474X347 REV 06 5.79

BI016954-06 (EN-US)

Hydraulic _______________________________________________________ Accumulator/brake circuit The accumulator is pre-charged with nitrogen. The accumulator circuit is supplied from the pilot pressure manifold, which is supplied by the hydraulic pump. This circuit is used for manual and automatic reset for the breaker on and off (main and tram) using hydraulic cylinders and also for the deluge fire suppression system. From the pilot pressure manifold, oil free flows thru a check valve and charges the one gallon accumulator. The check valve traps oil pressure in the circuit since the three unit solenoid manifold has normally closed cartridges. The manual control valve is blocked allowing pressure to be available when the machine pump is not running to reset the breakers and to set off the fire suppression system.

The breaker reset function can be operated by the manual breaker control valve or by radio via solenoids. The shuttle valve has two oil supply ports with one outlet port. One oil supply is from the manual breaker control valve and the other is from the solenoid valve. The outlet port goes to the cylinder to operate the breaker.

There are two shuttle valves, one to turn on the breaker and one to turn the breaker off. When the breaker is on, the coil is energized and shifts the spool, allowing oil to travel to the extend side of the main breaker cylinder and to the retract side of the tram breaker cylinders. In both cases, the BON turns on. When the breaker is off, the coil is energized and shifts the spool allowing oil to travel to the retract side of the main breaker cylinder and to the extend side of the tram breaker cylinders. If there is no radio function, the manual breaker control valve will use the accumulator pressure to supply oil for breaker reset on and off.

The remaining solenoid in the 3-unit manifold is for the deluge fire suppression system. When the solenoid coil is energized it shifts the spool, allowing oil to travel to the 2-way/2-position water valve, shifting its spool to allow water pressure to pass through it to the deluge fire spray manifolds. The water valve has a detent spool which keeps the water valve open if the battery back-up uses up its energy.

This circuit also contains the valves required to operate the traction brakes. The brakes require a higher pressure to release than is required for the other functions on this circuit. There is a pressure reducing valve installed to provide a separate high and low pressure, and a needle valve to bleed oil out of the high pressure circuit to allow maintenance.

The brakes are released when the two solenoids are activated by the radio control. The solenoids pilot higher flow three-way cartridges that allow oil to enter the brake housing.

WARNING! The pressure in this circuit must be released by using the needle valve before attempting any type of maintenance. There is a risk of severe injury or death.

________________________________________________________________ 5.80 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

______________________________________________________ Hydraulic IMPORTANT! The backup accumulator must maintain minimum pressure for 12 minutes after the pump has been de-energized. For maintenance on the circuit, loosen the fitting SLOWLY until the pressure is released.

The schematic shown in Fig. 53 is a typical accumulator circuit. Always refer to the schematic in the parts book for your machine.

Fig. 53: Accumulator/brake circuit

Note: See the water section for further scrubber and dust/cooling systems information and for the water circuit.

______________________________________________________________ A6474X347 REV 06 5.81

BI016954-06 (EN-US)

Hydraulic _______________________________________________________ Dust-scrubber sprays hydraulic circuit The pilot-auxiliary hydraulic pressure circuit is powered by the hydraulic pump. From the pump, oil passes through a 10 micron by-passing pressure filter and continues to a sequence valve where oil flows to a 2 -unit solenoid manifold which has normally closed cartridges. One cartridge is for the scrubber spray system and the other is for the dust/ cooling water system.

When the DS coil is energized it shifts the spool allowing oil to travel to the pilot operated normally closed water valve, shifting its spool to allow water pressure to pass through it to the dust/cooling water circuit.

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

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

The dust sprays automatically turn on when the cutter head starts. The dust sprays can be turned on or off manually from the radio.

The scrubber sprays automatically turn on when the scrubber motor starts. The scrubber sprays cannot be turned on or off from the radio.

The schematic shown in Fig. 54 is a typical dust-scrubber sprays circuit. Always refer to the schematic in the parts book for your machine.

________________________________________________________________ 5.82 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

______________________________________________________ Hydraulic Fig. 54: Dust and scrubber sprays hydraulic circuit

Note: See water circuit in Water section of this chapter.

______________________________________________________________ A6474X347 REV 06 5.83

BI016954-06 (EN-US)

Water___________________________________________________________ Water system overview Water is supplied to the continuous miner for the following purposes: ■

deluge water fire protection

■

cooling water for motors, transformers, etc.

■

cooling water for dust suppression

■

air cleaning via the scrubber system

■

washdown hoses

The water supplied by the mine must meet the following requirements: ■

flow rate of 20 gpm minimum for cooling

■

total flow rate: based on customer dust plan

The manufacturer offers straight, left hand, right hand, or bi-directional cutter head spray manifolds. This section describes bi-direction sprays.

The schematics in this section are for reference only. Always refer to the schematic in the parts book for your machine.

________________________________________________________________ 5.84 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

__________________________________________________________ Water Water supply circuit The water pressure manifold supplies water to all the water circuits (Fig. 60). Mine water is connected to a ball valve typically mounted on the right rear corner of the machine. The water passes from the ball valve through two reverse flushing strainers. The reverse flushing strainers have a waste port that is connected to a manifold that directs waste water to the mine floor while back flushing. After exiting the strainers, water flow goes to the two pressure reducing valves. One pressure reducing valve continues onto the rest of the cooling/dust suppression circuit, the other is installed for the sole purpose of controlling the wash down hose pressure. The water continues through a PRV valve, a water pressure switch, and on to the flow switch. For component location see Fig. 55.

Fig. 55: Water supply circuit

______________________________________________________________ A6474X347 REV 06 5.85

BI016954-06 (EN-US)

Water___________________________________________________________ Fig. 56: Scrubber and dust-cooling component locations LH CH spray manifold 3/8” spray nozzle

Center CH spray manifold 3/8” spray nozzle

RH CH spray manifold 3/8” spray nozzle 3-way, 3 position 3/4” ball valve (2)

3-way, 3 position 3/4” ball valve (2)

GA spray manifold (optional) 3/8” spray nozzle

GA spray manifold (optional) 3/8” spray nozzle

RH GA CLA side spray manifold 3/8” spray nozzle

LH GA CLA side spray manifold 3/8” spray nozzle Throat spray manifold 3/8” spray nozzle

Cleaning spray manifold Chassis side spray manifold 3/8” spray nozzle

Chassis side spray manifold 3/8” spray nozzle

0-1000 psi pressure gauge (2) 0-300 psi pressure gauge (4) Scrubber sprays 1/4” spray nozzle Backflush sprays 1/4” spray nozzle Sump suction strainer 1/4” flow control valve Spray nozzle HI/4 W-110 08 (flat) 1” jet pump 0-160 psi pressure gauge 1/2” pressure regulator valve Scrubber spray follow control 1/2” pressure regulator valve 0-160 psi pressure gauge Washdown hose

1/2” ball valve (2) Pilot operated water valve

Replacement element Reverse flushing strainer 1-1/4” ball valve 3/4” ball valve

Washdown hose Termination manifold 1/2” ball valve

________________________________________________________________ 5.86 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

__________________________________________________________ Water Deluge water fire circuit The deluge fire suppression circuit (Fig. 57) can be operated by manual or remote solenoid control (see Electrical section in this chapter).

When the solenoid coil is energized, it shifts a spool, allowing hydraulic oil to travel to a 2-way, 2-position water valve. The hydraulic fluid shifts the spool, allowing the water to pass through it to the deluge fire spray manifolds. For the hydraulic portion of this circuit, see Fig. 61 in the Hydraulic section of this chapter. The water valve has a detent spool, which keeps the valve open. The 2-way, 2-position valve can be operated manually and is typically mounted on the left hand side of the machine. The valve must be manually reset to reset the fire suppression circuit.

In addition, there is a ball valve used to manually operate the fire suppression circuit that is typically located on the right rear corner of the machine. The valve must be manually turned off to reset the fire suppression system.

The optional left hand washdown hose water is supplied by the deluge fire suppression system.

For deluge water fire circuit component locations, see Fig. 58.

IMPORTANT! You must manually reset the 2-way, 2-position water valve to reset the deluge fire spray circuit.

Fig. 57: Deluge water fire circuit

______________________________________________________________ A6474X347 REV 06 5.87

BI016954-06 (EN-US)

Water___________________________________________________________ Fig. 58: Deluge fire component location

3/8” spray nozzle 3-unit fire spray manifold

3/8” spray nozzle 3-unit fire spray manifold

3/8” spray nozzle 3-unit fire spray manifold

Fire activation/reset valve

3/8” spray nozzle 3-unit fire spray manifold 3/8” spray nozzle 3-unit fire spray manifold

1/2” ball valve

3/8” spray nozzle 3-unit fire spray manifold

________________________________________________________________ 5.88 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

__________________________________________________________ Water Scrubber screen backflush sprays circuit The manual scrubber screen sprays backflush circuit (Fig. 59) consists of a ball valve, spray nozzles, and a spray bar mounted downstream of airflow behind the scrubber screen. A manual backflush ball valve is typically mounted on the right side of the machine, near the operator’s station. The valve should be used to keep the scrubber screen clean after each cut. The scrubber screen should be removed and completely cleaned (see Maintenance section of this chapter) as required to keep the scrubber working efficiently.

Fig. 59: Scrubber screen backflush and scrubber sprays circuit

______________________________________________________________ A6474X347 REV 06 5.89

BI016954-06 (EN-US)

Water___________________________________________________________ Dust-cooling left hand chassis circuit The dust-cooling left hand chassis circuit (Fig. 60) continues from the dust cooling water supply circuit. Water from the secondary dustcooling pressure manifold cools the pump, tram and continuous loading arm (CLA) motors. A portion of the CLA cooling water is used for the (optional) gathering head side sprays and pan sprays. There is an atmospheric relief located before the (optional) dust spray direction (left or right) diverter valve in case pressure builds up from clogged spray nozzles. A pressure gauge (optional), typically mounted with the gauge package on the right side of the machine, is used to monitor nozzle pressure. Water flows from the diverter valve to a split center cutter head bi-directional spray manifold. The manifold has two supply ports, one port feeds the left hand portion (dust-cooling left hand chassis circuit) and the other port feeds the right hand portion (dust-cooling right hand chassis circuit). Both portions of the manifold are set-up with cutter head bi-directional sprays.

The dust-cooling circuit described below is for a typical miner containing optional bi-directional spray manifolds and side sprays. The circuit for your machine may vary depending on your dust plan and unique requirements. Always refer to the schematic in the parts book for your machine.

Fig. 60: Dust-cooling left hand chassis circuit

________________________________________________________________ 5.90 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

__________________________________________________________ Water Dust-cooling right hand chassis circuit The dust-cooling right hand chassis circuit (Fig. 61) continues from the dust cooling water supply circuit. Water from the secondary dustcooling pressure manifold cools the tram motor, tram case, and continuous loading arm (CLA) motors. A portion of the CLA cooling water is used for the (optional) gathering head side sprays and the pan sprays.

The water continues up the right side of the miner to an atmospheric relief, in place in the event that pressure builds up from clogged spray nozzles. A pressure gauge (optional), typically mounted with the gauge package on the right side of the machine, is used to monitor nozzle pressure. Water flows from the diverter valve to a split center bidirectional spray manifold. The manifold has two supply ports, one port feeds the left hand portion (dust-cooling left hand chassis circuit) and the other port feeds the right hand portion (dust-cooling right hand chassis circuit). Both portions of the manifold are set-up with cutter head bi-directional sprays.

The dust-cooling circuit described below is for a typical miner containing optional bi-directional spray manifolds and side sprays. The circuit for your machine may vary depending on your dust plan and unique requirements. Always refer to the schematic in the parts book for your machine.

Fig. 61: Dust-cooling right hand chassis circuit

______________________________________________________________ A6474X347 REV 06 5.91

BI016954-06 (EN-US)

Water___________________________________________________________ Dust-cooling left hand cutter head motor circuit The dust-cooling left hand cutter head motor circuit (Fig. 62) continues from the dust cooling water supply circuit. Water from the secondary dust-cooling pressure manifold cools the left hand cutter motor. Water flows from the side port of the cutter head motor to an atmospheric relief mounted on a pressure manifold. The atmospheric relief is in place in the event that the pressure builds up from clogged spray nozzles. A pressure gauge (optional), typically mounted with the gauge package on the right side of the machine, is used to monitor nozzle pressure.

The water continues from the left hand cutter motor to a (optional) diverter valve, then on to the left hand bi-directional spray manifold.

There are two supply lines going to the manifold, one each for the left and right hand spray set-ups.

An optional spray package is available for chassis spray. In this package, a tee is added between the diverter valve and the supply port for the right hand spray of the cutter head manifold. From this tee, water flows to a ball valve, used to turn off or on the chassis side sprays for the right hand spray. With the ball valve open, water supplies three manifolds: two mounted on the left hand side of the machine (with four sprays total spraying towards the front of the machine) and one mounted on the right hand side of the machine (with two sprays total spraying towards the rear of the machine). The side sprays assist airflow direction and dust control.

The dust-cooling circuit described below is for a typical miner containing optional bi-directional spray manifolds and side sprays. The circuit for your machine may vary depending on your dust plan and unique requirements. Always refer to the schematic in the parts book for your machine.

Fig. 62: Dust-cooling left hand cutter motor circuit

________________________________________________________________ 5.92 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

__________________________________________________________ Water Dust-cooling right hand cutter head motor circuit The dust-cooling right hand cutter head motor circuit (Fig. 63) continues from the dust cooling water supply circuit. Water from the secondary dust-cooling pressure manifold cools the right hand cutter motor.

Water flows from the side port of the cutter head motor to an atmospheric relief mounted on a pressure manifold. The atmospheric relief is in place in the event that the pressure builds up from clogged spray nozzles. A pressure gauge (optional), typically mounted with the gauge package on the right side of the machine, is used to monitor nozzle pressure. The water continues from the right hand cutter motor to a (optional) diverter valve, then to the right hand bi-directional spray manifold. There are two supply lines going to the manifold, one each for the left and right hand sprays.

An optional spray package is available for chassis spray. In this package, a tee is added between the diverter valve and the supply port for the left hand spray of the cutter head manifold. From this tee, water flows to a ball valve, used to turn off or on the chassis side sprays for the left hand spray. With the ball valve open, water supplies three manifolds: two mounted on the right hand side of the machine (with four sprays total spraying towards the front of the machine) and one mounted on the left hand side of the machine (with two sprays total spraying towards the rear of the machine). The side sprays assist airflow direction and dust control.

Fig. 63: Dust-cooling right hand cutter motor circuit

______________________________________________________________ A6474X347 REV 06 5.93

BI016954-06 (EN-US)

Electrical _______________________________________________________ Basic principles Electrical energy is used to power the Continuous Miner. The electrical system is assembled for 995V 3-phase AC voltage at 50 Hertz (Hz) to match local mine power, which is supplied via a trailing cable. Mine electrical power, stepped down by transformers, fed through circuit breakers, and set up through electrical control circuitry, provides energy for the water-cooled drive motors.

An electrical circuit provides a means of changing electrical energy into some other form of energy. An electrical circuit may cause electrical energy to change into mechanical energy, as in the case of an electrical motor, or into heat or light , as in the case of a light bulb. Just as the components in a hydraulic circuit control the flow of hydraulic fluid, many electrical components are used in an electrical circuit to direct or limit the flow of electrical energy so it can be utilized to do a particular job on the miner. Other components in an electrical circuit are protective devices to avoid damage to equipment and injuries to personnel.

Electrical components in the operator’s case, main case and tram case are housed in explosion-proof enclosures.

Schematics A schematic diagram is an illustration which shows the electrical relationship of the various components and the circuits. A schematic diagram does not show the physical location of the components.

In an electrical schematic, components are shown in their de-energized position. A set of normally open contacts (N.O.) close when the coil is energized and a set of normally closed (N.C.) open when the coil is energized.

Related components share the same designation. In tracing a particular circuit, it may be helpful to think of the flow of electricity as being similar to the flow of water through a hose. When a set of contacts are open, the current cannot flow across them, and when contacts are closed, the current can flow. When three (3) lines are connected in a tee, the current will flow in whatever direction that it can. Like water or hydraulic fluid, an electrical current will also tend to follow the path of least resistance through a circuit. Finally, for a circuit to work, the electrical current must make a complete loop, similar to hydraulic fluid going through a circuit and returning to a tank.

________________________________________________________________ 5.94 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

_______________________________________________________Electrical Fig. 64: Standard electrical symbols

______________________________________________________________ A6474X347 REV 06 5.95

BI016954-06 (EN-US)

Electrical _______________________________________________________ Trailing cable A trailing cable with three power conductors, labeled L1, L2, L3, two (2) ground conductors (G), and a ground check conductor (GC) supplies power to the machine. A three-conductor 2/0 to 4/0 cable is used with the 995V machines.

Cables are designed with a fire-proof, tough outer jacket to withstand the constant abuse of flexing, reeling, and exposure to sharp objects on the mine floor. They are not designed to withstand being run over by mobile equipment, especially continuous miners. Trailing cables exposed to moving equipment are required to be hung to prevent damage to insulation.

IMPORTANT! Hang trailing cables to prevent damage from moving equipment!

WARNING! Never run over an unprotected trailing cable. Damaged cables should be repaired immediately.

The trailing cable may have breaks in its insulation. These defects in the insulation could cause exposure to high electrical currents. Never handle an energized trailing cable without the properly rated personal protective equipment (electrically insulated gloves and shoes or boots).

Never let the energized trailing cable come in contact with unprotected (uninsulated) parts of your body.

DANGER! Never handle energized trailing cable without proper protective equipment. Contact with an energized trailing cable with compromised insulation could result in death by electrocution.

Trailing cables on reels can present a hazard. The reels keep the trailing cable under tension at all times. Starting and stopping of the equipment causes a tension change on the trailing cable causing the cable to move or flex constantly. The closer to the machine, the more noticeable the movement. Anyone standing near or crossing over the trailing cable could be tripped or struck by the trailing cable as it flexes.

WARNING! Always use caution when standing near or crossing trailing cables. The trailing cable may move as the machine moves.

Trailing cable temporary splices Trailing cables may only be repaired under certain conditions and following specific guidelines which are outlined in local regulations.

________________________________________________________________ 5.96 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

_______________________________________________________Electrical Operator’s case—control breakers Mounted on the front wall of the operator’s case (Fig. 65) are control breakers. control breaker “CB1”

“CB1” is a 15A breaker for the 120VAC+ supply voltage.

control breaker “CB2”

“CB2” is a 15A breaker for the 120VAC- supply voltage.

control breaker “CB3”

“CB3” is a 15A breaker for the 120VAC+ side of the area light circuit.

control breaker “CB4”

“CB4” is a 15A breaker for the 120VAC- side of the area light circuit.

control breaker “CB5”

“CB5” is a 25A breaker for the 12VAC+ side of the head light circuit.

control breaker “CB6”

“CB6” is a 25A breaker for the 12VAC- side of the head light circuit.

control breaker “CB7”

“CB7” is a 5A breaker for the 12VAC+ side of the motor temp module circuit..

control breaker “CB8”

“CB8” is a 5A breaker on the 12VAC- side of the motor temp module circuit.

control breaker “CB9”

“CB9” is a 5A breaker on the 120VAC+ side of the motor relay circuit.

control breaker “CB10”

“CB10” is a 5A breaker on the 90VDC+ side of the solenoid circuit.

control breaker “CB11”

“CB11” is a 5A breaker on the 24VDC+ side of the controller power circuit.

control breaker “CB12”

“CB12” is a 5A breaker on the 0VDC- side of the controller power circuit.

control breaker “CB13”

“CB13” is a 15A breaker on the 12VAC+ side of the reverse lights circuit.

control breaker “CB14”

“CB14” is a 15A breaker on the 12VAC- side of the reverse lights circuit.

control breaker “CB15”

“CB15” is a 5A breaker on the display communications circuit.

control breaker “CB16”

“CB16” is a 5A breaker on the display communications circuit.

Fig. 65: Operator’s case - control breakers

Control breakers

______________________________________________________________ A6474X347 REV 06 5.97

BI016954-06 (EN-US)

Electrical _______________________________________________________ Operator’s case - rear wall The operator’s case is located on the back right hand side of the machine. The rear wall of the operator’s case (Fig. 66) is accessed by opening the case cover and then opening the swing panel.

IMPORTANT! This component location information is typical. Always verify component layout with the information in the parts book for your machine. transformer “XFMR”

Transformer “XFMR” converts the incoming 995V to 120VAC and 12 VAC.

“IS1”

“IS1” is an intrinsically safe (IS) barrier that provides an approved IS circuit between the oil temperature switch and oil level switch and the control system.

“IS2”

“IS2” is an intrinsically safe (IS) barrier that provides an approved IS circuit between the water pressure switch and the water flow switch and the control system.

“IS3”

“IS3” is an intrinsically safe (IS) barrier that provides an approved IS circuit between the left brake pressure switch and right brake pressure switch and the control system.

Fig. 66: Operator’s case - rear wall “IS3”

“IS2”

“IS1”

Transformer “XFMR”

________________________________________________________________ 5.98 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

_______________________________________________________Electrical Traction case The traction case (Fig. 67) is typically located on the right hand side of the machine, and is accessed by opening the controller cover and then opening the swing panel. Typically mounted on the rear wall are traction drives and a terminal block.

IMPORTANT! This component location information is typical. Always verify component layout with the information in the parts book for your machine.

Left traction drive “LD” Right traction drive “RD”

Left traction drive “LD” controls the left traction motor.

Right traction drive “RD” controls the right traction motor.

Fig. 67: Traction case

Left drive “LD”

Right drive “RD”

______________________________________________________________ A6474X347 REV 06 5.99

BI016954-06 (EN-US)

Electrical _______________________________________________________ Main controller case - rear wall The rear wall of the main controller case (Fig. 68) is accessed by opening the controller cover and then opening the swing panel. It is typically located on the left side of the machine, midway the tractor frame inside the crawler frame.

IMPORTANT! This component location information is typical. Always verify component layout with the information in the parts book for your machine. vacuum contactor “A”

Vacuum contactor “A” is the contactor for the left cutter motor.

vacuum contactor “B”

Vacuum contactor “B” is the contactor for the right cutter motor.

vacuum contactor “CF”

Vacuum contactor “CF” is the contactor for the conveyor forward motor.

vacuum contactor “CR”

Vacuum contactor “CR” is the contactor for the conveyor reverse motor.

vacuum contactor “F”

Vacuum contactor “F” is the contactor for the pump motor.

vacuum contactor “P”

Vacuum contactor “P” is the contactor for the fan motor.

Fig. 68: Main controller case - rear wall Vacuum contactor “CF”

Vacuum contactor “F”

Vacuum contactor “P”

Vacuum Contactor “A”

Vacuum Contactor “B”

Vacuum contactor “CR”

________________________________________________________________ 5.100 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

_______________________________________________________Electrical Main controller case - inside swing panel The swing panel of the main controller case (Fig. 69) is accessed by opening the controller cover and then opening the swing panel. It is typically located on the left side of the machine, midway the tractor frame inside the crawler frame.

IMPORTANT! This component location information is typical. Always verify component layout with the information in the parts book for your machine.

“PCT”

“PCT” is the power center trip relay and is used to open the power relay, ultimately opening the pilot core of the trailing cable to trip the power center. It is controlled by the PLC.

“CT10”

“CT10” is a current transducer used with earth leakage relay “EL12” on the 12V circuit.

“CT11”

“CT11” is a current transducer used with earth leakage relay “EL120” on the 120V circuit.

“CT12”

“CT12” is a current transducer used with earth leakage relay “EL270” on the 270V circuit.

“BRE”

“BRE” is a bridge rectifier used to convert the AC input from the emergency stop push button circuit to a DC output used to pull in the emergency stop relay, “ESR”.

“BRM”

“BRM” is a bridge rectifier used to convert the AC input from the methane system to a DC output used to pull in the methane monitoring relay, “MMR”.

“BR9”

“BR9” is a bridge rectifier used to convert the AC input from to a 90 DC output used to pull in the earth leakage monitor, “EL120”.

“ETR”

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

“PTOL”

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

“MMR”

Contactor “MMR” is a relay in the methane monitoring circuit.

“ESR”

Contactor “ESR” is a contactor in the emergency stop circuit. When this contactor is open, power is removed from the machine.

______________________________________________________________ A6474X347 REV 06 5.101

BI016954-06 (EN-US)

Electrical _______________________________________________________ “L”

“L” is the head light contactor. When this contactor is closed, the head lights are on.

“RL”

“RL” is the reverse light contactor. When this contactor is closed, the reverse lights are on.

“EL12”

“EL12” is an earth leakage monitor on the 12V circuit.

“EL120”

“EL120” is an earth leakage monitor on the 120 V circuit.

“EL270”

“EL270” is an earth leakage monitor on the 270 V circuit.

Fig. 69: Main controller case - inside swing pan“PCT”

“ETR”

“PTOL”

“CT10”

“MMR”

“ESR”

“L”

“CT11”

“RL”

“BRE”

“BRM”

“BR9”

“CT12”

“EL12”

“EL120”

“EL270”

________________________________________________________________ 5.102 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

_______________________________________________________Electrical Main controller case - front side swing panel The front side of the main controller case swing panel (Fig. 70) is accessed by opening the main controller case cover. Typically mounted on the front side of the swing panel are the control system components.

IMPORTANT! This component location information is typical. Always verify component layout with the information in the parts book for your machine. power supply central processor

The power supply module converts a 995VAC input to 24VDC output for the control system.

The control system software is stored on the central processor (control module).

Fig. 70: Main controller case - outside swing panel

Central processor

Power supply

______________________________________________________________ A6474X347 REV 06 5.103

BI016954-06 (EN-US)

Electrical _______________________________________________________ Power circuit with control Electric power is supplied to the control transformer and is available to the methane monitor and to all contactors after the trailing cable is connected, the circuit breakers CB1 and CB2 are turned on, and when CB2 contacts close in the control circuit.

The schematic shown in Fig. 71 is typical of a power schematic. Always refer to the schematic in the parts book for your machine.

Fig. 71: Power circuit with control

________________________________________________________________ 5.104 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

_______________________________________________________Electrical Methane monitor circuit The methane monitor detects methane gas when the continuous miner is powered up. Before any motor or function occurs, the methane monitor checks for methane gas. If the methane monitor shows zero methane, the methane monitor relay will close. When the methane monitor relay closes, it supplies power to the area lights including the head light if the light switch is on. The methane monitor is powered from the control transformer. The low oil system will also have control power.

The schematic shown in Fig. 72 is a typical methane monitor circuit.

Always refer to the schematic in the parts book for your machine.

Fig. 72: Methane monitor circuit

______________________________________________________________ A6474X347 REV 06 5.105

BI016954-06 (EN-US)

Electrical _______________________________________________________ Control headlights and area lights circuit The area lights on the machine are energized and will turn on as soon as power is applied to the machine and the main circuit breaker is closed.

The headlights and reverse lights are energized when power is applied to the machine and the main circuit breaker is closed.

The schematic shown in Fig. 73 is a typical lighting circuit. Always refer to the schematic in the parts book for your machine.

Fig. 73: Control headlights and area lights circuit

________________________________________________________________ 5.106 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

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

The schematic shown in Fig. 74 is typical. Always refer to the schematic in the parts book for your machine.

Fig. 74: Power center trip relay control circuit

______________________________________________________________ A6474X347 REV 06 5.107

BI016954-06 (EN-US)

Electrical _______________________________________________________ Machine stop circuit Power to the motor control circuits is isolated by a machine stop relay, “ESR”. Relay “ESR” is controlled by two machine stop switches, on located at the operator’s station on the front of the controller case and the other on the off side of the machine. The control system will prevent motor start if either machine stop is pressed.

The schematic shown in Fig. 75 is a typical. Always refer to the schematic in the parts book for your machine.

Fig. 75: Machine stop circuit

________________________________________________________________ 5.108 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

_______________________________________________________Electrical Earth leakage relay circuit There are three earth leakage relay monitors: EL12, EL120, and EL270 (Fig. 76). earth leakage relay monitor “EL12”

EL12 is the earth leakage monitor on the 12V lighting and control power circuit. There is a toroid (current transformer), CT10, located on line Y2 of the circuit. The current through CT10 is fed to EL12 by lines E1 and E2. If the head lights, reverse lights, or thermistor circuit has a ground, the current flowing through CT10 will increase. When the current exceeds .1 A, earth leakage relay EL12A will open the two contactors EL12A located in lines 407A and 408A, interrupting input to the lighting relays L and RL and removing power from the forward and reverse lights. An input signal is sent to the processor at X3-P (line 107) and a fault message will be displayed.

earth leakage relay monitor “EL120”

EL120 is the earth leakage monitor for the 120VAC lighting and control circuit. There is a toroid, CT11, located on line X2 of the circuit. The current through CT11 is fed to EL120 by lines E3 and E4. If the 120VAC circuit has a ground, the current flowing through CT11 will increase. When the current exceeds .1 A, earth leakage relay EL120A will open the four EL120A contactors located in lines 803 and 804 (area lights circuit) and 90B and 91B (processor module power circuit), removing power from the area lights and processor module power supply. And input signal is sent to the processor at X1-D (line 108) and a fault message will be displayed.

earth leakage relay monitor “EL270”

EL270 is the earth leakage detector on the 270VDC tram circuit. There is a toroid, CT12, located in line X0 which comes off of the tram transformer. The current through CT12 is fed to the EL270 by lines E5 and E6. If there is a ground in the tram circuit, the current through CT12 will increase. When the current exceeds .1 A, earth leakage relay EL270A will open the two EL270A contactors located in lines 401A and 6A, interrupting input to the pump relay, P. This will open the pump contactor, shutting down the machine. An input signal is sent to the processor at X3-S (line 109) and a fault message will be displayed.

earth leakage test switch

The earth leakage test switch, located on the front of the controller, is used to test the earth relay monitors. After a circuit is tested, the switch must be turned to the reset position to reset the monitor.

The schematic shown in Fig. 76 is a typical. Always refer to the schematic in the parts book for your machine.

______________________________________________________________ A6474X347 REV 06 5.109

BI016954-06 (EN-US)

Electrical _______________________________________________________ Fig. 76: Earth leakage circuits

________________________________________________________________ 5.110 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

_______________________________________________________Electrical Fig. 76: Earth leakage circuits (continued)

______________________________________________________________ A6474X347 REV 06 5.111

BI016954-06 (EN-US)

Electrical _______________________________________________________ Tram pendant circuit In the event that the radio remote cannot communicate with the miner, the miner may be operated, with limited functions, using the tram pendant. The control system allows tramming, stab raise, and cutter raise and lower. There are pump and tram motor thermal overloads built into the tram pendant circuit that will shutdown the pump.

The schematic shown in Fig. 77 is a typical. Always refer to the schematic in the parts book for your machine.

Fig. 77: Tram pendant circuit

________________________________________________________________ 5.112 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

_______________________________________________________Electrical Thermistor module The thermistor module receives inputs from the motors and sends the information to the control system. The thermistors (resistors whose resistance varies with temperature) monitor all the motors.

The schematic shown in Fig. 78 is a typical. Always refer to the schematic in the parts book for your machine.

Fig. 78: Thermistor module control

______________________________________________________________ A6474X347 REV 06 5.113

BI016954-06 (EN-US)

Electrical _______________________________________________________ Solenoid module control The control module communicates to the solenoids through the solenoid module. The hydraulic cylinders and the water sprays are controlled by solenoids.

The schematic shown in Fig. 79 is a typical. Always refer to the schematic in the parts book for your machine.

Fig. 79: Solenoid module control circuit

________________________________________________________________ 5.114 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

_______________________________________________________Electrical Motor control The control system monitors the motor load by reading the current in each phase to the motor. The motor mate (control transformer) takes the current for each phase of the motor and converts it to a 4mA to 20mA signal to the processor.

The schematic shown in Fig. 80 is a typical. Always refer to the schematic in the parts book for your machine.

Fig. 80: Motor control

______________________________________________________________ A6474X347 REV 06 5.115

BI016954-06 (EN-US)

Electrical _______________________________________________________ Methane monitoring and protective devices The 25M3 (CM240) Continuous Miner is equipped with a flammable gas sensor, programmable trip amplifier and an intrinsically safe power supply to assist with safety monitoring and minimizing risk in mining applications.

Fig. 81 shows the locations of these devices, and the following pages include copies of the manufacturer’s literature detailing performance parameters and technical details.

Fig. 81: Protective device locations Methane sensor

I.S. power supply Trip amplifier

________________________________________________________________ 5.116 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

_______________________________________________________Electrical

______________________________________________________________ A6474X347 REV 06 5.117

BI016954-06 (EN-US)

Electrical _______________________________________________________

________________________________________________________________ 5.118 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

_______________________________________________________Electrical

______________________________________________________________ A6474X347 REV 06 5.119

BI016954-06 (EN-US)

Electrical _______________________________________________________

________________________________________________________________ 5.120 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

_______________________________________________________Electrical

______________________________________________________________ A6474X347 REV 06 5.121

BI016954-06 (EN-US)

Electrical _______________________________________________________

________________________________________________________________ 5.122 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

_______________________________________________________Electrical

______________________________________________________________ A6474X347 REV 06 5.123

BI016954-06 (EN-US)

Electrical _______________________________________________________

________________________________________________________________ 5.124 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

____________________________________________________ Maintenance Instructions on the maintenance Maintenance at regular intervals increases the operational safety and prolongs the service life of the machine. Observe the safety instructions in chapter 2 “Your safety”.

Important notes Please observe the following: ■

In order to avoid individual components not being serviced or being only inadequately serviced during maintenance work on the machine as a whole, we recommend that a general maintenance plan be drawn up. You can, for example, draw up a checklist using this operation manual and the manuals of the other components.

■

Inadequate maintenance can result in machine damage which leads to considerable costs.

■

Use only suitable and approved tools for maintenance work.

■

Use only original spare parts when replacing components.

■

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

■

Anyone performing maintenance on this equipment must be trained to operate it and be familiar with this guide.

Before maintenance Please observe the following: ■

Shutdown the machine on level ground.

■

Disconnect the electrical power. The circuit breaker must be in the "OFF" position. If work is to be done inside the electrical controller, the power should be disconnected.

WARNING! Before performing maintenance on the machine the circuit breaker must be in the “OFF” position and the power should be disconnected at the main power source. Follow all mine safety regulations for lockout/tagout procedures. Accidental machine movement or electrical shock can result in serious injury or death to you or other personnel.

■

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

■

All explosion-proof characteristics of enclosures must be maintained.

■

Block any and all elevated assemblies before working under them.

Make sure that the blocking can support the weight of the assembly without slipping or failing.

■

Relieve all hydraulic pressures and position the levers and controls in Neutral or Off.

______________________________________________________________ A6474X347 REV 06 5.

BI016954-06 (EN-US)

Maintenance _____________________________________________________ ■

Test the controls to ensure that the unit will not move.

WARNING! Do not move any hydraulic control lever unless you are certain that everyone is completely clear of any machine movement. Accidental machine movement can cause serious injuries or even death to you or the maintenance person.

■

Test the air for methane before and during any maintenance or repair work.

■

Do not perform maintenance on a circuit while there is a load resting on the hydraulic cylinder. Booms must be securely blocked with the boom in the raised position if maintenance is to be performed.

WARNING! Never disconnect a hydraulic hose if the circuit is pressurized or if there is a load on the circuit. If a hose is disconnected while the circuit is pressurized or a load is on the circuit, the load will fall causing damage to the machine or serious injury or death to you or other workers.

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

■

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

■

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

■

Cleanliness cannot be overemphasized as the essential ingredient of a good maintenance program. Machines should be kept as free as possible of dirt and debris which could impede performance or infiltrate systems and cause premature wear or failure.

________________________________________________________________ 5.126 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

____________________________________________________ Maintenance Torque values When installing bolts, refer to the torque values on the drawings in the parts book for your machine. If a torque value is not listed, refer to Chapter 6 of this manual

Lubricants and fluid capacities Table 1: Lubricants and fluid capacities Location

Specification

Approximate capacity

Notes

Hydraulic oil tank GH Assembly CLA Primary GH Assembly CLA POT Tram Drive Assembly

Spec. 100-1 Spec. 100-15 Spec. 100-15 Spec. 100-15

75 gals. (284 L) 1 gal (3.79 L) 2.5 gal (9.46 L) 3 gal (11.36 L)

2 2 2 2

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

Spec. 100-15

0.5 gallon (1.89 L)

2

Spec. 100-15

5 gal (18.93 L)

2

Spec. 100-14

variable

1, 2

Notes: 1. All motor lube hoses are to be filled with high temperature synthetic lithium complex grease (Spec. 100-14) before assembling them to the electric motor to ensure that there are no air gaps between the grease nipple and the point where the grease enters the motor.

2. See Chapter 6, Permissible Media, for approved lubricants for each specification.

______________________________________________________________ A6474X347 REV 06 5.

BI016954-06 (EN-US)

Maintenance _____________________________________________________ Table 2: Lubrication and maintenance schedule Item

Description

Places

Lubricant type

Specification

1

Every Shift Cutter head lift cylinder pins

2

Lithium based grease

Spec. 100-3

2

Conveyor swing cylinder pin, front

1

Lithium based grease

Spec. 100-3

3

Conveyor swing cylinder pin, rear

1

Lithium based grease

Spec. 100-3

4

Cutter head frame pivot pin, right

1

Lithium based grease

Spec. 100-3

5

Cutter head frame pivot pin, left

1

Lithium based grease

Spec. 100-3

6

Cutter head bits

Inspect

7

Conveyor roller

2

Lithium based grease

Spec. 100-3

8 9

Daily Gathering head hinge pin, left Gathering head hinge pin, right

1 1

Lithium based grease Lithium based grease

Spec. 100-3 Spec. 100-3

10

Crawler idler roller

2

Lithium based grease

Spec. 100-3

11

Conveyor to tractor frame pin, left

1

Lithium based grease

Spec. 100-3

12

Conveyor to tractor frame pin, right

1

Lithium based grease

Spec. 100-3

13

Stabilizer shoe pin

2

Lithium based grease

Spec. 100-3

14

Conveyor lift pin

2

Lithium based grease

Spec. 100-3

15

Conveyor swivel pin, top

1

Lithium based grease

Spec. 100-3

16

Conveyor swivel pin, bottom

1

Lithium based grease

Spec. 100-3

17

Hood hinge pin (Inside/Outside)

2

Lithium based grease

Spec. 100-3

18

Gathering pan raise pin

4

Lithium based grease

Spec. 100-3

19

Conveyor chain take-up pin

2

Lithium based grease

Spec. 100-3

20

CLA head pot assembly (Check)

2

High demulsibility gear oil

Spec. 100-15

21

CLA head transfer case (Check)

2

High demulsibility gear oil

Spec. 100-15

22

Tram gear case (Check)

2

High demulsibility gear oil

Spec. 100-15

23

Input cutter head gear case (Check)

2

High demulsibility gear oil

Spec. 100-15

24

Main cutter head gear case (Check)

2

High demulsibility gear oil

Spec. 100-15

25

Hydraulic oil level (Check)

1

Spec. 100-1

Weekly 26

Crawler chain (Inspect)

2

Heavy duty gear oil

Spec. 100-8

27

Conveyor chain (Inspect)

1

Heavy duty gear oil

Spec. 100-8

28

Fasteners (nuts, bolts, screws)

Inspect

29

Electrical cables, conduits, and glands

Inspect

30

Hydraulic/water hoses and connections

Inspect

31

Lighting

Inspect

32

Reflectors and warning tags

Inspect

33

E-stop switch

Inspect

34

Chain take-up locknut

2

Lithium based grease

Spec. 100-3

35

Jet pump, hydraulic (Inspect)

1

See Parts Book

36

Jet pump, water (Inspect)

1

See Parts Book

37

Water filter (Change)

1

See Parts Book

________________________________________________________________ 5.128 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

____________________________________________________ Maintenance Table 2 (continued): Lubrication and maintenance Item

Places

Lubricant type

Specification

38 39 40 41 42 43 44 45 46 47 48 49 50 51

Monthly CLA head pot assembly (Change) CLA head transfer case (Change) Input cutter head gear case (Change) Main cutter head gear case (Change) CLAs Input cutter head gear case Main cutter head gear case CLA head pot assembly CLA head transfer case Tram gear case Main hydraulic tank Pilot circuit primary filter element (Change) In-line filter element (Change) Return filter element (Change)

Description

2 2 2 2 Inspect 2 2 2 2 2 1 1 2 1

High demulsibility gear oil High demulsibility gear oil High demulsibility gear oil High demulsibility gear oil

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

52 53 54 55

Every three months RH cutter motor rear bearings (Front & Rear) LH cutter motor front bearings (Front & Rear) Pump motor bearings (Front & Rear) Scrubber motor bearings (Front & Rear)

56 57 58 59 60

Sample Sample Sample Sample Sample Sample

See Note 1 See Note 1 See Note 1 See Note 1 See Note 1 See Note 1 See Parts Book See Parts Book See Parts Book

2 2 2 2

Hi temp lithium complex grease Hi temp lithium complex grease Hi temp lithium complex grease Hi temp lithium complex grease

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

Every six months Tram gear case (Change)

2

High demulsibility gear oil

Spec. 100-15

Hydraulic oil (Change) Strainers (Change) Hydraulic oil filter (Change) Breather, hydraulic tank (Change)

1 1 1 3

Spec. 100-1 See Parts Book See Parts Book See Parts Book

Note 1: When the oil sample and oil change interval are identical, a sample of the old oil is to be taken and sent for analysis prior to changing the oil (see the Oil sampling procedure in this chapter). Always inspect breathers when taking hydraulic oil samples.

______________________________________________________________ A6474X347 REV 06 5.

BI016954-06 (EN-US)

Maintenance _____________________________________________________ Fig. 82: Lubrication chart 6

24,41,44

23,37,46 21,36,43 (fill)

46,47

20,35,42 (fill)

1

21,34,41 (check)

17 11,5,1

20,35,42 (check)

12,4,1 18

10,45,51 8,9

4,12,1 57,58

25,46,52,53 22,44,50 (check)

55 54

14,13 2,44,50 (fill)

56

49

48

2 15,16

34

3 19

7 ________________________________________________________________ 5.130 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

____________________________________________________ Maintenance Specific lubrication and maintenance procedures Every shift cutter head lift cylinder pins

Lubricate the right and left cylinder pins (upper and lower) through the grease fittings located on each cylinder (Fig. 83). Pump approximately 3 cu. in. (50 cu. cm.) into each fitting.

Fig. 83 : Cutter head cylinder pin location

Cutter head cylinder pin (upper) (2)

Cutter head cylinder pin (lower) (2) (remote lube block)

conveyor swing cylinder pin (front and rear)

Lubricate the front and rear conveyor swing cylinder pins through the grease fittings located on each end of the cylinder (Fig. 84). Pump approximately 3 cu. in. (50 cu. cm.) into each fitting.

Fig. 84: Conveyor swing cylinder pin lubrication Conveyor swing cylinder pin grease fitting

Conveyor swing cylinder pin grease fitting

______________________________________________________________ A6474X347 REV 06 5.

BI016954-06 (EN-US)

Maintenance _____________________________________________________ cutter head frame pivot pin (left and right)

Lubricate left and right cutter head pivot points through the grease fittings located on the left and right front lubrication blocks (Fig. 85).

Pump approximately 3 cu. in. (50 cu. cm) of grease into each fitting.

Fig. 85: Cutter head frame pivot pins

Cutter head frame pivot pin lube block

cutter head bits

Inspect the cutter head bits to ensure that they will rotate in their holders and for damaged or missing bits (Fig. 86). Replace bits immediately if any are missing or damaged.

Fig. 86: Cutter head bit

Bit

Holder

________________________________________________________________ 5.132 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

____________________________________________________ Maintenance conveyor roller

Lubricate the conveyor roller through the two (2) grease fittings located on the shaft (Fig. 87). Pump approximately 3 cu. in. (50 cu. cm.) into each fitting.

Fig. 87: Conveyor take-up shaft lubrication

Grease fitting

Grease fitting

Daily gathering head hinge pin (right and hand)

Lubricate the left and right upper and lower gathering head hinge pins through the grease fittings located on the left and right front lubrication blocks (Fig. 88). Pump approximately 3 cu. in. (50 cu. cm.) of grease into each fitting.

Fig. 88: Gathering head hinge pin

Gathering head hinge pin

______________________________________________________________ A6474X347 REV 06 5.

BI016954-06 (EN-US)

Maintenance _____________________________________________________ crawler idler roller (right and left) conveyor to tractor frame pin (left and right)

Lubricate the left and right crawler idler rollers (Fig. 89) through the grease fittings located on the outside face of the crawler idler roller.

Lubricate the left and right conveyor to tractor frame pin through the grease fittings located on the right and left front lubrication blocks (Fig. 94). Pump approximately 3 cu. in (50 cu. cm) of grease into each fitting.

Fig. 89: Crawler idler roller and conveyor to tractor frame pin lubrication

Conveyor to tractor frame pin

Crawler idler roller

stabilizer shoe pin (right and left)

Lubricate the stabilizer shoe pins (right and left) through the grease fittings located on the lubrication block on the right side of the machine (Fig. 90). Pump approximately 3 cu. in (50 cu. cm) of grease into each fitting.

conveyor lift pin (right and left)

Lubricate the conveyor lift pins (right and left) through the grease fittings located on the lubrication block on the right side of the machine (Fig. 90). Pump approximately 3 cu. in (50 cu. cm) of grease into each fitting.

Fig. 90: Lubrication block - stabilizer shoe and conveyor lift pins

Lubrication block

________________________________________________________________ 5.134 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

____________________________________________________ Maintenance conveyor swivel pins (top and bottom)

Lubricate the top and bottom conveyor swivel pin located on the pins (Fig. 91). Pump approximately 3 cu. in (50 cu. cm) of grease into each fitting.

Fig. 91: Conveyor swivel pins

Conveyor swivel pin (top)

Conveyor swivel pin (bottom)

cutter head boom pivot pin

Lubricate the cutter head boom pivot pins (Fig. 92) through the grease fitting located on the pin. Pump approximately 3 cu. in (50 cu. cm) of grease into each fitting.

Fig. 92: Cutter head boom pivot pin

Cutter head boom pivot pin

______________________________________________________________ A6474X347 REV 06 5.

BI016954-06 (EN-US)

Maintenance _____________________________________________________ gathering head raise cylinder pins (left and right)

Lubricate the gathering head raise cylinder pins (Fig. 93) through the grease fittings located on each end of the cylinder. Pump approximately 3 cu. in (50 cu. cm) of grease into each fitting.

Fig. 93: Gathering pan raise cylinder pins

Gathering head raise cylinder pin (upper)

conveyor chain take-up pin (left and right)

Gathering head raise cylinder pin (lower)

Lubricate the conveyor chain take-up pin (Fig. 94) through the grease fitting located on the pin. Pump approximately 3 cu. in (50 cu. cm) of grease into each fitting.

Fig. 94: Conveyor chain take-up pin and nut

Conveyor chain take-up pin

________________________________________________________________ 5.136 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

____________________________________________________ Maintenance CLA head pot assembly (right and left)

Level the miner and place the gathering head on grade before checking or adding lubricant. Check the oil level in the pot assembly (Fig. 95). If oil is needed, add oil through the fill hole until oil comes out the breather.

CLA head transfer case (right and left)

Level the miner and place the gathering head on grade before checking or adding lubricant. Check the oil level in the hydraulic transfer case (Fig. 95). If oil is needed, add oil through the fill hole until oil comes out the breather.

Fig. 95: CLA head pot assembly and transfer case lubrication

Oil check, pot assembly

Oil check, transfer case

Oil fill, pot assembly

tram gear case (right and left)

Oil fill, transfer case

With the miner in a level position, check the oil level in both tram gear cases by looking at the sight glass located on the side of each gear case (Fig. 96). Oil should be visible in each sight glass. If oil level is low, add oil through the fill plug hole.

Fig. 96: Tram gear case oil level

Oil check

Oil fill

______________________________________________________________ A6474X347 REV 06 5.

BI016954-06 (EN-US)

Maintenance _____________________________________________________ input cutter gear case

With the gathering head lowered to ground level and the cutter head boom level with ground, check the oil level in both of the input cutter gear cases by removing the check plug located on each side of the cutter head assembly (Fig. 97). Oil should flow from check plug hole when plug (s) is removed. If oil level is low, add oil through the fill plugs located on each side of the gathering head.

Fig. 97: Input cutter gear case (s) oil level Oil fill plug (one per side)

main cutter gear case

Oil check plug (one per side)

With the cutter head boom level with ground, check the oil level in both of the main cutter head gear cases by removing the check plug located on the front of each gear case (Fig. 98). Oil should flow from check plug hole when plug (s) is removed. If oil level is low, add oil through the fill plug hole located on top of each gear case.

Fig. 98: Main cutter head gear case (s) oil level Oil fill plug (one per side)

Oil check plug (one per side)

________________________________________________________________ 5.138 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

____________________________________________________ Maintenance hydraulic oil level

With all of the machine cylinders in the fully collapsed position, check the hydraulic oil level (Fig. 99). Remove dipstick from tank and wipe clean. Insert dipstick back into tank and remove. The oil should be level with the full line indicated on dipstick. If oil level is low, add oil until full level is met.

Fig. 99: Hydraulic oil tank level

Hydraulic oil tank

Dip stick location

Weekly crawler track tension

Check the crawler tracks for proper tension. If adjustment is necessary, see the Crawler track adjustment procedure in this chapter.

conveyor chain tension

Check the conveyor chain tension with the machine running. If adjustment is necessary, see the Conveyor chain tension adjustment procedure in this chapter.

fasteners

Due to the machine being subjected to continual shock loading and vibration, close attention to all mounting bolts and screws is required.

Loose fasteners will cause premature wear and failure to bearings, couplings, etc. Inspect and tighten as required the following fasteners: ■

Cutter head gear case: hex head bolts

■

Cutter head motors: Super bolts

■

Center drums: socket head capscrews

■

End drums: hex head bolts

■

Tram cases: socket head capscrews

■

Tram motors: hex head bolts

■

Gathering head CLAs: hex head bolts

■

Gathering head pots: hex head bolts

■

Gathering head motors: socket head capscrews

______________________________________________________________ A6474X347 REV 06 5.

BI016954-06 (EN-US)

Maintenance _____________________________________________________ electrical cables, conduits, and glands hoses and fittings

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

Visually inspect and hydraulic and water hoses and fittings for signs of wear, damage, or leakage. This inspection should be performed with the machine running. Observe the following precautions/procedures while checking for leaks: ■ ■ ■

Relieve pressure before disconnecting hoses.

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

Do not exceed the working pressure of hydraulic hoses.

WARNING! Use extreme caution when inspecting for leaks with the machine running. Unexpected machine movement, or contact with moving parts, could result in injury.

Escaping fluids under pressure can penetrate skin and cause serious injury. Do not attempt to locate hydraulic leaks be feeling hoses and fittings with bare hands. Pin hole leaks can penetrate the skin. lighting

Turn on the lights and visually inspect for bulbs that need to be replaced.

reflectors and warning tags

Visually inspect the condition and readability of all warning tags, labels, and reflectors for signs of wear or damage. Replace any reflector or tag that is missing or damaged.

machine stop switches

Check the machine stop switches located on each side of the machine for proper operation. Start the machine and strike a machine stop switch; the machine pump motor will shutdown, in turn shutting down all other motors. Repeat for the other switch.

chain take-up pin (right and left)

Lubricate the chain take-up pin (Fig. 100) through the grease fitting located on the nut. Pump approximately 3 cu. in (50 cu. cm) of grease into each fitting.

Fig. 100: Chain take-up pin

Chain pin lubrication

________________________________________________________________ 5.140 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

____________________________________________________ Maintenance

water filter, jet pump

The following components must be changed as required by the conditions at the mine. Refer to the Hydraulic component location drawing (Fig. 37) in the Hydraulic section of this chapter and the dust-cooling component location drawing (Fig. 57) in the Water section of this chapter for component locations.

■

Water filter

■

Jet pump, hydraulic (inspect)

■

Jet pump, water (inspect)

______________________________________________________________ A6474X347 REV 06 5.

BI016954-06 (EN-US)

Maintenance _____________________________________________________ Monthly CLA head pot assembly

Change the oil in both CLA head pot assemblies (Fig. 101).  Level the miner, raise the gathering head pan, and secure in place.  Clean dirt and debris from around the drain plug located under the gear case.  Remove the drain plug and allow oil to completely drain from the gear case.  Clean and reinstall drain plug.  Clean dirt and debris from around the check plug and remove the plug.  Clean dirt and debris from around the fill plug and remove the plug.  Slowly add oil through the fill plug until oil begins to flow from the check plug hole. Allow sufficient time for the oil to ravel through the gear case when filling.  Clean and reinstall the check and fill plugs.

CLA head transfer case

Change the oil in both CLA head transfer cases (Fig. 101).  Level the miner, raise the gathering head pan, and secure in place.  Clean dirt and debris from around the drain plug located under the gear case.  Remove the drain plug and allow oil to completely drain from the gear case.  Clean and reinstall drain plug.  Clean dirt and debris from around the check plug and remove the plug.  Clean dirt and debris from around the fill plug and remove the plug.  Slowly add oil through the fill plug until oil begins to flow from the check plug hole. Allow sufficient time for the oil to ravel through the gear case when filling.  Clean and reinstall the check and fill plugs.

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

IMPORTANT! Always collect oil samples using a siphon pump. Do not remove the drain plug and collect oil by allowing it to run out into the bottle.

________________________________________________________________ 5.142 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

____________________________________________________ Maintenance Fig. 101: CLA pot assembly and input transfer case

Oil check, pot assembly

Oil check, transfer case

Oil fill, pot assembly

CLA head transfer case drain plug

Oil fill, transfer case

CLA head pot drain plug

______________________________________________________________ A6474X347 REV 06 5.

BI016954-06 (EN-US)

Maintenance _____________________________________________________ input cutter head gear case

Change the oil in both input cutter head gear cases (Fig. 102).  Position the cutter head horizontally (flat back in a vertical position).

Clean dirt and debris from around the drain plug located under the gear case.  Remove the drain plug and allow oil to completely drain from the gear case.  Clean and reinstall the drain plug.  Clean dirt and debris from around the check plug and remove the plug.  Clean dirt and debris from around the fill plug and remove the plug.  Slowly add oil through the fill plug until oil begins to flow from the check plug hole. Allow sufficient time for the oil to travel throughout the gear case when filling.  Clean and reinstall the check and fill plugs.

Fig. 102: Input cutter head gear case Oil fill plug (one per side)

Drain plug (one per side)

Oil check plug (one per side)

Flat back

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

IMPORTANT! Always collect oil samples using a siphon pump. Do not remove the drain plug and collect oil by allowing it to run out into the bottle. ________________________________________________________________

5.144

25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

____________________________________________________ Maintenance main cutter head gear case

Change the oil in both main cutter head gear cases (Fig. 103).  Lower the cutter head completely to the ground. Clean dirt and debris from around the drain plug, located under the gear case.  Remove the drain plug and allow oil to completely drain from the gear case.  Clean and reinstall the drain plug.  Clean dirt and debris from around the check plug and remove the plug.  Clean dirt and debris from around the fill plug and remove the plug.  Slowly add oil through the fill plug until oil begins to flow from the check plug hole. Allow sufficient time fro the oil to travel throughout the gear case when filling.  Clean and reinstall the check and fill plugs.

Fig. 103: Main cutter head gear case Oil fill plug (one per side)

Oil check plug (one per side)

______________________________________________________________ A6474X347 REV 06 5.

BI016954-06 (EN-US)

Maintenance _____________________________________________________ CLAs

Inspect the CLAs (Fig. 104) for damage. If a CLA needs replaced, see CLA removal and installation procedure in this chapter.

Fig. 104: CLAs

CLA

Oil sampling plan This plan contains specific instructions to be followed in order to correctly collect gear case lubricant samples, and preparation of the samples for laboratory analysis. Adherence to these instructions will insure that all oil sample analysis reports give an accurate picture of the oils condition as well as wear trends of gears, bearings, etc. Accurate reporting and analysis of oil samples will prove extremely beneficial providing a tool to allow planning of scheduled down-time and prevention of costly equipment breakdown.

Preparation prior to sample collection For each machine to be sampled, you will need a supply of sample collection bottles and identification labels (Fig. 105) sufficient to sample each identified gear case (every sixty shifts).

One sample bottle and collection hose is required for each gear case to be sampled. Label each container with the identifying name of the gear case (crawler gear case, left or cutter head gear case, right front, etc.).

Collection of oil samples NOTICE! If the gear case is scheduled for oil drain and refill, obtain the oil sample prior to the oil change.

Each oil sample should be taken while the oil is at normal operating temperature. If the machine has not been operating just prior to sampling, run the machine until oil temperature reaches approximate normal operating temperature. Shutdown the machine and allow 2 - 3 minutes for the oil to drain back and stabilize it’s level.

IMPORTANT! Always collect oil samples using a siphon pump. Do not remove the drain plug and collect oil by allowing it to run out into the bottle.

________________________________________________________________ 5.146 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

____________________________________________________ Maintenance IMPORTANT! Always use the collection hose provided with each bottle. Always discard hose immediately following collection of the oil and do not use it for the next sample. To do so will contaminate the next sample with oil from the previous sample.

After taking sample, check and refill gear case back to proper fill level.

Following collection of all oil samples, record the specific brand and product name of the lubricant that has been installed in each gear case.

Recommended gear cases to be sampled: ■

Input cutter head gear case (left and right)

■

Main cutter head gear case (left and right)

■

Input gathering head gear case (left and right)

■

Main gathering head gear case (left and right)

■

Main hydraulic oil tank

Fig. 105: Oil sampling Oil fill plug

Typical siphon pump and bottle

Oil level

Place end of siphon tube approximately half way into sump

Note: Hold sample pump and bottle below oil level

______________________________________________________________ A6474X347 REV 06 5.

BI016954-06 (EN-US)

Maintenance _____________________________________________________ Every three months IMPORTANT! For motor bearings that require high temperature lithium complex grease (Spec. 100-15), The manufacturer provides a special “button” style lubrication fitting (Fig. 111) to prevent the accidental use of multi-purpose lithium complex grease at these locations. cutter motor bearings

Lubricate the left and right cutter head motor bearings (Fig. 106) with high temperature lithium complex grease through the grease fittings located on each side of the cutter head assembly . To lubricate the motors:  Remove the cover to access the motor.  Inspect the grease fittings on the exit side of the front and rear motor bearing.  If the exit side motor bearing ports are equipped with spring loaded relief fittings (Fig. 106):  Lubricate both motor bearings using the button type fittings (Fig. 114) until new grease appears out of the relief port on the exit side of the bearing.  Operate the motor for five minutes.  Inspect for any grease leakage in the area around the bearing.  If the grease fitting on the exit side of the motor bearing is fitted with a plug:  Remove the plug.  Lubricate both motor bearings using the button fitting until new grease appears out of the exit side of the bearing.  Operate motor (s) for five (5) minutes.  Inspect for any grease leakage in the area around the bearing.  Replace grease plug (s) in all port (s).

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

________________________________________________________________ 5.148 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

____________________________________________________ Maintenance Fig. 106: Cutter motor bearing lubrication Button type grease fitting located behind cover Cutter head motor cover

Spring loaded grease fitting

pump motor bearings

Lubricate the pump motor (Fig. 107) with high temperature lithium complex grease (Spec. 100-14) through the two (2)grease fittings located the right side of the machine . To lubricate the motors: IMPORTANT! For motor bearings that require high temperature lithium complex grease (Spec. 100-15), The manufacturer provides a special “button” style lubrication fitting (Fig. 114) to prevent the accidental use of multi-purpose lithium complex grease at these locations.  Remove the cover to access the motor.  Inspect the grease fittings on the exit side of the front and rear motor bearing.  If the exit side motor bearing ports are equipped with spring loaded relief fittings (Fig. 107):  Lubricate both motor bearings using the button type fittings (Fig. 114) until new grease appears out of the relief port on the exit side of the bearing.  Operate the motor for five minutes.  Inspect for any grease leakage in the area around the bearing.

______________________________________________________________ A6474X347 REV 06 5.

BI016954-06 (EN-US)

Maintenance _____________________________________________________  If the grease fitting on the exit side of the motor bearing is fitted with a plug:  Remove the plug.  Lubricate both motor bearings using the button fitting until new grease appears out of the exit side of the bearing.  Operate motor (s) for five (5) minutes.  Inspect for any grease leakage in the area around the bearing.  Replace grease plug (s) in all port (s).

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

Fig. 107: Pump motor bearings

Pump motor (located behind cover)

scrubber motor bearings

Lubricate the scrubber motor bearings (Fig. 108) with high temperature lithium complex grease (Spec. 100-14) as follows: IMPORTANT! For motor bearings that require high temperature lithium complex grease (Spec. 100-15), The manufacturer provides a special “button” style lubrication fitting (Fig. 108) to prevent the accidental use of multi-purpose lithium complex grease at these locations.  Remove the cover to access the motor.  Inspect the grease fittings on the exit side of the front and rear motor bearing.  If the exit side motor bearing ports are equipped with spring loaded relief fittings (Fig. 108):  Lubricate both motor bearings using the button type fittings (Fig. 114) until new grease appears out of the relief port on the exit side of the bearing.  Operate the motor for five minutes.  Inspect for any grease leakage in the area around the bearing.

________________________________________________________________ 5.150 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

____________________________________________________ Maintenance  If the grease fitting on the exit side of the motor bearing is fitted with a plug:  Remove the plug.  Lubricate both motor bearings using the button fitting until new grease appears out of the exit side of the bearing.  Operate motor (s) for five (5) minutes.  Inspect for any grease leakage in the area around the bearing.  Replace grease plug (s) in all port (s).

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

Fig. 108: Scrubber motor bearings

Scrubber motor (located under cover)

______________________________________________________________ A6474X347 REV 06 5.

BI016954-06 (EN-US)

Maintenance _____________________________________________________ Every six months tram gear cases

Change the oil in both tram gear cases (Fig. 109).  Remove the drain plug and allow oil to completely drain from the gear case.  Clean and reinstall the drain plug.  Remove the fill plug located on top of the gear case.  Add oil through the fill plug hole until oil is visible in the sight glass.

When filling, allow sufficient time for the oil to travel throughout the gear case.  Clean and reinstall the fill plug.

Fig. 109: Tram gear case

Oil check

Oil fill

________________________________________________________________ 5.152 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

____________________________________________________ Maintenance hydraulic oil

Change the oil in the hydraulic oil tank (Fig. 110).  Clean all dirt and debris from around the fill cap and the drain plug.  Remove the drain plug and allow the oil tank to completely drain.  Clean and remove the drain plug.  Fill the tank with oil (Spec. 100-1) using the power fill pump until the oil level reaches the full level as indicated on the dipstick. To activate the power fill:  Engage the conveyor down function.  Open the ball valve.  After filling, start the machine and engage all hydraulic cylinders for their full length of travel (full extend and retract) in order to purge the hydraulic system of air.  Recheck the oil level on the dipstick. Add more oil as needed.

Fig. 110: Hydraulic oil tank Hydraulic oil tank

______________________________________________________________ A6474X347 REV 06 5.

BI016954-06 (EN-US)

Maintenance _____________________________________________________

breathers and strainers

The following components must be changed as required by the conditions at the mine. Refer to the Hydraulic component location drawing (Fig. 37) in the Hydraulic section of this chapter and the Scrubber and dust-cooling component location drawing (Fig. 57) in the Water section of this chapter for component locations.

■

Breathers

■

Y strainers

■

Jet pump strainers

Scrubber cleaning  Lower the gathering head and cutter head assemblies until they touch the floor.  Lower the conveyor assembly until it is level with the floor.  Disconnect the trailing cable to de-energize the miner.

WARNING! Follow all Federal and mine regulations regarding lockout/tagout procedures. Failure to do so may result in serious injury or death.  Insert the hose in both the right and left hand scrubber air intakes at the front of the miner. Thoroughly flush each scrubber inlet duct.  Remove any accumulated debris from inside the duct. Insert the hose into the duct and thoroughly flush it with water.  Locate the scrubber rub rail (Fig. 111), which is directly to the rear of the tram case on the fan exhaust side of the miner.  Remove the rub rail pin that secures the scrubber rub rail to the rail adjacent to it. Swing open the scrubber rub rail.  Locate the mist eliminator/screen clean-out cover (Fig. 111).

________________________________________________________________ 5.154 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

____________________________________________________ Maintenance Fig. 111: Scrubber rubber rail and mist eliminator/screen cover Mist eliminator cleanout cover Rub rail pin

Scrubber rub rail

 Pull the clean-out cover’s flip pin from the half-link to free the cover from the tractor-frame. Remove the cover and its rubber gasket.  Slide the brush filter screen (Fig. 112) out of its frame.  Thoroughly rinse the brush filter screen and the set the screen aside.  Slide the mist eliminator assembly out of its frame (Fig. 112).  Thoroughly rinse the mist eliminator assembly and set the assembly aside.

Fig. 112: Brush filter screen and mist eliminator assembly Flip pin

Mist eliminator cleanout cover

Half link

Rubber gasket

Brush filter screen

Mist eliminator assembly

______________________________________________________________ A6474X347 REV 06 5.

BI016954-06 (EN-US)

Maintenance _____________________________________________________  14. Remove the sump screen (Fig. 113).  15. Remove any accumulated debris from the sump and thoroughly flush it with water.  16. Replace the sump screen Fig. 113: Sump screen

Sump screen

 17. Replace the mist eliminator assembly into its frame (Fig. 114), making sure that the eliminators air flow arrow points toward the scrubber exhaust fan.

Fig. 114: Mist eliminator assembly replacement Mist eliminator assembly

 18. Replace the brush filter screen into its frame (Fig. 115).

Fig. 115: Brush filter screen replacement Brush filter screen

________________________________________________________________ 5.156 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

____________________________________________________ Maintenance  19. Replace the mist eliminator/screen clean-out cover (Fig. 116) and gasket and secure it by sliding the pin into the half-link.  20. Swing the scrubber rub rail closed and secure with the rub rail pin.

Fig. 116: Cover replacement Mist eliminator cleanout cover Rub rail pin

Scrubber rub rail

______________________________________________________________ A6474X347 REV 06 5.

BI016954-06 (EN-US)

Adjustment procedures ___________________________________________ Setting hydraulic pressures ■

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

■

Most relief valves are set to factory specifications and should require no further adjustment. If a problem occurs which requires the reliefs to be adjusted, make certain the correct procedures are followed and all work is performed by a qualified person.

■

Remember when adjusting relief valves that turning the adjusting screw in (clockwise) will increase the pressure setting.

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

The miner is equipped with seven pressure gauges, typically mounted in a gauge panel, to aid in setting relief pressures. The gauges are for: ■

main flow - primary pressure circuit (all functions of the main control valve can be read from this gauge),

■

pilot/auxiliary pressure circuit,

■

accumulator,

■

conveyor chain take-up,

■

anti-chatter/maintenance (shear down) valve for cutter head,

■

gathering head float valve, and

■

the reduced pilot pressure circuits.

There will be occasions when relief valves, or other pressure control valves, must be set or adjusted. Setting relief valve pressure is necessary when a relief valve is replaced with a new unit or when an existing relief valve needs to be adjusted, for example, during the course of troubleshooting a hydraulic system fault. This section describes the proper procedure for setting the relief valves.

________________________________________________________________ 5.158 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

__________________________________________ Adjustment procedures IMPORTANT! Always use the proper tools when adjusting valve cartridges.

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

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

Always refer to your parts manual when ordering load holding valves for the cutter or conveyor cylinders.

Never rely on the load holding valve as a means of supporting the cutter boom or conveyor boom while making repairs. Always support the cutter boom and conveyor boom with adequate material before working around or underneath the cutter or conveyor.

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

Adjustment procedure should start with the pilot/auxiliary pressure circuit because this system is a “closed center circuit” and will build pressure as soon as the pump is started. The main flow-primary pressure circuit is an “open-center circuit” and no pressure is present in this circuit until a function is activated.

Reference Pilot/auxiliary and Main flow-primary pressure circuits and Abbreviation and terms in the Hydraulic section of this chapter.

______________________________________________________________ A6474X347

REV 06

BI016954-06 (EN-US)

Adjustment procedures ___________________________________________ Pilot/auxiliary pump circuit relief valve adjustments The following procedure is for start up of new and rebuilt machines.

IMPORTANT! Reference the Hydraulic section in this chapter for individual circuit information. Always refer to the hydraulic schematic in your parts manual for your miner.

WARNING! Two people are required to adjust pressure settings. One person will make the adjustments while the second person must remain at the “E-STOP” at all times during the adjustment procedure.

Failure to do so may result in serious injury or death.  1. Loosen the nut on the relief valve cartridge and turn the screw out (counter-clockwise) using an Allen wrench to prevent over pressuring the gauge on this circuit. Remove the hose and cap or plug the outlet port of the relief valve. Take care to prevent dirt from entering the system.  2. Conveyor chain take-up circuit (optional): open the needle valve by turning the knob counter-clockwise, opening flow to tank.  3. Start the pump motor (see Startup procedure in this chapter) and adjust the pilot pressure 2 relief valve.

IMPORTANT! Before making any further adjustments, verify that the hydraulic oil is at operating temperature.  4. Adjust the conveyor chain take-up pressure reducing valve (optional).  Close the needle valve by turning the knob clockwise, opening flow to the take-up cylinders. The pressure reading should be 200 psi.  Remove the hex socket head plug to adjust the inner spool.

Using an Allen wrench, turn the screw in (clockwise) to increase pressure or out (counter-clockwise) to decrease pressure.  Replace the hex socket head plug.

________________________________________________________________ 5.160 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

__________________________________________ Adjustment procedures  5. Adjust the reduced pilot pressure valve.  Loosen the nut on the sequence valve cartridge and turn the screw out (counter-clockwise) using an Allen wrench to prevent over pressuring the gauge on this circuit.  While holding the cartridge in place, tighten the nut to lock the spool in place. Double check the pressure reading to ensure that the cartridge was not turned while tightening the nut.  Loosen the nut on the relief valve cartridge and turn the screw out (counter-clockwise) using an Allen wrench to prevent over pressuring the gauge on this circuit.  6. Readjust the pilot relief pressure valve, is necessary, to 600 psi.

Relief valve replacement  Pilot relief valve replacement: Set the pilot relief to 600 psi, per Step 3, making sure that the conveyor chain take-up knob is closed (turn clockwise to close).  Conveyor chain take-up pressure reducing valve replacement: Set the pilot relief to 175 psi, per Step 4, making sure the conveyor chain take-up knob is closed (turn clockwise to close).  Reduced pilot pressure valve replacement: See Steps 1 and 5.

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

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

______________________________________________________________ A6474X347

REV 06

BI016954-06 (EN-US)

Adjustment procedures ___________________________________________ Main control valve adjustment IMPORTANT! The main relief is set higher than the port reliefs and will only relieve if a spike occurs in the system or if the port relief does not function properly. This provides protection of the main pump section, A1.

CAUTION! Do not adjust the main relief over 3,000 psi. Destruction of the valve bank and the main pump could result.

CAUTION! Always be alert for any unintended machine movement.

IMPORTANT! Reference the Hydraulic section in this chapter for individual circuit information. Always refer to the hydraulic schematic in your parts manual for your miner.

WARNING! Two people are required to adjust pressure settings. One person will make the adjustments while the second person must remain at the “E-STOP” at all times during the adjustment procedure.

Failure to do so may result in serious injury or death.

Main relief adjustment  Remove the protective cap on the rear port relief of the stabilizer working section and loosen the nut on the adjusting screw. Turn the adjusting screw in all the way.  Loosen the nut on the main relief cartridge. Turn the main relief adjusting crew two turns clockwise.  Start the pump (see Start up procedure in this chapter) and activate the stabilizer shoe down function. This will raise the back portion of the machine off the ground.

WARNING! Keep body parts clear of machine while in raised position or serious injury could result.  With the stabilizer shoe down function bottomed out, turn the main relief cartridge adjusting screw in (clockwise) until a pressure of 3,000 psi is obtained.  With the stabilizer shoe function in the neutral position, hold the main relief cartridge screw in place and tighten the nut to lock the screw in place. Check the pressure setting to verify that the screw was not moved while tightening the nut.  Adjust the stabilizer shoe down port relief (see Port relief adjustment procedure in this chapter).  Replace the protective cap. ________________________________________________________________ 5.162 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

__________________________________________ Adjustment procedures Port relief valve adjustment Port relief valves are functional when operating the circuit in which they are installed. As the particular function is activated and the pressure reaches the adjusted setting, the port relief will relieve excessive pressure to the tank cavity within the valve bank, preventing damage to the circuit.

WARNING! Always allow function to bottom out and stop moving before adjusting any pressure.

If the correct pressure reading is not obtained as noted in Items 1 through 5 below, the port relief for that function must be adjusted.

The adjustment procedure for each port relief is the same and is:  Remove the protective cap on the port relief and loosen the nut on the adjusting screw.  Turn the port relief screw in (clockwise) to increase pressure and out (counter-clockwise) to decrease pressure.  Once the correct pressure reading is obtained, return the function to the neutral position, hold the screw in place, and tighten the lock nut. Check the pressure reading to ensure that the screw did not turn while the lock nut was being tightened.

Pressure readings: 1. Stabilizer shoe port relief  Activate the stabilizer shoe raise circuit to fully raise the stabilizer shoe. The main control valve pressure gauge should read 1,200 psi.  Activate the stabilizer shoe lower circuit allow to fully lower the stabilizer shoe. The main control valve pressure gauge should read 2,500 psi.

2. Cutter head port relief  Activate the cutter head raise circuit to fully raise the cutter head. The main control pressure gauge should read 2,800 psi.  Activate the cutter head lower circuit to fully lower the cutter head and raise the front of the machine off the ground. The main control pressure gauge should read 2,800 psi.

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

______________________________________________________________ A6474X347

REV 06

BI016954-06 (EN-US)

Adjustment procedures ___________________________________________ 3. Conveyor raise/lower port relief  Activate the conveyor raise circuit to fully raise the conveyor.

The main control valve pressure gauge should read 2,700 psi.  Activate the conveyor lower circuit to fully lower the conveyor.

The main control valve pressure gauge should read 1,400 psi.

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

4. Conveyor swing port relief  Activate the conveyor swing left circuit to fully swing the conveyor to the left. The main control valve pressure gauge should read 1,800 psi.  Activate the conveyor swing right circuit to fully swing the conveyor to the right. The main control valve pressure gauge should read 1,800 psi.

5. Gathering head port relief  Activate the gathering head raise circuit to fully raise the gathering head. The main control valve pressure gauge should read 1,700 psi.  If 1,700 psi is not obtainable, check that the relief in the gathering head float valve that is stamped “CR” is set to 1,800 psi (see Gathering head raise/hold/float-lower circuit in the Hydraulic section of this chapter).

________________________________________________________________ 5.164 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

__________________________________________ Adjustment procedures Tram track adjustment  1. Lower the conveyor tail section until it is level with the floor.  2. Raise the gathering head and cutter head and block both assemblies following standard blocking procedures.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all blocking devices.  3. Lower the gathering head and cutter head onto the blocking so that the front end of the miner lifts off the floor.  4. Extend the stabilizer completely so that the rear end of the miner lifts off the floor.  5. Securely block under the machine. The machine must be securely supported off the ground with the tram track free to turn.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load of all blocking devices.  6. Raise the stabilizer, gathering head, and cutter head assemblies so that the weight of the miner rests on the blocking.  7. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine lockout/tagout regulations.

WARNING! Follow all Federal and mine lockout/tagout regulations and procedures. Failure to do so could result in machine damage or serious injury or death to personnel.  8. Double check the tractor frame support blocking now that the weight of the tractor frame is completely upon it.  9. Evaluate the tram track for proper tension (Fig. 117). The tram track is at the proper tension when it hangs approximately 4 – 5” (100 to 125 mm) from the bottom wear shoes when the tractor frame is blocked off the floor. Using this evaluation, determine whether step 13, 14, or 15 provides the appropriate subprocedure to correct improper track tension.

Fig. 117: Tram track adjustment

Bottom of tractor wear shoe

4 – 5” (100 to 125 mm) gap

Top of tram track

______________________________________________________________ A6474X347

REV 06

BI016954-06 (EN-US)

Adjustment procedures ___________________________________________  10. Remove the hex head capscrews and lock washers that secure the front rub rail to the tractor frame (Fig. 118) and open the front rub rail cover.

Fig. 118: Rub rail removal Capscrew and lock washer

View A

Tram rub rail

Capscrew and lock washer View A

 11. Remove the cover plate to allow access to the idler assembly.  12. Locate the front idler take-up jack grease fitting and attach the grease gun to the fitting.  13. If the tram track tension is too tight, read just the idler position using the following steps:  Pump grease into the take-up jack to extend the cylinder and remove pusher plate pressure on the idler shims.  Remove one or more idler adjustment shims from the idler slide channel.  Open the pressure release valve for the front idler take-up jack and allow the jack to contract. The pusher plate will slide backwards until it is stopped by the remaining idler shims.  Pump grease into the idler take-up jack to extend the cylinder, move the idler assembly forward and tighten the tram track until it is at the correct tension. The tram track is at the proper tension when it hangs 4 – 5” (100 to 125 mm) from the bottom wear shoes when the tractor frame is blocked off the floor.

________________________________________________________________ 5.166 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

__________________________________________ Adjustment procedures  14. If the tram track is too loose, readjust the idler position using the following steps:  Pump grease into the idler take-up jack to extend the cylinder, move the idler assembly forward and tighten the tram track until it is at the correct location. The tram track is at the proper tension when it hangs 4 – 5” (100 to 125 mm) from the bottom wear shoes when the tractor frame is blocked off the floor.  Insert shims (Fig. 119) into the idler slide channel until the space between the tractor frame and the pusher plate is filled.  Open the pressure release valve for the front idler take-up jack and allow the cylinder to contract. The idler adjustment shims will keep the idler stationary and the track tensioned.  Evaluate the resulting track tension and repeat these steps until the track reaches proper tension.

CAUTION! Shims must be inserted completely into the idler slide channel. A shim that is not correctly seated on the idler slide channel’s inside surface provides uneven support that can cause idler slant. A slanted idler can cause uneven wear and stress on the tram track and can cause improper operation of or damage to the tram system.

IMPORTANT! Check that the shims are correctly seated on the idler slide channel’s inside surface by looking at the channel’s inside surface from the opposite side of the miner through the space between the gathering head and the idler assembly.

Fig. 119: Tram track adjustment Take-up cylinder Pusher plate Pressure relief valve

Shims Idler assembly

______________________________________________________________ A6474X347

REV 06

BI016954-06 (EN-US)

Adjustment procedures ___________________________________________  15. If the tram track tension is still too loose when the entire 5” shim set is inserted into the idler slide channel, re-adjust the idler position after removing a tram track link using the following steps:  Pump grease into the take-up jack to extend the cylinder and remove the pusher plate pressure on the idler shims.  Remove all of the idler adjustment shims from the idler slide channel.  Open the pressure release valve for the front idler take-up jack and allow the cylinder to contract.  The tram track tension should now be reduced and separation of the tram track will be easier.  Locate a tram track link near the tram idler.  Using the hammer and punch, remove the four roll pins of the two tram track pins (Fig. 120) that secure the tram track link to the track.  Using the hammer and punch, remove the tram track pins to disconnect the link from the track. Remove the disconnected link.  Store the tram track link, one of the tram track pins and two of the roll pins in a safe place.  Connect the two ends of the tram track and using the hammer and punch, secure the two end links together with the remaining tram track pin.  Using the hammer and punch, secure the tram track pin between the two links with the remaining two roll pins.  Pump grease into the idler take-up jack to extend the cylinder, move the idler assembly forward and tighten the tram track until it is at the correct tension. The tram track is at the proper tension when it hangs approximately 4 – 5” (100 to 125 mm) from the bottom wear shoes when the tractor frame is blocked off the floor.  Insert shims into the idler slide channel until the space between the tractor frame and the pusher plate is filled.  Open the pressure release valve for the front idler take-up jack and allow the cylinder to contract. The idler adjustment shims will keep the idler stationary and the track tensioned.  The idler adjustment shims will keep the idler stationary and the track tensioned.  Evaluate the resulting track tension and repeat until the

track reaches proper tension. ________________________________________________________________ 5.168 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

__________________________________________ Adjustment procedures Fig. 120: Tram track adjustment Pad

Track retention pin

Lock pin

 15. When the tram track has been adjusted to the proper tension, remove the grease gun from the idler take-up jack grease fitting.  16. Open pressure release to take pressure off of take-up cylinder.  17. Close the front rub rail cover and secure the front rub rail to the tractor frame with hex head capscrews and lock washers.  18. Connect the trailing cable to energize the miner.  19. Raise the tractor frame off the blocking by lowering the stabilizer and gathering head and cutter head assemblies.  20. Carefully remove the support blocking from under the tractor frame.  21. Lower the tractor frame onto the floor by raising the stabilizer and gathering head and cutter head assemblies.  22. Carefully remove the blocking from underneath the raised stabilizer, gathering head, and cutter head assemblies.

______________________________________________________________ A6474X347

REV 06

BI016954-06 (EN-US)

Adjustment procedures ___________________________________________ Tail shim adjustment As the conveyor wears the tail section may sag relative to the conveyor front section. The conveyor has been designed to allow correction of the sag by adding shims.  1. Lower the cutter head and gathering head assemblies until they touch the floor.  2. Position the conveyor tail section directly behind the miner and raise it to its highest position.  3. Insert blocking under the tail section and lower the tail onto the blocking. The conveyor should be at an angle with the rear end of the tail section slightly higher than the front.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all blocking devices.  4. Insert blocking between the top of the tractor frame and the bottom of the conveyor, leaving about 2” of space between the blocking and the conveyor bottom.  5. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine lockout/tagout regulations.

WARNING! Follow all Federal and mine lockout/tagout regulations and procedures. Failure to do so could result in machine damage or serious injury or death to personnel. 

6. Loosen the hex head capscrews that secure the shims between the shim retainer and the conveyor lower pivot plate (Fig. 121).

Fig. 121: Shim removal Hex head capscrews

Lower pivot plate

Shim retainer

Shims

________________________________________________________________ 5.170 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

__________________________________________ Adjustment procedures  7. Connect the trailing cable to energize the miner.

WARNING! The following steps releases the shims, which will fall free. Watch out for falling shims when loosening the capscrews.  8.

Slowly lower the conveyor slightly so that the front section rests on the frame support blocking. The slotted shims will now fall free.

 9.

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

WARNING! Follow all Federal and mine lockout/tagout regulations and procedures. Failure to do so could result in machine damage or serious injury or death to personnel.  10. Replace the removed shims (Fig. 122) and add the number of shims required to level the conveyor front and tail sections.  11. Tighten the hex head capscrews.

Fig. 122: Tail shim adjustment

Hex head capscrews

Shim retainer

Shims

Lower pivot plate

 12. Connect the trailing cable to energize the miner.  13. Raise the conveyor tail from the blocking.  14. Remove both sets of blocking and lower the conveyor tail until it is level with the floor.  15. Check the gap and alignment at the juncture of the conveyor front and tail sections for alignment. If the sections are not horizontally aligned, then add or subtract shims as required.

______________________________________________________________ A6474X347

REV 06

BI016954-06 (EN-US)

Adjustment procedures ___________________________________________ Fig. 123: Tail shim adjustment Correct gap and alignment Conveyor tail section

Conveyor front section

Add shims Conveyor tail section

Conveyor front section

Remove shims Conveyor tail section

Conveyor front section

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

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all blocking devices.  17. Securely retighten the hex head capscrews.

________________________________________________________________ 5.172 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

__________________________________________ Adjustment procedures Chain tension adjustment - mechanical take-up  1. Lower the gathering head and cutter head until they touch the floor.  2. Position the conveyor tail section straight behind the miner and lower onto blocking until the tail is level with the floor. Follow all mine procedures for blocking.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all blocking devices.  3.

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

WARNING! Follow all Federal and mine lockout/tagout regulations and procedures. Failure to do so could result in machine damage or serious injury or death to personnel.  4. On the right side of the conveyor loosen (but do not remove) the two hex bolts that secure the rod guide to the take up rod (Fig. 124). The rod should be able to rotate freely.  5. Repeat this step on the conveyor’s left take up rod.

Fig. 124: Chain tension adjustment - mechanical take-up Take-up rod

Hex bolt (2)

Rod guide

 6. To tighten the conveyor chain: Using a 3/4” hex head socket wrench inserted in the take-up rod’s crank socket (Fig. 125), alternately rotate the right and left take-up rods clockwise one rotation at a time until the proper chain tension is reached.  7. To loosen the conveyor chain: Using a 3/4” hex head socket wrench inserted in the take-up rod’s crank socket (Fig. 125), alternately rotate the right and left take-up rods counter clockwise one rotation at a time until the proper chain tension is reached.

IMPORTANT! Left and right take-up rods should be rotated equally. This maintains steady, equal pressure on the tail roller assembly and keeps the conveyor chain from drifting off center.

______________________________________________________________ A6474X347

REV 06

BI016954-06 (EN-US)

Adjustment procedures ___________________________________________ Fig. 125: Chain tension adjustment Tighten

Crank socket

Loosen

Crank socket

Crank socket

Crank socket

Tighten

Loosen

 8. When the proper chain tension has been reached, tighten the two hex bolts that secure the rod guide to the conveyor’s right take-up rod. The take-up rod should be securely clamped between the split block.  9. Repeat step 6 or 7 if loosening or tightening the conveyor chain.  10. Connect the trailing cable to energize the miner.  11. Slowly raise the conveyor tail section and carefully remove the blocking from underneath.  12. Start the conveyor and CLAs running and observe the chain for proper tension.  13. When the chain tension is properly adjusted with the conveyor tail straight behind the miner, slowly swing the tail section from left to right behind the miner and check the chain’s tension when the tail section is farthest from center (Fig. 126).

________________________________________________________________ 5.174 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

__________________________________________ Adjustment procedures IMPORTANT! Chain tension decreases as the tail section moves away from center. Check the chain tension when the tail is at an angle to confirm that it is properly adjusted.

Fig. 126: Tail section position

Farthest from center

Farthest from center

Chain tension adjustment - grease take-up  1. Lower the gathering head and cutter head until they touch the floor.  2. Position the conveyor tail section straight behind the miner and lower onto blocking until the tail is level with the floor. Follow all mine procedures for blocking.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all blocking devices.  3. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine lockout/tagout regulations.

WARNING! Follow all Federal and mine lockout/tagout regulations and procedures. Failure to do so could result in machine damage or serious injury or death to personnel.  4. Pump grease into the take-up jack (Fig. 127) to extend the cylinder rod and remove pressure on the adjustment shims. Repeat this step on the other side.  5. Alternately, left and right, add shims to increase chain tension or remove shims to decrease chain tension. An equal number of shims must be used on each side of the conveyor.

______________________________________________________________ A6474X347

REV 06

BI016954-06 (EN-US)

Adjustment procedures ___________________________________________ Fig. 127: Chain tension adjustment - grease take-up Take-up rod

Shims

Grease fitting

Grease take-up valve

 6. Once proper chain tension is achieved open the grease takeup valve and allow pressure to bleed from the cylinder. Repeat for the other side.  7. Check for proper adjustment  Connect electrical power to the miner.  Slowly raise the conveyor tail section and remove the blocking.  Start the conveyor / gathering head and observe the chain for proper tension. The conveyor chain should rise about 2” or less above the gathering head’s foot shaft sprocket as the chain emerges from under the conveyor pan. Check that there is no contact between the CLAs and the chain flights.  Slowly swing the conveyor tail section from left to right behind the miner and check the chain tension. The chain tension decreases when the tail section moves away from center.

________________________________________________________________ 5.176 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

__________________________________________ Adjustment procedures Chain tension adjustment - hydraulic take-up If the machine is equipped with a hydraulic chain take-up, the only adjustment is to the conveyor chain take-up valve. If the valve needs adjusted, see Conveyor chain take-up valve adjustment procedure in this chapter.

______________________________________________________________ A6474X347

REV 06

BI016954-06 (EN-US)

Adjustment procedures ___________________________________________ Cutter motor feedback adjustment The tram motor speed voltages are limited in the forward direction when the cutter motors are running. How much the tram speed is limited is controlled by the load on the cutter motors. When the load is light, as in a clean-up operation, the tram speed is less limited that when there is high cutter motor loading, as in a sumping operation.

The cutter motor loading is monitored by using a current transformer, and electronic overload CTs. The following procedure should be used to properly set the sump speed when using a Super Simpson control system.  1.

Enter the “SUMP SETUP MENU” (Fig. 128) in the Engineering level and record all existing parameter values.

 2.

Set the “Max Left Hand Sump Speed” and “Max Right Hand Sump Speed” at 20%.

 3.

Set the “Min Left Hand Sump Speed” and “Min Right Hand Sump Speed” at 5% below the max speed.

 4.

Start the cutter head and observe and record the running cur rent in free air for the cutter motors.

 5.

Go to the “SUMP CONFIG MENU” (Fig. 129) and set the “Cutter in Face Current” at approximately 30 amps above the free air current observed in Step 4.

 6.

Operate the miner in the face and observe the peak current reached during sumping operation on the “PRODUCTION MONITOR” screen (Fig. 129).

 7.

Enter the peak current observed in Step 6 as the “Sump Tram Max Cutter Current” on the “SUMP CONFIG MENU”.

 8.

Set the “Sump Tram Min Cutter Current” 30 amps below the max value obtained in Step 7.

 9.

Raise the max sump tram cutter current in small increments until the cutter current levels out, as seen on the “PRODUCTION MONTIOR”.

 10. Enter the current observed in Step 9 as the “Sump Tram Max Cutter Current”.  11. Set the “Sump Tram Min Cutter Current” 30 amps below the value obtained in Step 10.  12. Start raising the “Max Left Hand Sump Speed” and “Max Right Hand Sump Speed” on the “SUMP SETUP MENU” until the crawlers start to break traction. This is the max sump speed.  13. Set the “Min Left Hand Sump Speed” and “Min Right Hand Sump Speed” at 5% below the max speed obtained in Step 12.

________________________________________________________________ 5.178 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

__________________________________________ Adjustment procedures  14. The miner may start cutting with a lurching motion while sumping. If this occurs, raise the “Sump Speed Delta” value, located on the “SUMP SETUP MENU”, in small increments until the lurching subsides.

These parameter values are the optimum values for the machine in the current cutting conditions.

Clean up speed allows faster tram when approaching the face with the cutters running, pulling only free air current. Once the “Cutter in Face Current” is met, the algorithm for the sump configuration is activated.

IMPORTANT! Machine power must be disconnected during installation of the current generator. Cutter motor feedback adjustment is normally set with the crawler tracks off the mine floor, stabilizer and cutter head down (machine jack-knifed). To jack knife the machine you should be familiar with the hydraulic circuits on the miner, and in particular, the cutter head cylinder circuit and the shear down/ maintenance valve (anti-chatter) operation as described in the Hydraulic section of this chapter.

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

Fig. 128: Sump displays

Sump setup menu

______________________________________________________________ A6474X347

REV 06

BI016954-06 (EN-US)

Adjustment procedures ___________________________________________ Fig. 129: Sump displays (cont.)

Sump configuration menu

Production monitor

________________________________________________________________ 5.180 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

________________________________________ Replacement of wear parts Instructions on the replacement of wear parts It is essential that wear parts are replaced before they reach the lowest wear limit. Inspect the wear parts at regular intervals. All explosionproof characteristics of enclosures must be maintained.

CAUTION! Because these maintenance techniques are specialized, they should only be performed by qualified personnel.

Cutter head (boom) assembly The cutter head assembly (Fig. 130) can be removed as an assembly or in individual components.

Fig. 130: Cutter head assembly Boom Drum drive gear case

Boom pivot pin

Shear cylinder

Drum drive torque limiting clutch

Drum drive motor

Center drum

End drum

cutter head assembly removal

To remove the cutter head assembly (Fig. 131)  1. Attach an appropriate lifting device to the boom assembly.

Take up the slack in the lift assembly so that the weight is supported as the assembly is unpinned from the miner.

WARNING! You could be seriously injured or even killed by falling loads. Observe the safe working load limits of lifting and blocking devices and keep a safe distance from suspended loads.  2. Lower the gathering head and the cutter head to the floor and position the conveyor tail section level with floor.  3. Disconnect and lock out the electrical power to the miner. Follow all applicable Federal and mine regulations regarding lockout/tagout procedures.

______________________________________________________________ A6474X347 REV 06 5.181

BI016954-06 (EN-US)

Replacement of wear parts _________________________________________ WARNING! Follow all Federal and mine regulations for lockout/tagout. Failure to do so may result in serious injury or death.  4. Disconnect the power cables and water hoses from the cutter motors (see Cutter motor removal procedure in this chapter).

Be sure to tape up the power cables since electrical power will be connected to the miner.  5. Disconnect the water hoses to the dust suppression sprays.  6. Remove the 2 boom pivot pins (see Boom pivot pin removal procedure in this chapter - note that there are two different procedures; one for straight pins and one for tapered (McSweeney) pins).  7. Connect electrical power to the miner.  8. Extend the shear cylinders to push the boom pivots out of their tractor frame clevises.  9. Block the boom and shear cylinders to keep them stationary during their pin removal.

WARNING! You could be seriously injured or even killed by falling loads. Observe the safe working load limits of lifting or blocking devices and keep a safe distance from suspended loads.  10. Disconnect power to the miner. Follow all applicable Federal and mine regulations regarding lockout/tagout procedures.

WARNING! Follow all Federal and mine regulations for lockout/tagout. Failure to do so may result in serious injury or death.  11. Remove the shear cylinder boom clevis pins (see Shear cylinder removal procedure in this chapter).  12. Connect electrical power to the miner.  13. Retract the shear cylinders to pull their bearings free from the boom clevises.  14. Disconnect power to the miner. Follow all applicable Federal and mine regulations regarding lockout/tagout procedures.  15. Raise the rear of the boom assembly until it is above the top edge of the gathering head backboard.  16. Slowly tram the mine backwards until the cutter boom pivot points clear the front of the gathering head.

________________________________________________________________ 5.182 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

________________________________________ Replacement of wear parts Fig. 131: Boom assembly removal Cutter boom pivot (not shown)

Shear cylinder

cutter head assembly installation

Cutter boom

Shear cylinder clevis pin

To install the cutter head assembly (Fig. 131)  1. 

Slowly tram the miner forward toward the raised end of the boom until the pivot pins clear the gathering head backboard.

2. Lower the boom pivot points until the shear cylinders can reach their boom clevises. Block the boom to keep it in a secure position.

 3. Extend the shear cylinders until their rod end bearings can be inserted into the cutter boom clevises.  4. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations regarding lockout/tagout procedures.

WARNING! Follow all Federal and mine regulations regarding lockout/tagout procedures. Failure to do so may result in serious injury or death.

WARNING! Do not test the alignment of the shear cylinder rod end bearings and the cutter boom clevis using your fingers. Shifting of the aligned pieces could cause serious injury.  5. Position the right cylinder’s rod end bearing in the boom clevis.

IMPORTANT! The pin should be inserted so that its retaining channel remains outside the bushing.  6. Insert the rod end pin through the aligned clevis bushings and rod end bearing.

______________________________________________________________ A6474X347 REV 06 5.183

BI016954-06 (EN-US)

Replacement of wear parts _________________________________________  7.

Insert the pin retaining plate and secure to the boom clevis with hex head capscrews and lock washers.

 8.

Repeat steps 4 through 7 on the left shear cylinder.

 9.

Connect the trailing cable to energize the miner.

 10. Once the shear cylinders are secured to the cutter boom, remove the boom blocking to allow the cylinders to move the boom.  11. Contract the shear cylinders to pull the cutter boom pivot points into position in the tractor frame boom pivot clevises.

IMPORTANT! In addition to the shear cylinders, the stabilizer and gathering head can also be used to adjust the cutter boom’s position to allow easier insertion of the cutter boom pivot pins.  12. Install both cutter boom pivot pins (see Boom pivot pin procedure - note that there are two procedures: one for straight boom pivot pins and one for tapered (McSweeney) pins).  13. Replace the motor cooling water and scrubber spray water hoses onto the cutter head boom.  14. Replace the electrical power cables onto the cutter head boom.

________________________________________________________________ 5.184 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

________________________________________ Replacement of wear parts Boom pivot pin removal and installation boom pivot pin removal

To remove the boom pivot pin  1. Lower the conveyor tail section until it is level with the floor and gathering head and cutter head until they rest on the floor.  2. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations regarding lockout/tagout procedures.

WARNING! Follow all Federal and mine regulations regarding lockout/tagout procedures. Failure to do so may result in serious injury or death.  3. Locate the miner’s front rub rail and remove the hex head capscrew and lock washer that secures the rub rail to the tractor frame.  4. Open the front rub rail (Fig. 132).

Fig. 132: Front rub rail Capscrew and lock washer

View A

Tram rub rail

Capscrew and lock washer View A

 5. Locate the front idler take-up jack bracket assembly (Fig. 133), which is mounted directly to the rear of the idler shim channel.  6. Pull the flip pin from the half link to release the take-up jack bracket from the tractor frame.  7. Lower the end of the bracket until it clears the half link and pull the bracket straight out to remove it from the tractor frame.

IMPORTANT! Pressure from the cutter boom onto the pivot pin can make its removal very difficult. The shear cylinders can be used to find the boom position that puts the least pressure on the pin.

CAUTION! When the pivot pin pull point is found, block the cutter boom to prevent it from dropping or moving when the pivot pin is removed.

______________________________________________________________ A6474X347 REV 06 5.185

BI016954-06 (EN-US)

Replacement of wear parts _________________________________________ Fig. 133: Half link

Tale-up jack bracket Half link

Flip pin

 8. Locate the end of the boom pivot pin in the area from which the take-up jack bracket was removed.

To remove a straight pin:  9.

Remove the hex head capscrews and lockwashers that secure the boom pivot pin retaining plate to the tractor frame.

 10. Remove the pin retaining plate and its support block.  11. Insert a slide hammer adapter into the threaded hole in the end of the boom pivot pin.

IMPORTANT! Pressure from the cutter boom onto the boom pivot pin can make its removal very difficult. The shear cylinders can be used to find the boom position that puts the least pressure onto the pin. This position can be determined by striking the pin, slightly contracting or extending the shear cylinder, then striking the pin again and comparing the “ring”; as boom pressure on the pin decreases, the “ring” of the pin when it is struck becomes lower. When the “ring” of the pin becomes short and low, pin removal is much easier.

CAUTION! Use extreme caution when adjusting the boom with the shear cylinder to find the pivot pin’s pull point.  12. When the pivot pin’s pull point is found, block the cutter boom to keep it from dropping or moving when the pin is pulled.  13. Attach the slide hammer to its adapter and pull the boom pivot pin.

________________________________________________________________ 5.186 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

________________________________________ Replacement of wear parts To remove the tapered (McSweeney) boom pivot pin:  9.

Remove the hex head bolts and nuts that secure the inside cap then remove the cap.

 10. Remove the hex head bolts and nuts that secure the outside cap then remove the cap.  11. Remove the pin. boom pivot pin installation

To install the straight boom pivot pin  1. Position the boom pivot pin so that the end with the two flats (the end without the adapter) is inserted first. The single flat of the pin’s opposite end must face the four retaining plate holes.

IMPORTANT! On the back of the tractor frame clevis there is a welded strap that keeps the boom pivot pin from rotating. One of the flats of the boom pivot pin must parallel this strap or the pin cannot be completely inserted.  2. Use the hammer to insert the boom pivot pin through the aligned tractor frame clevis and boom pivot bushings.

IMPORTANT! If it is extremely difficult to insert the boom pivot pin through the aligned tractor frame clevis and boom pivot bushings, extend or contract the shear cylinders to improve the alignment between the clevis and boom.

CAUTION! Use extreme caution when adjusting the clevis and boom alignment with the shear cylinders.  3. Replace the support block over the four threaded holes in the tractor frame.  4. Place the retaining plate onto the support block. The end of the retaining plate L-extension should be positioned against the flat of the boom pivot pin.  5. Insert and tighten the hex head capscrews lockwashers to secure the boom pivot pin retaining plate to the tractor frame.

______________________________________________________________ A6474X347 REV 06 5.187

BI016954-06 (EN-US)

Replacement of wear parts _________________________________________ To install the tapered (McSweeney) boom pivot pin (reference fig.

134)  1. If not already installed, install a bushing into the boom arm by pressing or shrinking the bushing into the boom arm. Check to insure that the pin will rotate freely in the bushing. It may be necessary to polish the bushing to allow the pin to rotate freely.  2. Install outside caps in frame, making sure that bolt holes are horizontal. Place the boom in the frame.  3. Apply anti-seize type lubricant to the straight area of the pin prior to installation into boom arm. Install the pin into the boom arm through the inside of the frame. Make sure the holes in pin align properly with the holes in the outside cap and grease porting is toward the outside of the machine.  4. Install installation cap into inside of the frame making sure that holes are aligned. Install bolts and nuts making sure that the4 outside cap and pin are located correctly. Tighten the bolts and nuts by alternating from on to the other. Tighten as tight as possible.  5. Remove bolts and nuts and replace installation cap with the inside cap making sure that the unthreaded holes line up with the pin and the outside cap holes before install and tightening nuts and bolts. Alternate from on bolt to the other when tightening. Tighten to approximately 600 ft-lbs. Check for tightness with the first eight hours of operation and occasionally thereafter.  6. Replace the take-up jack bracket assembly into the tractor frame and secure it by inserting the flip pin through the half link.  7. Close the front rub rail.  8. Insert and tighten the hex head capscrews and lock washers to secure the closed front rub rail against the tractor frame.

________________________________________________________________ 5.188 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

________________________________________ Replacement of wear parts Fig. 134: Tapered pin (McSweeney)

Outside cap

Boom pivot pin (McSweeney)

Inside cap

______________________________________________________________ A6474X347 REV 06 5.189

BI016954-06 (EN-US)

Replacement of wear parts _________________________________________ Center cutter drum center cutter drum removal

To remove the center cutter drum WARNING! Replacement of the cutter head center drum involves working around a raised cutter head assembly. Never work under any raised assembly without proper blocking. Always block between the raised assembly and the tractor frame in addition to between the raised assembly and the floor.

WARNING! This procedure involves disconnecting and reconnecting the miner’s trailing cable. Always be aware of whether or not the miner is energized. Never perform maintenance on an energized miner.

Fig. 135: Center cutter drum removal/installation (typical shown) Center drum Capscrews Center drum seam Center drum upper half

Center drum lower half

Alignment keys

________________________________________________________________ 5.190 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

________________________________________ Replacement of wear parts  1. Lower the gathering head completely until its touches the floor.

Lower the conveyor tail assembly until it is level with the floor.  2. Rotate the cutter head slowly until one of the center drum seams (Fig. 135) appears directly in front and one appears directly in rear of the cutter head.  3. Lower the cutter head assembly until it touches the floor.  4.

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

WARNING! Follow all Federal and mine lockout/tagout regulations and procedures. Failure to do so could result in machine damage or serious injury or death to personnel.

CAUTION! Make sure the lifting device is capable of lifting the drum weight.

Use care when handling the cutter drum.

DANGER! Never work under any raised assembly without proper blocking.  5. Remove the socket head capscrews securing the front seam of the center drum.  6. Remove the socket head capscrews securing the rear seam of the center drum.  7. Collect the retaining plates for the center drum’s capscrews.

Store the retaining plates in a safe place for a center drum reassembly.  8. Attach chains to the upper half of the center drum. The chains should be capable of supporting the entire weight of the upper half of the center drum.  9. Using the pry bar and other necessary force, break the seal between the center drum so that the bottom half is free from the top half.  10. Attach the chain falls to the ceiling bolts.  11. Connect the chain falls to the chains on the upper half of the center drum.  12. Use the chain falls to lift the upper half of the center drum off the cutter head assembly. The cutter head and the lower half of the center drum should remain on the floor.

WARNING! Serious injury or death can result from falling loads. Observe the safe working load limits of lifting devices and keep a safe distance from suspended loads.

______________________________________________________________ A6474X347 REV 06 5.191

BI016954-06 (EN-US)

Replacement of wear parts _________________________________________  13. Remove the ten center drum alignment keys from the keyway slots around the edge of the bottom half of the center drum and store the keys in a safe place.  14. Connect trailing cable energize the miner.  15. Slowly raise the cutter head assembly until it is completely clear of the lower half of the center drum.  16. Slowly tram the miner backwards away from the suspended upper half and the resting lower half of the center until the cutter head assembly is completely clear of both of these pieces. center cutter drum installation

To install the center cutter drum (Fig. 135)  1. Place the ten center drum alignment keys into the keyway slots around the edge of the bottom half of the center drum.  2. Slowly rotate the cutter head until the center drum drive keys are positioned directly on the top and on the bottom of the cutter head assembly.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of lifting devices and keep a safe distance from suspended loads.  3. Slowly lower the cutter head assembly into the bottom half of the center drum. The bottom drum drive keys should fit into the interior of the lower half of the center drum.

WARNING! Stand clear of the cutter head assembly and the unsecured upper half of the center drum while lowering it.  4. Using the chain falls, slowly lower the upper half of the center drum onto the cutter head assembly. The top drum drive keys should fit into the underside interior of the upper half of the center drum.  5. Disconnect the chains that supported the upper half of the center drum from the chain falls.  6. Remove the chains from the upper half of the center drum.  7. Carefully verify that the top and bottom halves of the center drum fit together securely. The center drum alignment keys should fit into the upper half of the center drum. Using a rod, test that capscrews can be inserted through both halves of the drum and the alignment keys. Adjust as necessary to obtain a good close fit.

________________________________________________________________ 5.192 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

________________________________________ Replacement of wear parts  8. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine lockout/tagout regulations.

WARNING! Follow all Federal and mine lockout/tagout regulations and procedures. Failure to do so could result in machine damage or serious injury or death to personnel.  9. Insert the socket head capscrews into the holes in the top half of the drum through the alignment keys and through the bottom half of the drum. Use the following steps to equally distribute the torque over the center drum (Fig. 136):  Starting with the pair of capscrews at the right front of the center drum, place a retaining plate under the bottom half of the drum where the capscrews emerge and thread the capscrews into the retaining plate.  Alternating from front to back and moving from right to left, repeat this threading process on the other nine pairs of capscrews and nine retaining plates.  When all capscrews have been inserted into their retaining plates, start with the paired capscrews on the right of the front seam of the center drum and torque.  Proceed to the paired capscrews on the back right seam of the center drum and torque.  Alternating from front to back and moving from right to left, torque the eight remaining pairs of capscrews into their retaining plates.  10. Double check that all bolts have been properly torqued.

Fig. 136: Bolt torque order

______________________________________________________________ A6474X347 REV 06 5.193

BI016954-06 (EN-US)

Replacement of wear parts _________________________________________ End cutter drum end cutter drum removal

To remove the end cutter drum  1. Lower the gathering head completely until it touches the floor.

Lower the conveyor tail assembly until it is level with the floor.  2. Raise the cutter head assembly to its highest position. Place blocking underneath the cutter head assembly and lower the cutter head assembly onto the blocking.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of lifting devices and keep a safe distance from suspended loads.  3. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine lockout/tagout regulations.

WARNING! Follow all Federal and mine lockout/tagout regulations and procedures. Failure to do so could result in machine damage or serious injury or death to personnel.  4. Using the chisel and hammer, remove the strapping (Fig. 137) that pairs the cutter end drum and capscrew heads.

Fig. 137: Strapping Strapping

 5. Remove the hex head capscrews that secure the end drum cover plate.  6. Remove the end drum cover plate.  7. Remove the hex head capscrews and washers that secure the end drum to the cutter drum drive gear case (Fig. 138).

WARNING! You could be seriously injured by falling loads. Use extreme caution when working near suspended loads.

________________________________________________________________ 5.194 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

________________________________________ Replacement of wear parts Fig. 138: End cutter drum removal

Cover plate

End drum

End drum capscrews

Cover plate capscrews

 8. Using the pry bar and other necessary force, remove the end drum from the cutter head assembly. end cutter drum installation

To install the end cutter drum  1.

Insert 1” wooden dowels (Fig. 139) into the two holes located on the opposite sides of each key cutout on the planetary casting of the cutter drum drive gear case.

Fig: 139: Wooden dowel location Cutter drum drive gear case

Key cutouts

Wooden dowels

Key cutouts

______________________________________________________________ A6474X347 REV 06 5.195

BI016954-06 (EN-US)

Replacement of wear parts _________________________________________  2. On the outside of the end drum, mark the capscrew holes located on either side of the drum keys welded to the drum’s interior.  3. Locate the timing arrows (Fig. 140) on the cutter center drum and the end drum about to be installed. The end drum must be installed so that its timing arrow is directly adjacent to the center drum timing arrow.

Fig. 140: End drum capscrew and timing arrow locations Timing arrow Bolt hole marks

Drum keys

End drum

 4.

Slide the end drum onto the cutter drum drive gear case. Using the wooden dowels as guides, align the end drum so that the guide dowels come out of the marked holes in the end drum.

The keys of the end drum should seat into the key cutouts of the cutter drum drive gear case planetary casting.

 5.

Double-check that the timing arrows (Fig. 141) of the cutter end drum and the center drum align.

Fig. 141: Timing arrow alignment Timing arrow Timing arrow

End drum

Wooden dowels

________________________________________________________________ 5.196 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

________________________________________ Replacement of wear parts  6. Insert hex head capscrews into the open holes (those not blocked by the guides) of the end drum.  7. Tighten the capscrews into the threaded holes of the cutter drum drives gear case planetary casting.  8. Remove the wooden alignment dowels and insert the last four hex head capscrews through the end drum and into the threaded holes of the cutter drum drive gear case planetary casting.  9. Using the torque wrench with 20-to-1 multiplier, tighten all hex head capscrews to 1,200 ft-lb.

IMPORTANT! Make sure that the holes for the cover plate’s capscrews are not covered by the strapping.  10. When all bolts have been properly torqued, strap the bolts together in pairs and tack weld with the welding equipment.  11. Install the cover plate by inserting hex head capscrews through lock washers, through the cover plate, and into the holes in the end drum.

______________________________________________________________ A6474X347 REV 06 5.197

BI016954-06 (EN-US)

Replacement of wear parts _________________________________________ Drum drive motor drum drive motor removal

To remove the drum drive motor  1. Lower the gathering head completely until it touches the floor.

Lower the conveyor tail assembly until it is level with the floor.  2. Raise the cutter head assembly to its highest position. Place blocking underneath the cutter head assembly. Lower the cutter head assembly WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all blocking devices. Do not stand near the blocked cutter head.  3.

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

WARNING! Follow all Federal and mine lockout/tagout regulations and procedures. Failure to do so could result in machine damage or serious injury or death to personnel.  4. Remove the hex head capscrews and lock washers that secure the debris guard under its retaining strap (Fig. 142).  5. Remove the retaining strap and debris guard.

Fig. 142: Debris guard removal

Capscrews

Retaining strap

Debris guard

 6. Remove the hex head capscrews and lock washers that secure the top motor cover.  7. Remove the cover to expose the top of the motor.  8. Remove the hex head capscrews and lockwashers that secure the side motor cover.

________________________________________________________________ 5.198 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

________________________________________ Replacement of wear parts  9. Remove the cover (Fig. 143) to expose the side of the motor and the motor’s junction box.  10. Remove the drum drive shaft and cutter head drum drive torque limiting clutch (see Drum drive torque limiting clutch removal procedure in this chapter).  11. Place blocking under the motor to keep it supported when it becomes free from the cutter boom.

WARNING! You could be seriously injured or killed by falling loads. Observe the working load limits of lifting and blocking devices.

Fig. 143: Cover removal

Capscrews

Top motor cover

Side motor cover

 12. Remove the hex head caps crews and lockwashers that secure the junction box cover (Fig. 143).  13. Remove the cover and O-ring.  14. Locate the three taped power connections.  15. Strip off the three layers of tape covering these lug connections.

IMPORTANT! Before detaching these lugs, mark the wires to facilitate reconnection during motor installation.  16. Tag the lugs for correct reconnection then remove the hex head capscrew, flat washer, lock washer and hex head nut that secure the three power cable lugs to the three motor lugs.

______________________________________________________________ A6474X347 REV 06 5.199

BI016954-06 (EN-US)

Replacement of wear parts _________________________________________  17. Remove the socket head capscrews and lockwashers that secure the stuffing box’s half-moon clamp to the junction box.  18. Remove the clamp and slide the stuffing box out of the junction box. The power cable should be completely disconnected from the motor.

WARNING! While this power cable is detached from the motor, the trailing cable should not be reconnected to energize the miner. Damage to the miner, personal injury or death could result.  19. To prevent damage to the power cable lugs and gland assembly, cover the power cable and secure it to the miner in a safe location.  20. To protect the motor’s electrical connections, replace the motor junction box cover and secure it using hex head capscrews and lock washers.  21. Disconnect the two cooling water hoses from the front and rear motor cooling water fittings (Fig. 144). Plug the hose ends to keep them clean.  22. Using an adjustable wrench, remove the two water fittings from the motor and store in a clean place.  23. Plug the two motor cooling water ports to keep them clean.  24. Attach an appropriate lifting device to the motor and take up and slack so that the weight of the motor will rest on the lifting device when the motor is unbolted.  25. Remove the bolts and washers that attach the support mount to the motor (Fig. 144) and remove the support.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all lifting devices.  26. Remove the four Superbolts that secure the cutter head drum drive motor to the boom (Fig. 144) (see Superbolt procedure in this chapter).

________________________________________________________________ 5.200 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

________________________________________ Replacement of wear parts Fig. 144: Drum drive motor

Cooling water connection

Motor mount bolts

Cooling water connection

Junction box Superbolts (4)

drum drive motor installation

To install the drum drive motor WARNING! Federal law requires that mining equipment electrical connections must be inspected by a certified electrician before the equipment can be operated.

WARNING! This procedure involves attaching an electrical power cable to the cutter head drum drive motor. The trailing cable must be disconnected to safely perform this operation or serious injury or death will result.  1.

Block up cutter head drum drive motor into position against the rear of the boom so that the motor’s mounting holes align with the boom’s threaded motor mounting holes.

WARNING! You can be seriously injured or killed by a falling load. Follow the safe working load limits of all blocking devices.

______________________________________________________________ A6474X347 REV 06 5.201

BI016954-06 (EN-US)

Replacement of wear parts _________________________________________  2. Insert the four Superbolts through the motor mounting holes (Fig. 144) and hand tighten them into the boom’s threaded motor mounting holes  3. Torque the four Superbolts to approximately 1,800 ft-lbs (see Superbolt installation procedure in this chapter) to secure the drive motor to the boom.  4. Attach rear support mount to motor with bolts and lock washers (Fig. 144). Torque bolts to proper setting (see Torque tables in Chapter 6).  5. Install the two motor cooling water fittings into the front and rear cooling water ports of the motor.  6. Attach the two motor cooling water hoses to the fittings (Fig. 144).  7. Using a socket wrench, remove the four hex head capscrews and lock washers that secure the junction box cover.  8. Remove the cover and O-ring.  9. Insert the three lugs of the power cable (with gland and stuffing box already installed) into the motor’s junction box.  10. Replace the stuffing box’s half-moon clamp in its channel to secure the stuffing box in the junction box.  11. Tighten the two socket head capscrews to secure clamp to the junction box.  12. Inside the junction box, locate the motor’s lug connections.  13. Match the motor lug connections to the corresponding power cable lugs.  14. Attach the first motor lug to its corresponding power cable lug by inserting a hex head capscrew through the motor lug, through the power cable lug, through a flat washer, and through a lock washer. Secure the capscrew with a hex nut.  15. Repeat this step for the other two lugged connections.  16. When all three connections have been secured, wrap each of the three connections with a layer of rubber tape, then a layer of black tape and then a layer of glass tape.  17. Verify correct phasing.  18. Replace the junction box O-ring and cover.  19. Insert the four hex head capscrews and lockwashers to secure the junction box cover and tighten using a socket wrench.

________________________________________________________________ 5.202 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

________________________________________ Replacement of wear parts  20. An MSHA certified electrician must inspect all work and check for permissibility.  21. Replace the top motor cover.  22. Tighten the hex head capscrews and lock washers to secure the top cover.  23. Replace the side motor cover.  24. Install the drum drive shaft and the cutter head drum drive torque limiting clutch (see Drum drive torque limiting clutch removal and installation procedure in this chapter).  25. Replace the debris guard (optional) under the retaining strap.

The holes of the guard and strap should align with the threaded holes in the motor top cover.  26. Tighten the hex head capscrews and lock washers to secure the debris guard and its retaining strap to the top motor cover.

______________________________________________________________ A6474X347 REV 06 5.203

BI016954-06 (EN-US)

Replacement of wear parts _________________________________________ Drum drive torque limiting clutch drum drive motor torque limiting clutch removal

To remove the drum drive torque limiting clutch  1. Lower the gathering head completely until it touches the floor.

Lower the conveyor tail section until it is level with the floor.  2. Raise the cutter head assembly to its highest position. Place blocking underneath the cutter head assembly. Lower the cutter head assembly onto the blocking.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all blocking devices.  3. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine lockout/tagout regulations.

WARNING! Follow all Federal and mine lockout/tagout regulations and procedures. Failure to do so could result in machine damage or serious injury or death to personnel.  4. Remove the hex head capscrews and lock washers that secure the debris guard under its retaining strap.  5. Remove the retaining strap and debris guard.  6. Locate the clutch housing on the rear of the cutter motor assembly (Fig. 145).  7. Remove the hex head capscrews and lock washers that secure the clutch housing to the motor housing. 

8. Remove the clutch housing to expose the clutch assembly.



9. At the center of the clutch assembly, locate the drum drive shaft.

 10. Using the screwdriver, remove the retaining ring that secure the cutter shaft inside the clutch assembly.  11. Pull the cutter shaft from the motor and clutch assemblies.  12. Store the cutter shaft in a clean, safe place.

________________________________________________________________ 5.204 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

________________________________________ Replacement of wear parts Fig. 145: Cutter shaft removal

Lock nuts

Retaining ring Cutter motor assembly

Cutter shaft

Clutch assembly

 13. Using wire cutters, remove the lock wire that secures the lock nuts on the outside of the pressure plate.  14. Remove the lock nuts (Fig. 146) on the outside of the pressure plate.  15. Remove the pressure plate and the output hub assembly (with seal and bearing) from the clutch.

Fig. 146: Pressure plate removal

Bearing Seal Output hub assembly Pressure plate

Input assembly Lock nut

______________________________________________________________ A6474X347 REV 06 5.205

BI016954-06 (EN-US)

Replacement of wear parts _________________________________________  16. Using a screwdriver, remove the retaining ring (Fig. 147) found on the exterior of the keeper plate.  17. Remove the low head socket head capscrews and the serrated washers that secure the keeper plate to the input hub.

Fig. 147: Keeper plate removal

Input hub Serrated washer

Low head socket head capscrews

Keeper plate

Retaining ring

 18. Remove the keeper plate and disc spring to reveal the motor shaft secured by a retaining ring.

WARNING! The remaining clutch assembly is extremely heavy. Be prepared to support its weight when removing the retaining ring.  19. Use retaining ring pliers to remove the retaining ring from the motor shaft (Fig. 148). The input assembly of the clutch assembly is now unattached and can be slipped off the motor shaft.  20. Use the retaining ring pliers to remove the final retaining ring on the motor shaft.

Fig. 148: Motor shaft removal Motor Motor shaft Retaining ring

Input assembly

Retaining ring

________________________________________________________________ 5.206 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

________________________________________ Replacement of wear parts drum drive motor torque limiting clutch installation

To install the drum drive torque limiting clutch  1. Using retaining ring pliers, place a retaining ring into the motor shaft ring channel nearest the motor (Fig. 149).  2. Slide the input assembly onto the motor shaft.  3. Using the retaining pliers, place the retaining ring on the end of the motor shaft to secure the input assembly.

Fig. 149: Input assembly installation Motor Motor shaft Retaining ring

Input assembly Retaining ring

 4. After placing the disc spring input the motor side of the keeper plate, place the keeper plate into position against the input hub.  5. Secure the keeper plate to the input hub with low head socket head capscrews and serrated washers.  6. Tighten all the keeper plate’s socket head capscrews to 50 ft-lb.  7. Double-check the socket head capscrew torque.  8. Place the retaining ring into the exterior of the keeper plate.  9. Place the seal and then the bearing onto the output hub (with friction disc).  10. Place the output assembly against the input assembly.  11. Slide the pressure plate onto the input assembly’s spring shafts.  12. Secure the pressure plate to the spring shafts with the lock nuts.  13. Tighten all the locknuts to 87 ft-lb..

______________________________________________________________ A6474X347 REV 06 5.207

BI016954-06 (EN-US)

Replacement of wear parts _________________________________________  14. Double check lock nut torque.  15. Lock wire the lock nuts to secure their position.  16. Slide the cutter shaft (Fig. 150) through the clutch assembly, through the motor, and into the cutter head drum drive gear case. The shaft may require some adjustment so that its end fits into the gear case.  17. When the cutter shaft is positioned in the motor and clutch assemblies, insert the retaining ring to secure it in place.

Fig. 150: Cutter shaft installation Cutter motor assembly

Output assembly

Spring shafts Lock nuts

Cutter shaft

Retaining ring Input assembly

 18. Place the clutch housing against the motor housing.  19. Secure the clutch housing to the motor housing with the hex head capscrews and lock washers.  20. Replace the debris guard and retaining strap over the cutter motor and clutch.  21 Insert and tighten the hex head capscrews and lock washers through the retaining strap to secure the debris guard.

________________________________________________________________ 5.208 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

________________________________________ Replacement of wear parts Drum drive gear case removal and installation drum drive gear case removal

To remove the drum drive gear case  1. Remove the cutter head center drum (See Center cutter drum removal procedure in this chapter).  2. Remove the water spray manifold.  3. Remove the cutter head end drum (See End cutter drum removal procedure in this chapter).  4. Carefully lower the cutter head assembly (now with the cutter drum drive gear case exposed) onto blocking.

WARNING! You could be seriously injured or killed by falling loads. Always observe the safe working load limits of blocking devices.  5. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine lockout/tagout regulations.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.  6. Remove both the drum drive key retainers and the drum drive keys (Fig. 151) from their key slots in the center drum drive shaft. Store the keys and retainers in a safe place.

Fig. 151: Drum drive keys

Drum drive gear cases (2) Drum drive keys

______________________________________________________________ A6474X347 REV 06 5.209

BI016954-06 (EN-US)

Replacement of wear parts _________________________________________  7. On the rear of the cutter drum drive motor, locate the clutch housing and the drum drive shaft access cover plate.  8. Remove the hex head capscrews that secure the drum drive shaft access cover plate to the clutch housing. Remove the access cover plate to expose the end of the drum drive shaft.  9. Using the screwdriver, remove the retaining ring that secures the drum drive shaft in the clutch assembly.  10. Pull the drum drive shaft from the motor and clutch assembly.  11. Store the drum drive shaft in a clean, safe place.  12. To protect the clutch from damage and dirt, replace the access cover plate on the clutch housing and secure with the hex head capscrews and lock washers.  13. Locate the two drain plugs on the underside of the cutter drum drive gear case (Fig. 152). One plug is located on the bottom of the gear case mounting brace near the boom, in front of a cover plate. The other plug is located on the center drum side of the gear case.  14. Remove these plugs and completely drain the lubricant from the gear case.

Fig. 152: Drum drive gear case drain plugs

Drain plugs

________________________________________________________________ 5.210 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

________________________________________ Replacement of wear parts  15. Securely block the cutter drum drive gear case to support it when it becomes separated from the boom.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of blocking devices.  16. Use a hammer and chisel to remove the strapping from the capscrews securing the gear case to the boom (Fig. 153).

Fig. 153: Capscrew strap removal Capscrew strap

Capscrews

 17. Remove the hex head capscrews that secure the cutter drum drive gear case to the cutter boom.  18. Connect the trailing cable to energize the miner.

WARNING! You could be seriously injured or killed by falling loads. Stand clear of the gear case and the miner when tramming it in reverse.  19. Now that the gear case is separated from the boom, slowly tram the miner in reverse away from the blocked gear case. drum drive gear case installation

To install the drum drive gear case  1.

Securely block the gear case so that the miner’s boom can be trammed forward into position behind it.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all blocking devices.  2.

Insert four guides into the cutter boom face, spacing the guides equally over the boom face.

 3. Mark the holes on the exterior of the gear case mounting brace that corresponds to the positions of the guides on the boom face.

______________________________________________________________ A6474X347 REV 06 5.211

BI016954-06 (EN-US)

Replacement of wear parts _________________________________________ WARNING! The cutter drum gear case is extremely heavy. Keep body parts and other objects from underneath it until it is completely secured.  4. Apply RTV silicon sealer to the gear case center alignment key and install the key into the boom face. Also install the gear case’s two larger side alignment keys into the boom face.  5. Connect the trailing cable to energize the miner.  6. Using the boom face alignment keys and the guide pins to direct placement, tram the miner forward until the gear case is positioned against the cutter boom face. The guide pins should come out of the marked holes in the mounting brace.  7. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine lockout/tagout regulations.

Fig. 154: Capscrew installation Capscrews

 8. Insert the hex head capscrews (Fig 154) into the open holes (those not blocked by the guides) in the cutter drum drive gear case mounting brace.  9. Tighten the capscrews into the threaded holes in the cutter boom face.  10. Remove the alignment guides and insert and tighten the remaining four hex head capscrews through the gear case mounting brace and into the threaded holes in the cutter boom face.  11. Using a torque wrench with 20 to 1 multiplier, tighten all twentyone hex head capscrews to 1,850 ft-lb.  12. Double check capscrew torque.  13. Strap the hex head capscrews into sets of two and three and tack weld.  14. On the rear of the cutter drum drive motor, locate the clutch housing and its square drum drive shaft access cover plate.  15. Remove the hex head capscrews that secure the drum drive shaft access cover plate on the clutch housing.

________________________________________________________________ 5.212 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

________________________________________ Replacement of wear parts  16. Slide the drum drive shaft through the clutch assembly, through the motor, and into the cutter drum drive gear case. The shaft may require some adjustment so that its end fits into the gear case.  17. When the drum drive shaft is positioned in the motor and clutch assemblies, insert the retaining ring to secure it in place.  18. Replace the access cover plate. Insert and tighten the hex head capscrews and lock washers to secure the cover to the clutch housing.  19. Locate the two fill plugs on the top of the cutter drum drive gear case. One plug is located on the gear case mounting brace near the boom. The other plug is located on the center drum side of the gear case.  20. Remove the plugs and fill the gear case to the proper level with lubricant.  21. Replace the plugs.  22. Examine the cutter drum drive gear case and cutter boom face for leaking oil, which indicates improper installation or gear case damage.  23. Insert a drum drive key into a key slot on the center drum drive shaft (Fig. 155). Secure the key in the slot with a drum drive key retainer.

Fig. 155: Drum drive key installation

Key slot Key Key retainer

 24. Insert a drum drive key into the key slot directly across the center drum drive shaft from the key inserted in the previous step.

Secure the key in the slot with a drum drive key retainer.  25. Install the cutter head end drum (see Cutter head end drum installation procedure in this chapter).  26. Install the cutter head center drum (see Center drum installation procedure in this chapter).  27. Install the water spray manifold.

______________________________________________________________ A6474X347 REV 06 5.213

BI016954-06 (EN-US)

Replacement of wear parts _________________________________________ Gathering head assembly The gathering head assembly (Fig. 156) consists of the gathering pan, the continuous loading arms (CLAs), lift cylinders, and drive motors.

Fig. 156: Gathering head assembly

Gathering pan Foot shaft Motor (behind Continuous loading arm (CLA)

gathering head assembly removal

To remove the gathering head assembly  1. Lower the conveyor tail section until it is level with the floor.

Lower the gathering head until it rests on the floor. Place blocking under the rear of the gathering head to stabilize its position during and after removal of the pivot pins and disconnection of the lift cylinders.  2. Raise the cutter head to its highest point and place blocking underneath it. Lower the cutter head onto the blocking.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of blocking devices.  3. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.

________________________________________________________________ 5.214 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

________________________________________ Replacement of wear parts  4. Double check that the cutter head is securely blocked.  5. Separate the conveyor chain and remove the foot shaft (see Foot shaft removal procedure in this chapter).  6. Remove the hex head capscrews and lock washers that secure each of the front rub rails to the tractor frame and open both front rub rails.  7. Remove the electrical power cables from the gathering head.  8. Disconnect, tag, and cap the motor cooling water and scrubber spray water hoses from the gathering head.

WARNING! You could be seriously injured or killed by falling loads. Do not remove the gathering head pivot pins unless the gathering head is securely blocked into a stationary position. Use extreme caution when removing the pivot pins.  9. Remove the hex head capscrews and lockwashers that secure the right gathering head pivot pin retaining plate to the tractor frame (Fig. 157).  10. Remove the hex head capscrews and lock washers that secure the pin retaining plate to the gathering head pivot pin and remove the retaining plate.

Fig. 157: Gathering head pivot pin Hex head capscrews (retaining plate to tractor frame)

Pivot pin retaining plate

Gathering head pivot pin

Hex head capscrews (retaining plate to pivot pin)

______________________________________________________________ A6474X347 REV 06 5.215

BI016954-06 (EN-US)

Replacement of wear parts _________________________________________  11. Using a slide hammer, pull the pivot pin.  12. Repeat steps 9 through 11 for the left gathering head pivot pin.

WARNING! You can be seriously injured or killed by falling loads. Do not disconnect the gathering head cylinder unless the gathering head is securely blocked. Use extreme caution when disconnecting the gathering head lift cylinder.  13. Remove the hex head capscrews and lock washers that secure the piston pin retaining bar on the right gathering head lift cylinder to the gathering head side panel and remove the retaining bar (Fig. 158).  14. Repeat step 13 for the left gathering head lift cylinder.

Fig. 158: Gathering head lift cylinder piston pin retaining bar Piston pin

Lock washer

Gathering head lift cylinder

Retaining bar

Hex head capscrew

 15. Connect the trailing cable to energizer the miner.

WARNING! Stand clear of the blocked cutter head and gathering head assemblies during the contraction of the gathering head lift cylinders.  16. Slowly contract the lift cylinders until the piston ends come free from their gathering head clevises.

CAUTION! When separating the gathering head from the tractor frame, ensure that the disconnected ends of the conveyor chain smoothly slide out of the gathering head.  17. Lift the cutter head off the blocking and slowly tram the miner in reverse until the cutter head clears the backboard of the gathering head. ________________________________________________________________

5.216

25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

________________________________________ Replacement of wear parts gathering head assembly installation

To install the gathering head assembly  1. Position the gathering head assembly at the front of the tractor frame. Block up the rear of the gathering head so that it’s pivot points are at the level of the tractor frame clevises.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of blocking devices.

CAUTION! When tramming the miner toward the gathering head, be careful that the conveyor chain and gathering head lift cylinders do not become pinched between the tractor frame and the gathering head.  2. Raise the cutter head assembly to its highest point.  3. Slowly tram the miner forward until the gathering head pivot points are inserted into the tractor frame clevises.  4. Place blocking underneath the cutter head and lower the cutter head onto the blocking.  5. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.  6.

Thread the lower end of the conveyor chain into the gathering head assembly return pan so that the end appears on the foot shaft return plate. Place the upper end of the conveyor chain down the front of the gathering head entrance pan.

 7.

Connect the trailing cable to energize the miner.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of blocking and lifting devices and stand clear of the blocked cutter head and the gathering head during the gathering head lift extension.  8.

Extend the gathering head lift cylinders so that the piston end bearings can be inserted into the gathering head lift cylinder clevises.

 9.

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

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.

______________________________________________________________ A6474X347 REV 06 5.217

BI016954-06 (EN-US)

Replacement of wear parts _________________________________________  10. Insert the piston end bearing of the right gathering head lift cylinder into the gathering head clevis.  11. Using the hammer, insert the piston end pin through the aligned clevis bushings and the rod end bearing.

IMPORTANT! Insert the pin far enough to avoid obstructing the placement of the pin retaining bar.  12. Place the pin retaining bar over the end of the pin and insert and tighten the two hex head capscrews and lock washers that secure the piston pin retaining bar to the gathering head side panel.  13. Repeat steps 10 - 12 on the left gathering head lift cylinder.

CAUTION! Use caution when using the lift cylinders and stabilizer to adjust the alignment of the clevis and pivot pins.  14. Use the gathering head lift cylinders and tractor frame stabilizer to align the tractor frame clevis and the gathering head pivot points to make inserting pivot pins easier.  15. Gently tap the right gathering head pivot pin through the aligned tractor frame clevis and gathering head pivot bushings.

IMPORTANT! The pin must be inserted far enough so that it does not obstruct positioning of the retaining plate flat against the tractor frame.  16. Place the pivot pin retaining plate so that edge with two cutouts located in the corners is positioned against the backup strip.

The edge of the plate with two cutouts and a hole for the pin’s grease fitting must be positioned over the pivot pin.  17. Insert and tighten the two hex head capscrews and lock washers to secure the pivot pin retaining plate to the gathering head pivot pin.  18. Insert and tighten the hex head capscrews and lock washers to secure the pivot pin retaining plate to the tractor frame.  19. Repeat steps 16 - 18 for the left gathering head pivot pin.  20. Replace the motor cooling water and scrubber spray water hoses onto the gathering head assembly.  21. Replace the electrical power cables onto the gathering head assembly.  22. Close the front rub rails and insert and tighten a hex head capscrew and lock washer to secure the front rub rail closed against the tractor frame.  23. Replace the foot shaft into the gathering head (see Foot shaft removal and installation procedure in this chapter) and reconnect the conveyor chain. ________________________________________________________________

5.218

25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

________________________________________ Replacement of wear parts Gathering head drive motor removal and installation gathering head drive motor removal

To remove the gathering head drive motor  1. Lower the gathering head completely until it touches the floor.

Lower the conveyor tail assembly until it is level with the floor.  2. Raise the cutter head assembly to its highest position. Place blocking underneath the cutter head assembly. Lower the cutter head assembly onto the blocking.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of blocking devices.  3. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.  4. If necessary, remove the CLA to allow access to the motor (See CLA removal and installation procedure in this chapter).  5. Remove the hex head capscrews and lock washers that secure the upper deck cover (Fig. 159) to the gathering head assembly.  6. Remove the upper deck cover. The gear case and drive shaft end of the motor should be exposed.  7. Locate the side cover of the gathering head motor and remove the hex head capscrews and lock washers that secure the side cover to the gathering head assembly.  8. Remove the cover to expose the end of the motor.

Fig. 159: Upper deck cover Upper deck cover

______________________________________________________________ A6474X347 REV 06 5.219

BI016954-06 (EN-US)

Replacement of wear parts _________________________________________  9. Remove the square-headed pipe plug on the end of the gathering head motor.  10. Remove the retaining ring that secures the shaft end plug inside the motor housing (Fig. 160).  11. Using a slide hammer, pull the drive shaft end plug out.  12. Pull the drive shaft from the motor and store in safe place.

Fig. 160: Drive shaft and end plug removal

Drive shaft end plug

O-ring

Retainer ring Drive shaft

 13. Use the adjustable wrench to replace the pipe plug into the end of the motor.  14. Remove the hex head capscrews and lock washers that secure the motor junction box cover.  15. Remove the cover and its o-ring.  16. Locate the three taped power connections inside the junction box and strip the tap covering each lug connection.  17. Tag each connection and remove the hex head capscrew, flat washer, lock washer, and hex head nut that secures each of the power cable lugs.  18. Remove the socket head capscrews and lock washers that secure the stuffing box’s half-moon clamp to the junction box.  19. Remove the clamp and slide the stuffing box out of the junction box. The power cable should be completely disconnected from the motor.

WARNING! While the power cable is detached from the motor, the trailing cable should not be reconnected to the miner. Damage to the machine or injury or death to personnel could result.

________________________________________________________________ 5.220 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

________________________________________ Replacement of wear parts  20. To prevent damage to the power cable lugs, stuffing box, and gland assembly, cover and secure the power cable to the miner in a safe location.  21. Replace the junction box o-ring and cover and secure with the hex head capscrews and lock washers to protect the motor’s electrical connections.  22. Tag, disconnect, and cap the two cooling water hoses (with elbow and adapter) from the two motor cooling water fittings on the gear case end of the motor.  23. Remove the two motor cooling water fittings from the motor and store in a clean place.  24. Plug the two motor cooling water ports to keep them clean.

WARNING! The next steps disconnect the gathering head drive motor from the adapter that links it to the gathering head gear case. The gathering head drive motor is extremely heavy. Be prepared to support this weight before performing the following steps.  25. Remove the socket head capscrews that secure the motor to the gear case adapter plate.  26. The gathering head drive motor should now be detached from the gear case and able to be removed from the gathering head assembly through the motor side cover opening. gathering head drive motor installation

To install the gathering head drive motor  1. Insert the gear case to motor seal between the adapter plate and the gear case (Fig. 161). When the motor is inserted, the seal should be located between the surfaces of the motor and the gear case.  2. Insert the gathering head motor through the slide cover opening, attachment bolt holes first. The junction box of the motor should be positioned toward the front of the gathering head.

Fig. 161: Gear case to motor seal installation Gear case to motor seal

Gear case adapter plate Motor

______________________________________________________________ A6474X347 REV 06 5.221

BI016954-06 (EN-US)

Replacement of wear parts _________________________________________  3.

Position the motor against the gear case adapter plate and align the four attachment bolt holes on the gear case side of the motor with the four holes on the corners of the adapter plate.

 4.

Apply Loctite 242 (blue) to the four socket head capscrews.

 5.

Insert and tighten the socket head capscrews to secure the motor to the gear case adapter plate.

 6.

Using an adjustable wrench, insert the two motor cooling water fittings into the gathering head drive motor’s cooling water ports, which are located on the gear case end of the motor.

 7.

Attach the two motor cooling water hoses (with elbow and adapter) to the fitting.

 8.

Remove the hex head capscrews and lock washers that secure the junction box cover.

 9.

Remove the cover and its o-ring.

 10. Insert the three lugs of the power cable (with gland and stuffing box already installed) into the motor’s junction box.  11. Replace the stuffing box’s half-moon clamp in its channel to secure the stuffing box in the junction box.  12. Insert and tighten the two socket head capscrews and lock washers to secure clamp to the junction box.  13. Locate the motor’s lug connections inside the junction box and match the motor lug connections to the corresponding power cable lugs.  14. Attach the first motor lug to its corresponding power cable lug by inserting a hex head capscrew through the power cable lug, through the motor lug, through a flat washer, and through a lock washer. Secure the capscrew with a hex nut.  15. Repeat this step with the other two power cable and motor lugged connections.  16. When all three connections have been secured, wrap each of the three connections with a layer of rubber tape, then a layer of electrical (black) tape, and finally a layer of glass tape.  17. Replace the junction box o-ring and junction box cover and secure the cover with hex head capscrews and lock washers to secure the junction box cover.

________________________________________________________________ 5.222 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

________________________________________ Replacement of wear parts  18. Remove the pipe plug from the end of the motor (Fig. 162).  19. Slide the drive shaft through the gathering head motor and into the gathering head gear case (the drive shaft end without the threaded hole should be inserted first). The shaft may require some adjustment so that its end fits into the gear case.  20. Install the o-ring into the channel on the shaft end plug.  21. Insert the drive shaft end plug into position in the center of the motor.  22. Insert the retaining ring to secure the shaft end plug inside the motor housing.  23. Replace the pipe plug into the end of the motor.

Fig. 162: Drive shaft installation

O-ring Retainer ring

Pipe plug

Drive shaft Drive shaft end plug

 24. Replace the gathering head motor side access cover. Secure the cover to the gathering head by inserting and tightening the hex head capscrews.  25. Replace the upper deck cover and secure to the gathering head by inserting and tightening the hex head capscrews.  26. If removed, install the CLA over the motor (see CLA removal and installation procedure in this chapter).

______________________________________________________________ A6474X347 REV 06 5.223

BI016954-06 (EN-US)

Replacement of wear parts _________________________________________ Gathering head gear case removal and installation gathering head gear case removal

To remove the gathering head gear case  1. Lower the conveyor tail section until it is level with the floor.

Lower the gathering head until it touches the floor.  2. Raise the cutter head assembly to its highest position. Place blocking underneath the cutter head assembly. Lower the cutter head assembly onto the blocking.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of blocking devices.  3. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.  4. Remove the gathering head motor’s side cover by removing the hex head capscrews and lock washers that secure the side cover to the gathering head assembly.  5. Remove the cover to expose the end of the motor.  6. Remove the square-headed pipe plug on the end of the gathering head motor.  7. Remove the retaining ring that secures the shaft end plug inside the motor housing (Fig. 163).  8. Using a slide hammer, pull out the drive shaft end plug.  9. Pull the drive shaft from the motor and store in a safe place.  10. Replace the pipe plug into the end of the motor.

Fig. 163: Motor shaft removal

Drive shaft end plug

O-ring

Retainer ring Drive shaft ________________________________________________________________ 5.224 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

________________________________________ Replacement of wear parts  11. Remove the CLA to expose the gathering head gear case (see CLA removal and installation procedure in this chapter).  12. Remove the hex head capscrews and lock washers that secure the upper deck cover (Fig. 164) to the gathering head assembly. Remove the upper deck cover to expose the gear case and the drive shaft end of the motor.  13. Remove the hex head capscrews and lock washers that secure the lower deck cover (Fig. 164) to the gathering head assembly and remove the lower deck.

Fig. 164: Deck covers Upper deck cover Lower deck cover

 14. Loosen tension on the conveyor chain as much as possible (see Conveyor chain adjustment in the Adjustment procedures section of this chapter).  15. Separate the conveyor chain and remove the gathering head foot shaft (see the Foot shaft removal and installation procedure in this chapter).  16. Connect the trailing cable to energize the miner.  17. Raise the gathering head to its highest position. Place blocking underneath the gathering head and lower the gathering head onto the blocking.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of blocking devices.  18. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel. ______________________________________________________________ A6474X347

REV 06

5.225

BI016954-06 (EN-US)

Replacement of wear parts _________________________________________  19. Remove the plugs from the underside of the gathering head gear case and completely drain the gear case lubricant.  20. Replace the drain plugs into the underside of the gear case.  21. Connect the trailing cable to energize the miner.  22. Raise the gathering head off the blocking, remove the blocking, and lower the gathering head until it touches the floor.  23. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.  24. Disconnect, tag, and cap the four lubrication connections from the gathering head gear case.  25. Remove the socket head capscrews (Fig. 165) that secure the motor to the gear case adapter plate.  26. Remove the motor and clean out the cavity.  27. Remove the hex head capscrews that secure the gathering head gear case pot to the mounting plate.  28. The gathering head gear case is now unattached and can be removed from its position in the gathering head.

Fig. 165: Gear case removal

Plugs

Lubrication lines

Socket head capscrews (gear case to adapter plate)

Adapter plate

Hex head capscrews (gear case to mounting plate)

________________________________________________________________ 5.226 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

________________________________________ Replacement of wear parts gathering head gear case installation

To install the gathering head gear case  1. Insert a new gear case-to-motor seal between the adapter plate and the gear case (Fig. 166). When the gear case is inserted into the gathering head and the transfer case is positioned against the gathering head motor, the seal should be located between the surfaces of the motor and the gear case.  2. Carefully insert the gathering head gear case into position in the gathering head assembly.  3. Insert and tighten the hex head capscrews and lock washers to secure the gear case pot to its mounting plate.

Fig. 166: Gear case mounting Gear case adapter plate

Gear case-tomotor seal

Hex head capscrews

 4. Install the motor.  5. Align the four holes on the corners of the adapter plate with the four attachment bolt holes on the gear case side of the motor.  6. Apply Loctite 242 (blue) to the four socket head capscrews.  7. Insert and tighten the four socket head capscrews to secure the gear case adapter plate to the motor.  8. Attach the four lubrication connections to the gathering head gear case.  9. Attach the rose gun to the lower ports located adjacent to the gathering head side cover and fill the gathering head gear case to the proper level with lubricant. Check the gear case lubricant level at the sight glass adjacent to the gathering head side cover.

IMPORTANT! The bottom ports on the high speed input cases are the fill lines.

The top ports on the high speed input cases are the check lines.

______________________________________________________________ A6474X347 REV 06 5.227

BI016954-06 (EN-US)

Replacement of wear parts _________________________________________  10. Examine the gathering head gear case in various places for signs of leaking lubricant that identify improper installation or gear case damage.  11. Install the gathering head foot shaft and reconnect the conveyor chain (see Foot shaft installation procedure in this chapter).  12. Tighten the conveyor chain to the proper tension (see Conveyor chain adjustment in the Adjustment procedures section of this chapter).

IMPORTANT! Improper conveyor chain tension can lead to excessive wear, mechanical problems, and miner downtime. Always keep the conveyor chain at proper tension.  13. Replace the lower deck cover (Fig. 167) onto the gathering head assembly and secure to the gathering head assembly by inserting and tightening the hex head capscrews and washers.  14. Replace the upper deck cover (Fig. 167) onto the gathering head assembly and secure by inserting and tightening the hex head capscrews and washers.

Fig. 167: Deck covers Upper deck cover

Lower deck cover

 15. Install the CLA onto the gathering head gear case turntable (see CLA removal and installation procedure in this chapter).  16. Remove the pipe plug from the end of the motor.  17. Slide the drive shaft through the gathering head motor and into the gathering head gear case (the drive shaft end without the threaded hole should be inserted first.) The shaft may require some adjustment so that its end fits into the gear case.

________________________________________________________________ 5.228 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

________________________________________ Replacement of wear parts  17. Install the o-ring into the channel on the shaft end plug (Fig. 168).  18. Insert the drive shaft end plug into position in the center of the motor.  19. Insert the retaining ring to secure the shaft end plug inside the motor housing.

Fig. 168: Drive shaft installation

O-ring Retainer ring

Pipe plug

Drive shaft Drive shaft end plug

 20. Replace the pipe plug into the end of the motor.  21. Replace the side cover onto the gathering head assembly.  22. Insert and tighten the hex head capscrews and lock washers to secure the side cover to the gathering head assembly.

______________________________________________________________ A6474X347 REV 06 5.229

BI016954-06 (EN-US)

Replacement of wear parts _________________________________________ Gathering head foot shaft removal and installation gathering head foot shaft removal

To remove the gathering head foot shaft:  1. Lower the gathering head until it touches the floor.  2. Position the conveyor tail section directly behind the miner so that it is level with the floor.  3. Raise the cutter head assembly to its highest position. Place blocking underneath the cutter head assembly and lower the cutter head assembly onto the blocking.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of blocking devices.  4. Slowly advance the conveyor chain until a connecting link appears on the gathering head entrance pan.  5. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.  6. Loosen tension on the conveyor chain as much as possible (see Conveyor chain adjustment procedure in the Adjustment procedures section of this chapter).  7. With conveyor chain tension removed, remove the connecting link pins and the connecting link.  8. The conveyor chain should now be separated. Move the two pieces of the conveyor chain out of the way to allow for easier removal of the gathering head foot shaft.  9.

Remove the hex head capscrews and lock washers that secure the foot shaft cover to the gathering head and remove the foot shaft cover.

 10. Locate the two collars on the foot shaft and remove the hex head capscrews that secure each of the collars to the foot shaft. When the capscrews are removed, the flex lock nuts will fall free from the other side of the collar. Retrieve these nut and hand tighten them onto their capscrews for safe keeping.

Remove both collars from the foot shaft.

________________________________________________________________ 5.230 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

________________________________________ Replacement of wear parts  14. Slide the foot shaft couplings (Fig. 169) from the ends of the foot shaft toward the sprocket in the center. Once the couplings have been moved, the foot shaft is disconnected from the gear case bevel pinions.  15. The foot shaft can now be removed from the gathering head.

Fig. 169: Foot shaft removal Hex head capscrews

Gear case bevel pinion

Flex lock nuts

Foot shaft collar Foot shaft coupling

gathering head foot shaft installation

To install the gathering head foot shaft  1. Slide a coupling onto each end of the foot shaft (Fig. 169).  2. Insert the gathering head foot shaft into position between the two gathering head gear case bevel pinions.

IMPORTANT! Position the foot shaft so its sprocket will engage the conveyor chain links when the chain is reconnected.  3. Align the foot shaft splines with the bevel pinions’ splines.  4. Slide the right coupling over the foot shaft spline onto the bevel pinion splines until it touches the gear case seal carrier. Repeat with the left coupling.  5. Place a collar onto each end of the foot shaft so that the collars keep the couplings secure against the gear case seal carriers, bridged between the foot shaft and bevel pinion.  6. Insert and tighten the hex head capscrews through both halves of each collar and into the flex lock nuts to secure the collars to the foot shaft.  7. Replace the foot shaft cover.  8. Insert and tighten the hex head capscrews and lock washers to secure the foot shaft cover to the gathering head.

______________________________________________________________ A6474X347 REV 06 5.231

BI016954-06 (EN-US)

Replacement of wear parts _________________________________________  9.

Reattach the two ends of the conveyor chain by replacing the connecting link. Secure the link.

 10. Tighten the conveyor chain to the proper tension (see Conveyor chain adjustment procedure in the Adjustment procedure section of this chapter).

IMPORTANT! Improper conveyor chain tension can lead to excessive wear, mechanical problems, and miner downtime. Always keep the conveyor chain at proper tension.

________________________________________________________________ 5.232 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

________________________________________ Replacement of wear parts CLA removal and installation Fig. 171: Continuous loading arms (CLAs) CLA tip

Socket head capscrews Hog rings

CLA removal

Continuous loading arm (CLA)

To remove a CLA  1. Lower the conveyor tail section until it is level with the floor.

Lower the gathering head until it touches the floor.  2. Raise the cutter head assembly to its highest position. Place blocking under the cutter head assembly. Lower the cutter ead assembly onto the blocking.

WARNING! You can be seriously injured or killed by falling loads. Observe the safe working load limits of all blocking devices.  3. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.  4. Use a screwdriver to pry out the hog rings (Fig. 171) from around each of the CLA’s socket head capscrews.  5. Remove the socket head capscrews located where the arms meet the CLA hub.  6. Remove the socket head capscrews located in the center of the CLA hub. The CLA should now be free and able to be removed.

______________________________________________________________ A6474X347 REV 06 5.233

BI016954-06 (EN-US)

Replacement of wear parts _________________________________________  7. Remove the four CLA alignment keys (Fig. 172) from the exposed gathering head gear case turntable and store the keys in a safe place.

Fig. 172: CLA alignment key removal Alignment key

Inner hub

CLA installation

To install the CLA  1.

On the CLA exterior, mark the bolt hole (outer set of three holes) located directly adjacent to a key cut-out.

 2.

Place an alignment dowel (Fig. 173) in the gathering head gear case turntable bolt hole (outer set of three holes) that is directly adjacent to a key cut-out.

 3.

Place the four keys into their cutouts on the gathering head gear case turntable.

Fig. 173: Alignment dowel placement Alignment dowel

Alignment key

Inner hub Gear case turn table

________________________________________________________________ 5.234 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

________________________________________ Replacement of wear parts  4. Place the CLA onto the gear case turntable so that the dowel extends through the marked CLA hole. Adjust the CLA as necessary to fit the turntable keys into the CLA cut-outs.  5. Insert two socket head capscrews into the CLA outer holes not blocked by the dowel.  6

Remove the alignment dowel and insert the last socket head capscrew into the CLA hole.

 7. Tighten the three capscrews to secure the CLA to the gear case turntable.  8. Use the hammer to install three hog rings into the counterbore around each of the three outer socket head capscrews of the CLA.. The rings should be tapped down until they are below the chamfer of the socket head capscrews.

IMPORTANT! Hog rings should be installed so that their sharp points are directed clockwise.  9. Insert the socket head capscrews into CLA hub bolt holes and tighten.  10. Use the hammer to install hog rings into the counterbore around each of the socket head capscrews of the CLA hub (Fig. 174). The rings should be tapped down until they are below the chamfer of the socket head capscrews.

Fig. 174: Hog ring installation

Capscrew chamfer

Hog ring

Hog ring

Bottom of hog ring counterbore

______________________________________________________________ A6474X347 REV 06 5.235

BI016954-06 (EN-US)

Replacement of wear parts _________________________________________ Continuous loading arm tip replacement  1. Lower the conveyor tail section until it is level with the floor.

Lower the gathering head until it touches the floor.  2. Raise the cutter head assembly to its highest position. Place blocking under the cutter head assembly, both on the floor and on the gathering head. Lower the cutter head assembly onto the blocking.

WARNING! You can be seriously injured or killed by falling loads. Observe the safe working load limits of all blocking devices.  3. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.  4. Locate the CLA tip which requires replacement.  5. Remove the hex head capscrews that secure the tip to the CLA.  6. Use force as necessary to remove the tip from the CLA..  7. Slide the new tip onto the CLA..  8. Insert and tighten the hex head capscrews through the tip and the CLA.

________________________________________________________________ 5.236 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

________________________________________ Replacement of wear parts Tram motor removal and installation tram motor removal

To remove the tram motor  1. Lower the conveyor tail section until it is level with the floor.  2. Lower the gathering head and cutter head assemblies until they touch the floor.  3. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.  4. Remove the two rub ail pins that secure the tram rub rail to the two rub rail sections adjacent to it.  5. Remove the tram rub rail to expose the tram gear case and locate the tram drive motor inside the gear case (Fig. 175).

Fig. 175: Tram drive motor location

Tram drive motor

 6. Remove the hex head capscrews and hi-collar lock washers that secure the input shaft access cover to the motor housing.

Note that the cooling water hose support clamp is secured by one of the capscrews. Remove the tram motor cooling water bypass hose when the clamp capscrew is removed.  7. Remove the input shaft access cover and its o-ring.  8. Remove the retaining ring that secures the shaft plug in position.  9. Remove the shaft plug with o-ring that secures the input shaft in the motor (Fig. 176).

______________________________________________________________ A6474X347 REV 06 5.237

BI016954-06 (EN-US)

Replacement of wear parts _________________________________________ Fig. 176: Shaft plug removal

Shaft plug

O-ring Retaining ring

 10. Pull the input shaft from the motor and store in a safe place.  11. Replace the input shaft access cover on the motor housing and secure the cover with the hex head capscrews and hi-collar lock washers.  12. Tag, disconnect, and cap the cooling water hoses from the cooling water fittings located on the top left and right corners of the tram motor.  13. Remove the cooling water fittings from the top left and right corners of the tram motor and store in a safe place.  14. Remove the tram motor cooling water bypass hose that connects the two cooling water fittings on the back of the tram motor and store in a safe place.  15. Remove the cooling water fittings from the bottom left and right corners of the tram motor and store in a safe place.  16. Remove the hex head capscrews and disc lock washers that secure the tram motor bracket to the tram case.  17. Remove the socket head set screws that secure the tram motor bracket to the tram motor.  18. Remove the tram motor bracket from the tram motor.  19. Carefully slide the tram motor out from the tram case until the motor’s electrical connection and hand hole cover are accessible.  20. Remove the socket head capscrews and hi-collar lockwashers that secure the hand hole cover to the motor housing.

________________________________________________________________ 5.238 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

________________________________________ Replacement of wear parts  21. Remove the hand hole cover and its o-ring from the motor housing.  22. Remove the socket head capscrews and lock washers that secure the stuffing box's half moon clamp to the junction box.  23. Remove the clamp and slide the stuffing box out of the junction box. The power cable should be completely disconnected from the motor.

WARNING! Do not reconnect the trailing cable to the miner while the power cable is detached from the motor. Serious injury or death or damage to the machine may result.  24. To prevent damage to the power cable lugs and gland assembly, cover the power cable and secure it to the miner in a safe location.  25. To protect the motor’s electrical connections, replace the motor hand hole cover and o-ring and secure using the socket head capscrews and hi-collar lock washers.  26.. Carefully remove the tram motor from the tram case and slide onto blocking.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all blocking devices. tram motor installation

To install the tram motor  1. Place a motor to adapter seal onto the surface of the tram motor that will be positioned against the primary planetary adapter plate (Fig. 177).  2. Slide the tram motor into the tram case, leaving the motor’s hand hole cover and stuffing box accessible outside the tram case.

Fig. 177: Tram motor installation

Tram case Tram motor

Motor-to-adapter seal

______________________________________________________________ A6474X347 REV 06 5.239

BI016954-06 (EN-US)

Replacement of wear parts _________________________________________  3. Remove the socket head capscrews and hi-collar lock washers that secure the hand hole cover to the motor housing.  4. Remove the hand hole cover and its o-ring.  5. Insert the four lugs of the power cable (with gland and stuffing box already installed) into the tram motor’s junction box.  6. Replace the stuffing box’s half-moon clamp in its channel to secure the stuffing box in the junction box.  7. Tighten the socket head capscrews to secure the clamp to the junction box.  8. Match the power cable lugs to the corresponding terminal strip posts and secure each lug to the corresponding post with a flat washer, lock washer, and hex nut.  9. Replace the motor hand hole cover and o-ring, and secure it with socket head capscrews and hi-collar lockwashers.  10. Carefully slide the tram motor into position in the tram case.

The end of the motor must be completely flush against the primary planetary adapter plate.  11. Position the tram motor bracket (Fig. 178) against the motor.

The lower half of the bracket must be flush against the motor and upper bracket must be flush against the tram case. Reposition the tram motor until the bracket can be properly positioned.  12. Insert and tighten the socket head capscrews to secure the tram motor bracket to the tram motor.  14. Insert and tighten the hex head capscrews and disc lock washers to secure the tram motor bracket to the tram case.

Fig. 178: Motor bracket installation

Disc lock washer

Hex head capscrew

Socket head capscrew

Motor bracket

________________________________________________________________ 5.240 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

________________________________________ Replacement of wear parts  15. Insert the two cooling water fittings into the cooling water ports located on the top left and right corners of the tram motor.  16. Attach the cooling water hoses to the two cooling water fittings located on the top left and right corners of the tram motor.  17. Using the adjustable wrench, insert the two cooling water fittings into the cooling water port located on the rear of the tram motor.  18. Attach the tram motor cooling water bypass hose that connects the cooling water fittings located on the rear of the tram motor.  19. Remove the hex head capscrews and hi-collar lock washers that secure the input shaft access cover to the motor housing.  20. Remove the input shaft access cover and its O-ring.  21. Slide the input shaft through the tram motor and into the tram planetary primary gear (the input shaft end without the threaded hole should be inserted first). The shaft may require some adjusting so that its splined end fits into the gear.  22. When the drive shaft is correctly positioned in the motor, install the o-ring onto the input shaft plug and then insert the plug into the motor.  23. Insert the retaining ring to secure the input shaft plug inside the tram motor.  24. Replace the input shaft access cover and its O-ring on the motor housing. When replacing the input shaft access cover and its capscrews, carefully insert the tram motor cooling water bypass hose into the bypass hose clamp. The clamp is secured to the tram motor by the access cover’s lower capscrew. Secure the cover with hex head capscrews and hi-collar lock washers.  25. Replace the tram rub rail between the two adjacent rub rails and secure it with the two rub rail pins.

______________________________________________________________ A6474X347 REV 06 5.241

BI016954-06 (EN-US)

Replacement of wear parts _________________________________________ Tram primary planetary gear removal and installation primary planetary gear removal

To remove the primary planetary gear  1. Lower the conveyor tail section until it is level with the floor.  2. Lower the gathering head and cutter head assemblies until they touch the floor.  3. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.  4. Remove the two rub rail pins that secure the tram rub rail to the two rub rail sections adjacent to it and remove the tram rub rail to expose the tram gear case.  5. Remove the tram motor (see Tram motor removal and installation procedure in this chapter).  6. Remove the socket head capscrews that secure the motor adapter plate to the primary gear ring (and also secure the primary planetary carrier assembly to the tram case) (Fig. 179).  7. Remove the motor adapter plate from the tram case.  8. Carefully slide the primary planetary carrier assembly out of the primary gear ring and remove the assembly from the tram case.  9. Carefully slide the primary gear ring out of the tram case.

Fig. 179: Tram primary gear removal Tram case

Motor adapter plate Socket head capscrews

Primary planetary gear ring Primary planetary carrier assembly

________________________________________________________________ 5.242 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

________________________________________ Replacement of wear parts primary planetary gear installation

To install the tram primary planetary gear  1. Insert alignment dowels into four of the sixteen capscrew holes in the tram case (Fig. 180).  2. To facilitate gear ring insertion, mark the mounting holes of the primary planetary gear ring that corresponds to the holes in which dowels were placed.  3. Slide the primary planetary gear ring onto the alignment dowels so the dowels appear through the marked holes.

Fig. 180: Alignment dowels and gear ring mounting Tram case

Alignment dowels

Primary planetary gear ring

Tram drive pinion gear

Mounting marks (match with alignment dowels)

 4. Carefully insert the primary planetary gear assembly into the gear ring, ensuring that the extension of the sun gear faces out from the centerline of the miner and that the internal gear teeth of the primary carrier are seated securely onto the tram drive pinion gear.  5. Place the two adapter plate dowels into two 1” holes on the bottom left and right corners of the adapter plate.  6. Orient the adapter plate with the adapter dowels along the bottom edge.  7. Slide the adapter plate onto the four alignment dowels.  8. Insert and tighten twelve socket head capscrews into the holes in the adapter plate not blocked by the alignment dowels.  9. Remove the four alignment dowels and insert and tighten the final four socket head capscrews to secure the adapter plate and gear ring to the tram case.

______________________________________________________________ A6474X347 REV 06 5.243

BI016954-06 (EN-US)

Replacement of wear parts _________________________________________  10. Torque the sixteen socket head capscrews to the appropriate amount (see Torque tables in Chapter 6 of this manual).  11. Install the tram motor in the tram case (see Tram motor removal and installation procedure in this chapter).  12. Replace the tram rub rail between the two adjacent rub rails and secure it with the two rub rail pins.  13. Refill the tram gear case with oil.

________________________________________________________________ 5.244 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

________________________________________ Replacement of wear parts Tram brake removal and installation tram brake removal

To remove the tram brake:  Disconnect and lock out the electrical power to the miner. Follow all applicable regulations regarding lockout/tagout procedures.

WARNING! Failure to follow all applicable regulations regarding lockout/ tagout procedures may result in machine damage or serious injury or death of personnel.  Remove all necessary rubrails to access brake (Fig. 181).

Fig. 181: Cover removal

Tram brake access

 Thoroughly clean the area around the tram brake to keep debris from getting into the tram gear case once the tram brake has been removed.  Remove, tag, and cap all hydraulic lines to the tram brake.  Remove and tag all electrical lines to the tram brake.  Remove o-ring from housing.  Remove all oil plugs.  Release spring by removing outer bolts.  Remove retaining ring.

______________________________________________________________ A6474X347 REV 06 5.245

BI016954-06 (EN-US)

Replacement of wear parts _________________________________________ Fig. 182: Tram brake assembly removal Traction brake housing

Pressure plate

 Remove backing plate from assembly.  Remove brake discs and friction discs from assembly.  Remove hub from piston.  Remove piston from housing.  Remove thrust washer and o-ring on trust washer.  Remove pressure plate (Fig. 182) and piston assembly from housing.  Remove pressure plate from piston.  Remove springs (Fig. 183) and seal from pressure plate.  Remove o-rings, seals and bearing on piston.

________________________________________________________________ 5.246 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

________________________________________ Replacement of wear parts Fig. 183: Tram brake assembly removal

Tram brake

Spring

Bearing

O-ring

Seal

______________________________________________________________ A6474X347 REV 06 5.247

BI016954-06 (EN-US)

Replacement of wear parts _________________________________________ tram brake installation

To install the tram brake:  Install o-rings, seals and bearing on piston.  Install springs and seal on pressure plate.  Lubricate all surfaces and slide pressure plate onto piston.  Install o-ring on thrust washer, lubricate and press onto housing.  Press thrust washer onto hub, lubricate and place hub into piston.  Place housing over pressure plate and piston assembly. Outer holes in housing must be aligned with tapped holes in pressure plate.

Fig. 184: Tram brake assembly installation

Flatwasher Capscrew

 Align oil port in housing with oil port in piston, and bolt piston to housing.  Use 6 outer bolts and flatwashers (Fig. 184) to compress springs.  Starting with a friction disc, alternately place friction and brake discs into assembly.  Place backing plate into assembly.  Install retaining ring (Fig 185).  Release spring by removing outer bolts.  Install all oil plugs.  Install o-rings onto housing.

________________________________________________________________ 5.248 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

________________________________________ Replacement of wear parts Fig. 185: Tram brake assembly installation

Retaining ring

Retaining ring

______________________________________________________________ A6474X347 REV 06 5.249

BI016954-06 (EN-US)

Replacement of wear parts _________________________________________ Tram secondary planetary gear removal/installation secondary planetary gear removal

To remove the tram secondary planetary gear  1. Lower the conveyor tail section until it is level with the floor.  2. Lower the gathering head and cutter head assemblies until they touch the floor.

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

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.  4. Remove the two rub rail pins that secure the tram rub rail to the two rub rail sections adjacent to it and remove the tram rub rail.  5. Remove the plug from the bottom of the tram secondary planetary gear cover and drain the lubricant from the gear case.  6. Replace the oil drain plug in the gear cover (Fig. 186).  7. Remove the sixteen socket head capscrews that secure the secondary planetary gear cover to the tram case and carefully remove the secondary planetary gear cover.

Fig. 186: Tram secondary planetary gear cover and drain plug

Tram secondary planetary gear cover

Socket head capscrews

Drain plug

________________________________________________________________ 5.250 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

________________________________________ Replacement of wear parts  8. Remove the secondary planetary gear thrust washer (Fig. 187).

WARNING! The next step removes the secondary planetary gear ring from the secondary planetary gear assembly. The secondary planetary gear ring is extremely heavy. Be prepared to support its weight before removing it from the secondary planetary assembly.  9. Carefully slide the secondary planetary gear ring off the secondary planetary gear assembly.  10. Insert eight hex head capscrews into the sprocket bearing carrier to secure it to the tram case.  11. Carefully pull the secondary tram drive shaft from the gear and sprocket and store in a safe place.  12. Carefully slide the secondary planetary assembly out of the sprocket bearing carrier.

Fig. 187: Secondary planetary assembly removal Ring gear

Secondary planetary gear assembly

Thrust washer

Hex head capscrew

Secondary planetary gear assembly

Secondary tram drive shaft

Sprocket bearing carrier

Secondary planetary gear assembly

______________________________________________________________ A6474X347 REV 06 5.251

BI016954-06 (EN-US)

Replacement of wear parts _________________________________________ secondary planetary gear installation

To install the tram secondary planetary gear  1. Carefully insert the secondary planetary gear assembly into the sprocket bearing carrier (Fig. 188), ensuring that the splined extension of the planetary carrier seats securely in the interior teeth of the sprocket.

Fig. 188: Planetary carrier installation Sprocket bearing carrier

Secondary planetary gear assembly Sprocket teeth

Splined extension

 2. Slide the secondary tram drive shaft through the secondary planetary gear assembly and into the tram drive sprocket and reach gear set (the drive shaft end without the threaded hole should be inserted first). The shaft may require some adjustment so that the end fits into the reach gears.  3. Insert four alignment dowels into the holes in the sprocket bearing carrier not blocked by the eight hex head capscrews (Fig. 189).  4. To facilitate gear ring insertion, mark the mounting holes of the secondary planetary gear ring that corresponds to the holes in which the dowels were placed.  5. Remove the eight hex head capscrews that secure the sprocket bearing carrier to the tram.

Fig. 189: Gear ring installation Sprocket bearing carrier

Secondary planetary gear assembly Gear ring

Thrust washer

Alignment marks

Alignment dowels

Hex head capscrews

________________________________________________________________ 5.252 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

________________________________________ Replacement of wear parts  6. Apply silicon sealer to ring gear.  7. Carefully slide the secondary planetary gear ring onto the four alignment dowels so that the dowels appear through the marked holes. The planetary gear teeth should slide smoothly and securely into the gear teeth should slide smoothly and securely into the gear ring teeth.  8. Place the thrust water into the secondary planetary carrier directly behind the secondary tram drive shaft. The side of the thrust washer with the inscribed circles should face away from the drive shaft.  9. Apply silicon sealer to cover.  10. To facilitate gear cover replacement, mark the mounting holes of the secondary planetary gear cover that corresponds to the holes in which alignment dowels are placed.  11. Slide the secondary planetary gear case cover onto the alignment dowels so that the dowels appear through the marked holes.

IMPORTANT! The flat edge of the cover located adjacent to the lubrication fitting is the top of the cover. Orient the cover so that the lubricant level check plug is on the motor side of the cover and the drain plug is on the bottom.  12. Insert and tighten the twelve socket head capscrews into the holes in the gear case cover not blocked by the alignment dowels.  13. Remove the four alignment dowels.  14. Insert and tighten the remaining four socket head capscrews to secure the cover, the gear ring, and the sprocket bearing carrier to the tram case.  15. Using a torque wrench, torque all sixteen socket head capscrews to the proper torque (see Torque tables in Chapter 6 of this manual).  16. Using the lubrication fitting at the top of the gear cover (Fig. 190), fill the secondary planetary gear case to the proper level with lubricant (Conoco GLW Gear Oil 220).  17. Examine the secondary planetary gear case in various places for signs of leaking lubricant that identify improper installation or gear case damage.

______________________________________________________________ A6474X347 REV 06 5.253

BI016954-06 (EN-US)

Replacement of wear parts _________________________________________ Fig. 190: Gear case fill and check plugs (brake not installed)

Fill plug

Check plug

 16. Replace the tram rub rail between the two adjacent rub rails and secure it with the two rub rail pins.

________________________________________________________________ 5.254 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

________________________________________ Replacement of wear parts Tram case removal and installation tram case removal

To remove the tram case  1. Lower the conveyor tail section until it is level with the floor.  2. Raise the gathering head and cutter head and place a small stack of blocking under these two assemblies.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all blocking devices.  3. Lower the gathering head and cutter head onto the blocking so that the front end of the miner lifts off the floor.  4. Extend the stabilizer completely so that the rear end of the miner lifts off of the floor.  5. Place blocking in multiple locations under the miner tram track.

When the miner is lowered, the tram track should be secured between the blocking and the tractor frame.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all blocking devices.  6. Raise the stabilizer and the gathering head and cutter head assemblies so the weight of the miner rests on the blocking.  7. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.  8. Remove the two rub rail pins that secure the tram rub rail to the two rub rail sections adjacent to it and remove the tram rub rail to expose the tram case.  9. Remove the hex head capscrew and lock washer that secure the front rub rail to the tractor frame and open the front rub rail cover.  10. Attach the grease gun to the front idler take-up cylinder fitting (Fig. 191) and pump grease into the take-up cylinder to extend the cylinder and remove pusher plate pressure on the idler shims.

______________________________________________________________ A6474X347 REV 06 5.255

BI016954-06 (EN-US)

Replacement of wear parts _________________________________________  11. Remove all the idler adjustment shims and store the shims in a safe place.  12. Open the pressure release valve for the front idler take-up jack and allow the cylinder to contract.

Fig. 191: Idler take-up cylinder Idler take-up cylinder

Pressure release valve

Grease fitting

Idler adjustment shims

 13. Locate a tram track link near the track entry opening at the bottom of the tram case (Fig. 192) and, using a hammer and punch, remove the two roll pins that secure the tram track pin between the links. Store the roll pins in a safe place.  14. Using the hammer and punch, remove the tram track pin to disconnect the links and separate the track. Store the track pin in a safe place.

Fig. 192: Tram track removal

Roll pins

Separate track here

Tram track pin

________________________________________________________________ 5.256 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

________________________________________ Replacement of wear parts  15. Attach guide wires to the end of the tram track that passes through the tram case.  16. Connect the trailing cable to energize the miner.  17. Use the tram motor to slowly rotate the sprocket so that the end of the tram track that passes through the case is pulled up through the case and rolls off the sprocket.  18. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.  19. Pull on the tram track from the front of the miner (near the idler) so that the free end of the tram track is pulled clear of the tram case exit opening.  20. Remove the tram motor (see Tram motor removal and installation procedure in this chapter).  21. Remove the bolts and washers from the sprocket and motor sides of the tram case.  22. Place a stack of blocking in front of the tram case onto which the case can be removed.

WARNING! The next step removes the tram case from the tractor frame. The tram case (with sprocket and reach gears) is extremely heavy. Be prepared to support the tram case before removing it from the tractor frame.

WARNING! Ensure that the electrical cables and cooling water hoses for the tram motor are free from the tram cases before attempting to remove the tram case from the tractor frame.  25. Carefully slide the tram case out from the tractor frame and onto the blocking.

WARNING! You can be seriously injured or killed by falling loads. Observe the safe working load limits of all blocking devices.  26. Pull the tram track guide wires out of the tram case exit opening and secure the wires to the tractor frame.

______________________________________________________________ A6474X347 REV 06 5.257

BI016954-06 (EN-US)

Replacement of wear parts _________________________________________ tram case installation

To install the tram case  1. Block up the tram case adjacent to its tractor frame position at a level that makes it easy to slide the case into the tractor frame.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all blocking devices.  2. Thread the guide wires through the tram case exit opening, between the sprocket gears, and out the tram case entry opening.  3. Slide the tram case into position in the tractor frame.

IMPORTANT! The guide wires will be used to pull the tram track links onto the tram case sprocket after the tram case is installed.

WARNING! Before attempting to slide the tram case into the tractor frame, ensure that the tram motor electrical and water connections are out of the way. Failure to do so may result in damage to the electrical and water connections.  4. Install the bolts that secure the motor side of the tram case to the tractor frame.  5. Install the bolts that secure the sprocket side of the tram case to the tractor frame.  6. Replace the tram motor (see Tram motor removal and installation procedure in this chapter).  7. While feeding the tram track from the front of the miner (near the idler), pull on the tram track guide wires until a link of the tram track engages the sprocket.  8. Connect the trailing cable to energize the miner.

WARNING! Stand clear of the miner when using the motor to pull the tram track through the tram case.  9. Use the tram motor to slowly rotate the sprocket and pull the tram track through the case until the end appears out the bottom.

WARNING! Double check that the links of the tram track are correctly seated onto the tram drive sprocket. Improper engagement of the tram track links onto the sprocket can cause serious mechanical damage.

________________________________________________________________ 5.258 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

________________________________________ Replacement of wear parts  10. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.  11. Remove the guide wires from the tram track.  12. Connect the two ends of the tram track and using the hammer and punch, insert the track pin to secure the two track links together.  13. Using the hammer and punch, insert the two roll pins into the track pin to secure the pin in the links.  14. Adjust the tram track tension (see Tram track adjustment procedure in the Adjustment procedures section of this chapter).  15. Close the front rub rail cover and replace the hex head capscrews and lock washers that secure the front rub rail to the tractor frame.  16. Replace the tram rub rail between the two adjacent rub rails and secure it with the two rub rail pins.  17. Connect the trailing cable to energize the miner.  18. Remove blocking.

WARNING! You could be seriously injured or killed by falling loads. Follow mine procedure to remove blocking devices and use caution.

______________________________________________________________ A6474X347 REV 06 5.259

BI016954-06 (EN-US)

Replacement of wear parts _________________________________________ Tram reach gear set removal and installation tram reach gear set removal

To remove the tram reach gear set  1. Lower the conveyor tail section until it is level with the floor.  2. Raise the gathering head and cutter head assemblies and place a small stack of blocking under each.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of blocking devices.  3. Lower the gathering head and cutter head onto the blocking so that the front end of the miner lifts off the floor.  4. Extend the stabilizer completely so that the rear end of the miner lifts off the floor.  5. Place blocking in multiple locations under the miner tram track to securely support the tractor frame off the floor.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of blocking devices.  6. Raise the stabilizer and the gathering head and cutter head assemblies so the weight of the miner rests on the blocking.

When the tractor frame is lowered, the tram track should be secured between the blocking and the tractor frame.  7. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.  8. Double-check the tractor frame support blocking now that the weight of the tractor frame is completely upon it.  9. Remove the two rub rail pins that secure the tram rub rail to the two rub rail sections adjacent to it and remove the tram rub rail to expose the tram case.  10. Remove the tram case (see Tram case removal and installation procedure in this chapter).  11. Remove the plug from the motor end of the reach gear case bottom and drain the lubricant from the gear case.  12. When the lubricant has been completely drained, replace the plug.

________________________________________________________________ 5.260 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

________________________________________ Replacement of wear parts  13. Remove the hex head capscrews and lock washers (Fig. 193) that secure the reach gear case cover to the gear case and remove the cover.

Fig. 193: Reach gear case cover removal Hex head capscrews Lock washers

Reach gear case cover

Reach gear case

Rear side of tram case

Drain plug

 14. Locate the cap bearing carrier that secures the tram drive pinion inside the reach gear case.  15. Using retaining ring pliers, remove the retaining ring located outside the cap bearing carrier on the tram drive pinion (Fig. 194).  16. Using the wire cutters, cut and remove the wire securing the cap bearing carrier capscrews in position.  17. Remove the four drilled head capscrews and lock washers that secure the cap bearing carrier to the tram case and remove the cap bearing carrier.

Fig. 194: Cap bearing carrier removal Drilled head capscrews

Cap bearing carrier

Retaining ring

Tram drive pinion

______________________________________________________________ A6474X347 REV 06 5.261

BI016954-06 (EN-US)

Replacement of wear parts _________________________________________  20. Remove the three steel shims and the bearing found under the shims (Fig. 195).  21. Carefully pull the tram drive pinion out of the reach gear case through the cap bearing carrier opening.

Fig. 195: Tram drive pinion removal Bearing carrier opening Cap bearing carrier

Tram drive pinion Bearing cup and cone set

Shims

 22. Cut and remove the wire securing the idler shaft capscrews in position.  23. Remove the drilled hex head capscrews that secure the idler shaft cap to the tram case and remove the idler shaft and three steel shims located under the cap.  24. Carefully slide the idler shaft out of the reach gear case through the idler shaft cap opening.  25. Remove the idler reach gear through the top opening of the reach gear case (Fig. 196).  26. Remove the bearing cup and cone sets from the center indentions of the idler reach gear. 

27. Remove the hex head capscrews and lock washers that secure the sprocket reach gear bearing cap to the reach gear case (Fig. 197).

 28. Remove the bearing cap and the three steel shims under the cap.  29. Remove the bearing cone and cup set from the end of the splined sleeve.  30. Carefully slide the splined sleeve out of the sprocket reach gear.  31. Remove the sprocket reach gear through the top opening of

the reach gear case. ________________________________________________________________ 5.262 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

________________________________________ Replacement of wear parts Fig. 196: Idler reach gear and idler shaft removal Idler reach gear

Bearing cup and cone set Reach gear case

Rear side of tram case

Shims

Hex head capscrews

Idler shaft cap

Fig. 197: Sprocket reach gear removal Sprocket reach gear Splined sleeve Shims

Bearing cup and cone set Reach gear case

Sprocket reach gear bearing cap

Hex head capscrews

 32. Remove the second splined sleeve bearing cone and cup set from the rear of the reach gear case, located behind the sprocket reach gear.

______________________________________________________________ A6474X347 REV 06 5.263

BI016954-06 (EN-US)

Replacement of wear parts _________________________________________ tram reach gear set installation

To install the tram reach gear set  1. Insert one of the bearing cup and cone sets (cone side facing out) into the cut-out inside the reach gear case adjacent to the tram case sprocket (Fig. 198).

Fig. 198: Bearing cup and cone set installation Bearing cup and cone set

 2. Insert the sprocket reach gear into the top of the reach gear case and position it against the bearing cup and cone set adjacent to the tram case sprocket (Fig. 199).

Fig. 199: Sprocket reach gear installation Sprocket reach gear set

 3. Insert the splined sleeve into the reach gear case (Fig. 200), through the sprocket reach gear and through the bearing cup and cone set until it is positioned against the tram sprocket.  4. Slide the second bearing cup and cone set (cup side facing out) onto the end of the splined sleeve.  5. Replace the three steel shims over the bearing set.  6. Replace the sprocket reach bearing cap.  7. Insert and tighten the hex head capscrews and lock washers to secure the sprocket reach gear bearing cap to the reach gear case.

________________________________________________________________ 5.264 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

________________________________________ Replacement of wear parts Fig. 200: Splined sleeve and bearing cap installation Sprocket reach gear Splined sleeve Shims

Bearing cup and cone set Reach gear case

Sprocket reach gear bearing cap

Hex head capscrews

 8. Insert two cup and cone bearing sets into the central cut-outs on either side of the idler reach gear (Fig. 201). The cone side of the bearing sets should face out of the gear on both sides.  9. Insert the idler reach gear through the top opening of the reach gear case and position it against the sprocket reach gear, ensuring that the gear teeth securely mesh.  10. Insert the idler shaft through the bearing sets in the idler reach gear until it is positioned against the tractor frame.  11. Replace the three steel shims over the idler shaft.  12. Replace the idler shaft cap.

Fig. 201: Idler reach gear and idler shaft installation Idler reach gear

Rear side of tram case

Bearing cup and cone set Reach gear case

Shims

Hex head capscrews

Idler shaft cap

______________________________________________________________ A6474X347 REV 06 5.265

BI016954-06 (EN-US)

Replacement of wear parts _________________________________________  13. Insert and tighten the ten drilled hex head capscrews to secure the idler shaft cap.  14. Insert the tram drive pinion through the cap bearing carrier opening (located on the inside of the tram case tram motor bay) into the reach gear case. Ensure that the teeth of the pinion securely mesh with the idler reach hear teeth.  15. Replace the pinion bearing.  16. Replace the three steel shims over the pinion bearing.  17. Replace the cap bearing carrier over the pinion end.  18 Insert and tighten the drilled hex head capscrews and lock washers to secure the cap bearing carrier to the tram case.  19. Install the retaining ring on the tram drive pinion.  20. Double check that the tram drive pinion, idler reach gear and sprocket reach gear teeth are properly meshed and the gears rotate smoothly.  21. Tighten the sprocket reach gear bearing cap capscrews to correct torque (see Torque tables in Chapter 6 of this manual).  22. Tighten the idler shaft cap capscrews to correct torque (see Torque tables in Chapter 6 of this manual).  23. Lock wire the idler shaft cap capscrews to secure their positions.  24. Tighten the tram drive pinion cap bearing carrier capscrews to correct torque (see Torque tables in Chapter 6 of this manual).  25. Lock wire the tram drive pinion cap bearing carrier capscrews to secure their positions.  26. Replace the reach gear case cover onto the top of the reach gear case.  27. Insert and tighten fourteen hex head capscrews and lock washers to secure the reach gear case cover to the gear case.  28. Remove the plug from the sprocket side of the reach gear case cover.  29. Fill the reach gear case to the proper level with lubricant (Spec.

100-14).  30. Replace the fill plug.  31. Replace the tram case into the tractor frame (see Tram case removal and installation procedure in this chapter).

________________________________________________________________ 5.266 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

________________________________________ Replacement of wear parts IMPORTANT! The re-installation procedure for the tram case includes reinstallation of the primary and secondary planetary gears and the tram motor, and reconnection of the tram track.  32. Replace the tram rub rail between the two adjacent rub rails and secure it with the two rub rail pins.  33. Reconnect the trailing cable to energize the miner.  34. Raise the tractor frame by lowering the stabilizer and the gathering head and cutter head assemblies.  35. Carefully remove the support blocking from under the tractor frame.  36. Lower the tractor frame onto the floor by raising the stabilizer and the gathering head and cutter head assemblies.

______________________________________________________________ A6474X347 REV 06 5.267

BI016954-06 (EN-US)

Replacement of wear parts _________________________________________ Tram sprocket removal and installation tram sprocket removal

To remove the tram sprocket  1. Lower the conveyor tail section until it is level with the floor.  2. Raise the gathering head and cutter head and place a small stack of blocking under these two assemblies.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all blocking devices.  3. Lower the gathering head and cutter head onto the blocking so that the front end of the miner lifts off the floor.  4. Extend the stabilizer completely so that the rear end of the miner lifts off the floor.  5. Place blocking in multiple locations under the miner tram track.

When the miner is lowered, the tram track should be secured between the blocking and the tractor frame.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all blocking devices.  6. Raise the stabilizer and the gathering head and cutter head assemblies so the weight of the miner rests on the blocking.  7. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.  8. Double check the tractor frame support blocking now that the weight of the tractor frame is completely upon it.  9. Remove the two rub rail pins that secure the tram rub rail to the two rub rail sections adjacent to it and remove the tram rub rail to expose the tram case.  10. Remove the hex head capscrew and lock washer that secures the front rub rail to the tractor frame and open the cover.  11. Attach the grease gun to the fitting on the grease take-up cylinder (Fig. 202) and pump grease to extend the cylinder and remove pusher plate pressure on the idler shims.

________________________________________________________________ 5.268 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

________________________________________ Replacement of wear parts  12.

Remove all the idler adjustment shims and store the shims in a safe place.

 13.

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

Fig. 202: Idler adjustment shim removal Idler take-up cylinder

Pressure release valve

Grease fitting

Idler adjustment shims

 14. Locate a tram track link near the track entry opening at the bottom of the tram case (Fig. 203) and, using the hammer and punch, remove the two roll pins that secure the tram track pin between the links. Store the roll pins in a safe place.  15. Using the hammer and punch, remove the tram track pin to disconnect the links and separate the track. Store the track pin in a safe place.

Fig. 203: Tram track removal

Roll pins

Separate track here

Tram track pin

______________________________________________________________ A6474X347 REV 06 5.269

BI016954-06 (EN-US)

Replacement of wear parts _________________________________________  16. Attach guide wires to the end of the tram track that passes through the tram case.  17. Connect the trailing cable to energize the miner.  18. Use the tram motor to slowly rotate the sprocket so that the end of the tram track that passes through the case is pulled up through the case and rolls off the sprocket.  19. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.  20. Pull on the tram track from the front of the miner (near the idler) so that the free end of the tram track is pulled clear of the tram case exit opening.

WARNING! Ensure that the end of the tram track is out of the tram case exit opening before attempting to remove the tram case from the tractor frame.  21. Remove the plug from the bottom of the cover and drain the lubricant from the gear case (Fig. 204).  22. Replace the oil drain plug in the gear cover.  23. Remove the Secondary planetary gear assembly (see Secondary planetary gear assembly removal and installation procedure in this chapter).

Fig. 204: Tram secondary planetary gear cover and drain plug

Tram secondary planetary gear cover

Socket head capscrews

Drain plug

________________________________________________________________ 5.270 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

________________________________________ Replacement of wear parts  24. Remove the bearing carrier (Fig. 205).  25. Remove the bearing/seal sleeve assembly from the end of the sprocket.

Fig. 205: Sprocket bearing carrier removal

Bearing/seal sleeve assembly

Sprocket

Sprocket bearing carrier

WARNING! The next step removes the sprocket from the tram case. The sprocket is extremely heavy. Be prepared to support its weight before removing it from the tram case.  26. Remove the sprocket from the tram case (Fig. 206).  27. Remove the bearing/seal sleeve assembly from the rear of the sprocket bay of the tram case.

Fig. 206: Tram sprocket removal Bearing/seal sleeve assembly

Tram case

Sprocket

______________________________________________________________ A6474X347 REV 06 5.271

BI016954-06 (EN-US)

Replacement of wear parts _________________________________________ tram sprocket installation

To install the tram sprocket NOTICE! The manufacturer recommends the installation of a preassembled sprocket. If a pre-assembled sprocket is not used, the following sprocket assembly procedure should be followed.  1. Install a spherical bearing into one of the bearing sleeves (Fig. 207).  2. Install the o-ring into the outside channel of the bearing sleeve.

IMPORTANT! When the bearing sleeve is inserted into position, the o-ring forms a seal between the sleeve and the piece that holds it.  3. Install a Duo-Cone seal into the seal sleeve (see Duo-cone seal installation notes in this chapter). The rubber side of the seal should face toward the sleeve; the metal ring of the seal should face outward.

Fig. 207: Bearing/seal sleeve assembly

Seal sleeve

Spherical bearing

O-ring

Duo-cone seal

Bearing sleeve

Metal ring

Rubber seal

 5. Insert and tighten the three set screw into the bearing sleeve to secure the seal sleeve in the bearing sleeve.  6. Insert the bearing/seal sleeve assembly into position at the rear of the sprocket bay of the tram case.  7. Install the two Duo-Cone seals into the channel in each end of the sprocket. The rubber side of the seals should face into the sprocket channel; the metal rings of the Duo-Cone seals should face outward.  8. Insert the end of the sprocket into the seal sleeve so that it seats into the spherical bearing. Push the sprocket until the metal rings of the Duo-Cone seals are securely against each other.  9. Install the other spherical bearing into the remaining bearing sleeve. ________________________________________________________________ 5.272 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

________________________________________ Replacement of wear parts  10. Install the o-ring into the outside channel of the bearing sleeve.  11. Install a Duo-Cone seal into the remaining seal sleeve. The rubber side of the seal should face toward the sleeve; the metal ring of the seal should be facing outward.  12. Insert the seal sleeve into the bearing sleeve.  13. Insert and tighten the three set screws into the bearing sleeve to secure the seal sleeve in position.  14. Slide the bearing/seal sleeve assembly onto the end of the sprocket. Push the sleeve assembly until the end of the sprocket seats into the spherical bearing and the metal rings of the Duo-Cone seals are securely against each other.  15. Replace the bearing carrier over the bearing sleeve and end of the bearing sleeve and end of the sprocket.  16. Install the Secondary planetary gear assembly (see the Secondary planetary gear assembly removal and installation procedure in this chapter).  17. While feeding the tram track from the front of the miner (near the idler), pull on the tram track guide wires until a link of the tram track engages the sprocket.  18. Connect the trailing cable to energize the miner.

WARNING! Stand clear of the miner when using the motor to pull the tram track through the tram case.  19. Use the tram motor to slowly rotate the sprocket and pull the tram track through the case until the end appears out the bottom.

WARNING! Double check that the links of the tram track are correctly seated onto the tram drive sprocket. Improper engagement of the tram track links onto the sprocket can cause serious mechanical damage.  20. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.  21. Remove the guide wires from the tram track.

______________________________________________________________ A6474X347 REV 06 5.273

BI016954-06 (EN-US)

Replacement of wear parts _________________________________________

 22. Connect the two ends of the tram track and using the hammer and punch, insert the track pin to secure the two track links together.  23. Using the hammer and punch, insert the two roll pins into the track pin to secure the pin in the links.  24. Adjust the tram track tension (see Tram track adjustment procedure in the Adjustment procedures section of this chapter).  25. Close the front rub rail cover and replace the hex head capscrews and lock washers that secure the front rub rail to the tractor frame.  26. Replace the tram rub rail between the two adjacent rub rails and secure it with the two rub rail pins.  27. Connect the trailing cable to energize the miner.  28. Remove blocking.

WARNING! You could be seriously injured or killed by falling loads. Follow mine procedure to remove blocking devices and use caution.

________________________________________________________________ 5.274 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

________________________________________ Replacement of wear parts Tram track front idler removal and installation tram track front idler removal

To remove the tram track front idler  1. Raise the gathering head and cutter head assemblies to their highest points and place blocking underneath. Lower the assemblies onto the blocking. The gathering head and cutter head must be blocked high enough to allow the idler assembly to be removed from the tractor frame’s idler slide channel.

WARNING! You can be seriously injured or killed by falling loads. Observe the safe working load limits of all blocking devices.  2. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.  3. Remove the hex head capscrew and lock washer that secure the front rub rail to the tractor frame and open the front rub rail cover.  4. Attach the grease gun to the front idler take-up cylinder fitting (Fig. 208) and pump grease into the take-up cylinder to extend the cylinder and remove pusher plate pressure on the idler shims.  5. Remove all the idler adjustment shims and store the shims in a safe place.  6. Open the pressure release valve for the front idler take-up jack and allow the cylinder to contract.

Fig. 208: Idler take-up cylinder

Pressure release valve

Idler take-up cylinder

Grease fitting

Idler adjustment shims

______________________________________________________________ A6474X347 REV 06 5.275

BI016954-06 (EN-US)

Replacement of wear parts _________________________________________  7. Locate a tram track link near the track entry opening at the bottom of the tram case (Fig. 209) and, using the hammer and punch, remove the two roll pins that secure the tram track pin between the links. Store the roll pins in a safe place.  8. Using the hammer and punch, remove the tram track pin to disconnect the links and separate the track. Store the track pin in a safe place.

Fig. 209: Tram track removal

Roll pins

Separate track here

Tram track pin

 9. Attach guide wires to the end of the tram track that passes through the tram case.  10. Slide the front idler assembly out of the idler slide channel (Fig. 210).

Fig. 210: Front idler assembly removal

Pressure relief valve

Take-up cylinder

Idler slide channel Front idler assembly

________________________________________________________________ 5.276 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

________________________________________ Replacement of wear parts  11. Slide the pusher plate and the spacer pusher out of the idler slide channel (Fig. 211).

Fig. 211: Pusher plate removal Take-up cylinder Pressure relief valve

Spacer pusher

Pusher plate

Idler slide channel

tram track front idler installation

To install the tram track front idler  1. Insert the pusher spacer (Fig. 212) into the tractor frame’s idler slide channel so that it rests on the slide block support and is positioned against the take-up jack.  2. Ensuring that the channel guides face away from the take-up jack, insert the pusher plate into the idler slide channel until it touches the pusher spacer.

Fig. 212: Pusher plate installation Take-up cylinder Pressure relief valve

Pusher spacer

Pusher plate

Idler slide channel

______________________________________________________________ A6474X347 REV 06 5.277

BI016954-06 (EN-US)

Replacement of wear parts _________________________________________  3. Insert the block slides of the front idler assembly (Fig. 213) into the idler slide channel. The relief valve of the slide blocks must be oriented toward the front of the miner.  4. Push the front idler assembly into the slide channel until the block slides are against the pusher plate channel guides.

Fig. 213: Front idler installation Take-up cylinder Front idler assembly

Pressure relief valve

Idler slide channel Pusher plate channel guide Block slide

Relief valve

 5. Connect the two ends of the tram track and using the hammer and punch, insert the track pin to secure the two track links together.  6. Using the hammer and punch, insert the two roll pins into the track pin to secure the pin in the links.  7. Adjust the tram track tension (see Tram track adjustment procedure in the Adjustment procedures section of this chapter).  8. Close the front rub rail cover and replace the hex head capscrews and lock washers that secure the front rub rail to the tractor frame.

________________________________________________________________ 5.278 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

________________________________________ Replacement of wear parts Front idler take-up cylinder removal and installation front idler cylinder removal

To remove the front idler take-up cylinder  1. Lower the conveyor tail section until it is level with the floor.  2. Lower the gathering head and cutter head until these two assemblies touch the floor.  3. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.  4. Remove the hex head capscrew and lock washer that secures the front rub rail to the tractor frame and open the front rub rail cover.  5. Remove the hex head capscrews that secure the fill plate to the frame and remove the fill plate.  6. Locate the front idler take-up cylinder bracket assembly (Fig. 214) which is mounted to the rear of the idler shim channel.

Fig. 214: Front idler take-up cylinder bracket

Bracket assembly

Idler shim channel

 6. Pull the flip pin (Fig. 215) from the half link to release the takeup cylinder bracket from the tractor frame.  7. Lower the end of the bracket until it clears the half link and pull the bracket straight out to remove it from the tractor frame.

______________________________________________________________ A6474X347 REV 06 5.279

BI016954-06 (EN-US)

Replacement of wear parts _________________________________________ Fig. 215: Front idler take-up cylinder removal Idler take-up cylinder assembly

Bracket assembly

Flip pin

front idler cylinder installation

Flip pin

Tractor frame

To install the front idler take-up cylinder  1.

Replace the take-up cylinder bracket assembly into the tractor frame and secure it by inserting the flip pin through the half link.

 2.

Replace the fill plate and secure with capscrews.

 3.

Close the front rub rail cover and secure to the tractor frame with a hex head capscrew and lock washer to secure the front rub rail to the tractor frame.

________________________________________________________________ 5.280 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

________________________________________ Replacement of wear parts Hydraulic pump removal and installation hydraulic pump removal

To remove the hydraulic pump  1. Lower the conveyor tail section until it is level with the floor.  2. Lower the gathering head and cutter head assemblies until they rest on the floor.  3. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.

There are two alternative locations for the pump: in front of the demister box or behind the operator’s box.

When located in from of the demister box  4. Locate the rub rail directly behind the tram case on the scrubber exhaust side of the miner (Fig. 216). Remove the two rub rail pins that secure the rub rail to the two rub rail sections adjacent to it and remove the rub rail.

Fig. 216: Pump located behind demister Hydraulic pump

Scrubber exhaust

Rub rail

 5. Locate the hydraulic pump and motor assembly (Fig. 217).  6. Using the adjustable wrench, disconnect the inlet hose from the pump. Plug the hose end to keep it clean.  7. Using the adjustable wrench, disconnect the pilot and valve hoses from the pump fittings. Plug the hose ends to keep them clean.

______________________________________________________________ A6474X347 REV 06 5.281

BI016954-06 (EN-US)

Replacement of wear parts _________________________________________  8. Remove the hose fittings from the pump and store in a safe place.  9. Remove the two hex head capscrews and lockwashers that secure the pump assembly to the motor assembly.  10. Carefully remove the pump assembly by sliding it out of the pump motor.

When located behind the operator’s station  4. Locate the rub rail directly behind the tram case on the operator’s side of the miner. Remove the two rub rail pins that secure the rub rail to the two rub rail sections adjacent to it and remove the rub rail.  5. Swing the operator’s station outward and locate the hydraulic pump and motor assembly.  6. Using the adjustable wrench, disconnect the inlet hose from the pump. Plug the hose end to keep it clean.  7. Using the adjustable wrench, disconnect the pilot and valve hoses from the pump fittings. Plug the hose ends to keep them clean.

________________________________________________________________ 5.282 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

________________________________________ Replacement of wear parts To install the hydraulic pump hydraulic pump installation

 1. Slide the pump assembly into the pump motor (Fig. 217).  2. Insert and tighten, hex head capscrews and lockwashers to secure the pump assembly to the motor.

Fig. 217: Hydraulic pump installation Motor

Hex head capscrew (2)

Pump

Lockwasher (2)

 3. Insert the hydraulic hose fittings into the pump assembly and tighten.  4. Attach and tighten the exit pilot and valve hoses to the pump fittings.  5. Attach the inlet hose to the pump.  6. Replace the rub rail between the two adjacent rub rails and secure it with the two rub rail pins.  7. Check the hydraulic fluid level.  8. Jog the pump motor on and off a few times so that the pump is primed.

______________________________________________________________ A6474X347 REV 06 5.283

BI016954-06 (EN-US)

Replacement of wear parts _________________________________________ Hydraulic pump motor removal and installation hydraulic pump motor removal

To remove the hydraulic pump motor  1. Lower the conveyor tail section it is level with the floor.  2. Lower the gathering head and cutter head until they touch the floor. 

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

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel. 

4. Remove the hydraulic pump (see Hydraulic pump removal procedure in this chapter).

 5. Remove the two hex head capscrews that secures the motor to the pump stand (Fig. 218). 

6. Remove the two hex head capscrews and lockwashers that secure the pump stand to the tractor frame and remove the pump stand.

Fig. 218: Hydraulic pump stand removal Hex head capscrew (2)

Motor

Pump stand

Hex head capscrew (2)

________________________________________________________________ 5.284 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

________________________________________ Replacement of wear parts  7. Tag, disconnect, and cap the two cooling water hoses from the cooling water fittings on the pump motor.  8. Remove the cooling water fittings from the top left and right surface of the pump motor and store in a safe place.  9. Remove the cover and its o-ring from the motor’s junction box by removing four hex head capscrews and lockwashers.  10. Locate the three taped power connections inside the junction box.  11. Strip off the three layers of tape covering each of the three lug connections inside the junction box.  12. Tag the three lugs to facilitate reconnection during motor installation.  13. Remove the hex head capscrew, flat washer, lockwasher, and hex head nut that secures the three power cable lugs to the three motor lugs.  14. Remove the two socket head capscrews and lockwashers that secure the stuffing box’s half-moon clamp to the junction box.  15. Remove the clamp and slide the stuffing box out of the junction box. The power cable should be completely disconnected from the motor.  16. To prevent damage to the power cable lugs and gland assembly, cover the power cable and secure it to the miner in a safe location.  17. To protect the motor’s electrical connections, replace the motor junction box cover and secure it using four hex head capscrews and lockwashers.

WARNING! The hydraulic pump motor is now detached from the tractor frame and can be removed. The hydraulic pump motor is extremely heavy. Prepare to support its weight before removing it from the tractor frame.  18. Carefully slide the hydraulic pump motor out of the tractor frame.

______________________________________________________________ A6474X347 REV 06 5.285

BI016954-06 (EN-US)

Replacement of wear parts _________________________________________ hydraulic pump motor installation

To install the hydraulic pump motor  1. Slide the hydraulic pump motor into position in the tractor frame.  2. Remove the four hex head capscrews and lockwashers that secure the junction box cover and remove the cover and its oring.  3. Insert the three lugs of the power cable (with gland and stuffing box already installed) into the motor’s junction box.  4. Replace the stuffing box’s half-moon clamp in its channel to secure the stuffing box in the junction box.  5. Tighten the two socket head capscrews to secure the clamp to the junction box.  6. Inside the junction box, locate the motor’s lug connections.

Match the motor lug connections to the corresponding power cable lugs (refer to the wiring diagram supplied in your parts manual).  7. Attach the first motor lug to its corresponding power cable lug by inserting a hex head capscrew through the motor lug, through the power cable lug, through a flat washer, and through a lockwasher. Secure the capscrew with a hex nut.

Repeat this step for the other two lugged connections.  8. When all three connections have been secured, wrap each of the three connections with a layer of rubber tape, then a layer of black tape and finally a layer of glass tape.  9. Replace the junction box O-ring and cover.  10. Insert the four hex head capscrews and lockwashers to secure the junction box cover and tighten.  11. Verify correct motor direction.  12. Insert the two motor cooling water fittings into the pump motor cooling water ports.  13. Attach the two motor cooling water hoses to the fittings.  14. Position the pump stand against the motor and attach to the motor with two hex head capscrews.  15. Insert and tighten the two hex head capscrews and lockwashers to secure the pump stand to the tractor frame.  16. Install the hydraulic pump (see hydraulic pump installation procedure in this chapter).

________________________________________________________________ 5.286 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

________________________________________ Replacement of wear parts Scrubber fan/motor removal and installation scrubber fan/motor removal

To remove the scrubber fan/motor  1. Lower the conveyor tail section until it is level with the floor.  2. Lower the gathering head and cutter head assemblies until they rest on the floor.  3. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.  4. Locate the rub rail on the fan exhaust side at the rear of the miner (Fig. 219) and remove the pin that secures the rear rub rail to the rail adjacent to it. Open both rub rails.

Fig. 219: Scrubber fan/motor location

Scrubber fan/motor

 5. Remove the four capscrews and lockwashers that secure the rub rail hinge post to the tractor frame and remove the post.  6. Locate the scrubber fan motor junction box and remove the four hex head capscrews and lockwashers that secure the junction box cover. Remove the cover and o-ring.  7. Locate the three taped power connections inside the junction box.  8. Strip off the three layers of tape covering each of the three lug connections inside the junction box.  9. Tag the three lugs to facilitate reconnection during motor installation. ______________________________________________________________ A6474X347

REV 06

5.287

BI016954-06 (EN-US)

Replacement of wear parts _________________________________________  10. Remove the hex head capscrew, flat washer, lockwasher, and hex head nut that secures the three power cable lugs to the three motor lugs.  11. Remove the two socket head capscrews and lockwashers that secure the stuffing box’s half-moon clamp to the junction box.  12. Remove the clamp and slide the stuffing box out of the junction box. The power cable should be completely disconnected from the motor.  13. To prevent damage to the power cable lugs and gland assembly, cover the power cable and secure it to the miner in a safe location.  14. To protect the motor’s electrical connections, replace the motor junction box cover and secure it using four hex head capscrews and lockwashers.

WARNING! The scrubber fan/motor is now detached from the tractor frame and can be removed. The hydraulic pump motor is extremely heavy. Prepare to support its weight before removing it from the tractor frame.  15. Carefully slide the scrubber fan/motor out of the tractor frame.

________________________________________________________________ 5.288 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

________________________________________ Replacement of wear parts scrubber fan/motor installation

To install the scrubber fan/motor  1. Carefully insert the scrubber fan/motor assembly into the tractor frame so the motor face is toward the scrubber’s mist eliminator box.  2. Orient the scrubber fan/motor so the motor drain is directly at the bottom of the assembly. Ensure that the scrubber fan/motor is positioned correctly for airflow out the rear vent of the miner.  3. Insert and tighten the twelve hex head capscrews and lockwashers to secure the scrubber fan/motor assembly to the tractor frame.  4. Remove the four hex head capscrews and lockwashers that secure the junction box cover and remove the cover and its oring.  5. Insert the three lugs of the power cable (with gland and stuffing box already installed) into the motor’s junction box.  6. Replace the stuffing box’s half-moon clamp in its channel to secure the stuffing box in the junction box.  7. Tighten the two socket head capscrews to secure the clamp to the junction box.  8. Inside the junction box, locate the motor’s lug connections.

Match the motor lug connections to the corresponding power cable lugs (refer to the wiring diagram supplied in your parts manual).  9. Attach the first motor lug to its corresponding power cable lug by inserting a hex head capscrew through the motor lug, through the power cable lug, through a flat washer, and through a lockwasher. Secure the capscrew with a hex nut. Repeat this step for the other two lugged connections.  10. When all three connections have been secured, wrap each of the three connections with a layer of rubber tape, then a layer of black tape and finally a layer of glass tape.  11. Replace the junction box O-ring and cover.  12. Insert the four hex head capscrews and lockwashers to secure the junction box cover and tighten.  13. Replace the rub rail hinge post.  14. Insert and tighten the four hex head capscrews and lockwashers to secure the rub rail hinge post to the tractor frame.  15. Close both rub rails and secure with the rub rail pin.

______________________________________________________________ A6474X347 REV 06 5.289

BI016954-06 (EN-US)

Replacement of wear parts _________________________________________ Swivel pin assembly removal and installation swivel pin removal

To remove the swivel pin Reference Fig. 221:  1. Lower the cutter head and gathering head assemblies until they touch the ground.  2. Position the conveyor tail section to the extreme right or left of the miner so that the chain is drawn to one side as far as possible and the conveyor swivel pin is exposed.  3. Lower the conveyor tail section until it is level with the floor.  4. Insert blocking between the conveyor tail section and the floor.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all blocking devices. 

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

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.

Fig. 221: Conveyor swivel Dowel pin

Grease fitting

Set screw

Swivel pin

Socket head capscrews

Retainer

View A-A ________________________________________________________________ 5.290 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

________________________________________ Replacement of wear parts  6. Remove the socket head capscrews from the upper swivel pin.  7. Remove the center setscrew from the center of the upper conveyor swivel pin.  8. Use a slide hammer to remove the upper conveyor swivel pin.  9. Remove the center setscrew from the center of the lower conveyor swivel pin.  10. Remove the socket head capscrews from the lower conveyor swivel pin.  11. Use a slide hammer to remove the lower conveyor swivel pin.  12. Reach into the conveyor chain return channel and retrieve both upper and lower swivel pin retainers. swivel pin installation

To install the swivel pin Reference Fig. 221:  1. Working first on the upper swivel pin assembly, insert the dowel pin, center setscrew, and the grease fitting into the swivel pin.  2. Lower the swivel pin into the hole in the conveyor bed making sure the dowel pin is positioned in the notch and the top of the swivel pin is flush with the top surface of the conveyor bed.  3. Holding the swivel pin retainer with the flanged side downward, reach into the conveyor chain return channel and fit the swivel pin retainer into the hole.  4. Insert the socket head capscrews and tighten.  5. Working on the lower swivel pin assembly, insert the dowel pin, center setscrew and the grease fitting into the swivel pin.  6. Lift the swivel pin into the hole in the lower side of the conveyor making sure the dowel pin is positioned in the notch and the lower side of the swivel pin is flush with the lower surface.  7. Holding the swivel pin retainer with the flanged side upward, reach into the conveyor chain return channel and fit the swivel pin retainer into the hole.  8. Insert the socket head capscrews and tighten.

______________________________________________________________ A6474X347 REV 06 5.291

BI016954-06 (EN-US)

Replacement of wear parts _________________________________________ Tail roller removal and installation tail roller removal

To remove the tail roller Reference Fig. 222:  1. Lower the gathering head and cutter head assemblies until they rest on the floor.  2. Slowly advance the conveyor chain until a connecting link moves onto the conveyor tail section slide pan.  3. Using the procedure outlined in Chain Tension, Loosen tension on the conveyor chain as much as possible (see Conveyor chain adjustment procedure I n this chapter).  4. Lower the conveyor tail section onto blocking so it is level with the floor.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all blocking devices. 

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

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.  6. With conveyor chain tension removed, remove the retaining rings from the connecting link.  7. Remove the connecting link and its strap. The conveyor chain should now be separated. Move the two pieces of the conveyor chain out of the way to allow for easier removal of the conveyor tail roller assembly. 

8. Remove the socket head capscrews that secure the tail roller assembly to the slide pan.



9. Remove the tail roller assembly from its location in the slide pan.

________________________________________________________________ 5.292 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

________________________________________ Replacement of wear parts Fig. 222: Tail roller

Tail roller

Socket head capscrew

tail roller installation

To install the tail roller  1. Insert the tail roller assembly into the proper location in the slide pan (Fig. 222).  2. Insert and tighten the socket head capscrews through the holes in the tail roller shaft and into the threaded holes in the slide pan (Fig. 222).  3. Reattach the two ends of the conveyor chain by replacing the connecting link.  4. Secure the connecting link by replacing the side strap and the retaining rings onto the ends of its pins.  5. Tighten the conveyor chain to the proper tension (see Conveyor chain adjustment procedure in this chapter).

IMPORTANT! Improper conveyor chain tension can lead to excessive wear, mechanical problems and miner downtime. Always keep the conveyor chain at the proper tension.

______________________________________________________________ A6474X347 REV 06 5.293

BI016954-06 (EN-US)

Replacement of wear parts _________________________________________ Conveyor chain replacement  1. Lower the cutter head and gathering head assemblies until they touch the ground.  2. Position the conveyor tail section directly behind the miner and raise it. Insert the blocking under the tail section and lower the tail section onto the blocking.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all blocking devices. 

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

WARNING! Follow all federal and mine lockout/tagout regulations. Failure to do so could result in machine damage or serious injury or death to personnel.  4. Loosen the tension of the conveyor chain as much as possible (see Conveyor chain adjustment procedure in this chapter).  5. Remove the two retaining rings from a connecting link located near the rear of the conveyor bed.  6. Remove the connecting link. The chain is now separated.  7. Connect the come-along to the end of the chain on the conveyor bed.  8. Connect the new chain to the end of the lower chain and allow the new chain to extend behind the miner on the floor.  9. Use the come along to pull the old chain out of the miner. The new chain will follow the old through the conveyor return channel around the gathering head foot shaft and out onto the conveyor tail section.  10. When the entire length of old chain has been pulled through the miner and the replacement chain is in position, disconnect the old chain from the new and remove the come along.  11. Connect both ends of the new chain by replacing the connecting link, pins and retaining rings.  12. Tighten the conveyor chain (see Conveyor chain adjustment procedure in this chapter).

________________________________________________________________ 5.294 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

________________________________________________ Troubleshooting Troubleshooting procedures The following section lists possible problems encountered when servicing the Continuous Miner ® and can aid in locating and correcting these problems.

This section covers basic components, with each listed in a troublecause-remedy format.

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

For maintenance procedures and tests that DO NOT require the controller to be energized, precautions include: ■

Before removing the controller cover, remove power from the system by disconnecting the trailing cable. Follow all mine, local, State, and Federal lockout/tagout procedures.

■

Use insulated gloves and tools where possible.

■

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

For procedures that DO require that the controller be energized while the cover is off: ■

At no time should you reach inside the controller while it is energized. If it becomes necessary to make adjustments or to replace parts inside the controller, the machine circuit breaker must be turned to the “OFF” position and the capacitor bank discharged (see above). Once the circuit breaker is in the “OFF” position and the capacitor bank discharged, adjustments or parts replacements can be made.

■

Use insulated gloves and tools where possible.

■

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

______________________________________________________________ A6474X347 REV 06 5.295

BI016954-06 (EN-US)

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

Typical hydraulic problems The most common causes for improper function are: ■

contaminated oil or poor oil quality

■

low or insufficient oil in the system

■

using the wrong type of oil or wrong viscosity grade

■

air in the hydraulic system

■

internal or external leakage of the hydraulic system

■

improper mechanical adjustments, such as reliefs

■

mechanical or structural damage leading to component failure

■

components by-passing (internal leaking or inability to hold pressure) which leads to erosion of bushings, valve spools, and other costly, critical components

The greatest aid to troubleshooting a hydraulic system is the confidence that comes with knowing the intended operation of the system, along with a fundamental understanding of basic hydraulic principles. Every component in the system has an intended purpose. The construction and operating characteristics of each of these components should be clearly understood before attempting to troubleshoot the machine. For example, understanding that a solenoid controlled directional valve can be manually actuated will save considerable time in isolating a defective solenoid. Please familiarize yourself with the operational descriptions of the hydraulic circuits given in the Hydraulics section of this chapter.

It is also important to know the capabilities of the system. Each component in the system has a maximum rated speed, flow, torque, or pressure. If the system is loaded beyond the specifications, the possibility of failure is greatly increased. The correct operating pressures of a system must be known and must always be checked and set with a pressure gauge. Refer to the hydraulic schematic in the parts manual supplied with your machine for the correct operating parameters. When in doubt, always assume that the correct pressure is the lowest pressure that will allow adequate performance of the system function (s) while remaining below the maximum rating of the machine’s components.

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

________________________________________________________________ 5.296 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

________________________________________________ Troubleshooting The troubleshooting charts cover the following areas: ■

General safety procedure for shutting down the machine

■

Troubleshooting excessive noise

■

Troubleshooting excessive heat

■

Troubleshooting incorrect flow

■

Troubleshooting incorrect pressure

■

Troubleshooting faulty movement/operation

■

General restart checklist and procedure

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

Contaminants in hydraulic systems The primary cause of hydraulic component failure is SYSTEM CONTAMINATION! Cleanliness must be a high priority when servicing the hydraulic system. Even very small particles can damage system components by scoring valves, clogging orifices, and wearing seals prematurely. It is not the intent of this operation manual to outline a contamination control program but some of the most effective steps that have been identified in successful programs are given below: 1. Ensure that bulk oils are at acceptable cleanliness levels.

Areas where customers have made improvements in the past include: –

implement ISO Cleanliness Code standards for bulk hydraulic oils

–

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

–

minimize drum usage by utilizing tote tanks and five gallon pails

–

utilize plastic versus steel storage tanks, if possible

–

install desiccant breathers on all bulk tanks

–

use sealed plastic containers for adding oil to small sumps

–

locate bulk tanks near equipment and pump directly to reservoirs

–

utilize filter carts to maintain oil cleanliness standards

–

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

–

monitor your program closely and look for continuous improvement

______________________________________________________________ A6474X347 REV 06 5.297

BI016954-06 (EN-US)

Troubleshooting _________________________________________________

2. Eliminate contamination source through “clean” maintenance practices This is best achieved by understanding the primary sources of contamination during maintenance and troubleshooting which are given below: –

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

–

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

–

cap off all open hoses/fittings

–

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

–

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

Contact your representative for more information on implementing an effective program to ensure that your oil and maintenance practices are not contributing to your equipment failure.

Specific hydraulic circuit troubleshooting Multi-function failure If more than one function fails to operate on the machine, check the output of the pumps. Since this is an “open center” circuit, the normal pressure (with all directional control valves in the center position) should be less than 100 psi. This pressure reading illustrates the necessary pressure to circulate the oil through the system. If the pressure reading under these conditions is significantly greater than 100 psi, it is likely that one of the control valves is trying to direct oil to one (or more) of the circuits on the machine.

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

________________________________________________________________ 5.298 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

________________________________________________ Troubleshooting Individual hydraulic circuit failures Perform the following checks on the individual circuits in conjunction with the general troubleshooting: Oil tank fill  Check to see that the oil fill strainer is clean.  Check the venturi ejector for blockage.  Check for low oil in the new oil supply.

Cutter head raise  Check the directional control valve for proper operation.  Check to see that piping has not been crossed, especially if the problem occurs after maintenance or repair work.  Check that the "in-line" counterbalance holding valve is piloted and shifting to direct retract port cylinder oil flow back to tank.  Check to see that there is no mechanical bind.  Check cylinders for bypassing.  Check for pilot pressure on the cutter head cylinder’s holding valves. Also check that the valves are shifting to send (extend port) oil back to the tank. Note: cylinder removal will be required to safely achieve this) Cutter head lower  Check the direction control valve for proper operation.  Check to see that piping has not been crossed, especially if the problem occurs after maintenance or repair work.  Check to see that there is no mechanical bind or hydraulic block.  Check flow control valve cartridge.  Check cylinders for bypassing.  Check for pilot pressure on the cutter head cylinder's holding valves. Also check that the valves are shifting to send (extend port) oil back to the tank. Note: cylinder removal will be required to safely achieve this.

______________________________________________________________ A6474X347 REV 06 5.299

BI016954-06 (EN-US)

Troubleshooting _________________________________________________ Gathering head raise  Check the directional control valve for proper operation.  Check to see that piping has not been crossed, especially if the problem occurs after maintenance or repair work.  Check pressure at the LH pressure gauge on snubber.  Check to see that there is no mechanical bind.  Check cylinders for bypassing.  Check accumulator for 500 psi pre-charge, and that the bladder is functioning properly.  Check needle valve on pilot circuit to verify that it is not open or leaking off.  Check in-line counterbalance valve for proper operation or blockage.

Gathering head float  Check the control valve for proper operation.  Check to see that piping has not been crossed, especially if the problem occurs after maintenance or repair work.  Check to see that there is no mechanical bind.  Check accumulator for 500 psi pre-charge, and that the bladder is functioning properly.  Check cylinders for bypassing (they will leak out the top).  Check needle valve on pilot circuit to verify that it is not open or leaking off.  Check counterbalance valve for proper operation (see the schematic in the parts book supplied with your machine for the proper setting).

Conveyor Raise  Check the directional control valve for proper operation.  Check to see that piping has not been crossed, especially if the problem occurs after maintenance or repair work.  Be sure that the built-in atmospheric-vented reliefs on the cylinders are not dumping oil.  Check to see that there is no mechanical bind.  Verify that cylinders are not bypassing.

________________________________________________________________ 5.300 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

________________________________________________ Troubleshooting Conveyor Lower  Check the directional control valve for proper operation.  Check to see that piping has not been crossed, especially if the problem occurs after maintenance or repair work.  Verify that pilot pressure is being applied to open the piloted builtin checks.  Verify that cylinders are not bypassing.

Conveyor Swing  Check the directional control valve for proper operation.  Check for any mechanical bind or any obstruction blocking movement, either to the cylinder itself, the main pivot area, or to some point along or under the discharge conveyor itself. Also check to ensure that the pivot bushings have not frozen up from lack of lubrication.  Verify that the cylinder is not bypassing.

Stabilizer Raise  Check the directional control valve for proper operation.  Check to see that piping has not been crossed, especially if the problem occurs after maintenance or repair work.  Check the lubrication network for bound bushings.  Check for any mechanical bind or any obstruction blocking movement.  Check cylinder for bypassing.

Stabilizer Lower  Check the control valve for proper operation.  Check to see that piping has not been crossed, especially if the problem occurs after maintenance or repair work.  Check the lubrication network for bound bushings.  Check for any mechanical bind or any obstruction blocking movement.  Check cylinder for bypassing.

______________________________________________________________ A6474X347 REV 06 5.301

BI016954-06 (EN-US)

Troubleshooting _________________________________________________ General safety procedure for shutting down machine When shutting down the machine for maintenance:  lower or mechanically secure (block) all suspended loads  exhaust any pressure locked in the system  drain down all accumulators  isolate the electrical control system  isolate the electrical power supply Follow all procedures listed in the Shutdown procedure in this chapter.

________________________________________________________________ 5.302 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

________________________________________________ Troubleshooting Table 3: Flow chart I for troubleshooting excessive noise

Pump Noisy Cause

Motor Noisy Remedy

Cause

Cavitation

A

Coupling misaligned

Air in fluid

B

Motor or coupling worn or damaged

Coupling misaligned

C

Pump worn or damaged

E

Relief/Counterbalance Valve Noisy Remedy

Cause

Remedy

C

Setting too low or too close to another valve setting

D

Worn poppet and seat

E

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

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

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

______________________________________________________________ A6474X347 REV 06 5.303

BI016954-06 (EN-US)

Troubleshooting _________________________________________________ Table 4: Flow chart II for troubleshooting excessive heat Pump Heated

Motor Heated Cause

Fluid Heated

Cause

Remedy

Cause

Remedy

See Fluid Heated

System pressure too high

D

Cause

Remedy

Fluid heated

See Fluid Heated

Cavitation

A

Relief or unloading valve set too high

D

Valve setting incorrect

D

Unloading valve set too high

D

Air in fluid

B

Excessive load

C

Worn or damaged valve

E

Fluid dirty or low supply

F

Relief or unloading valve set too high

D

Worn or damaged motor

E

Incorrect fluid viscosity

F

Excessive load

C

Faulty fluid cooling system

G

Worn or damaged pump

E

Worn pump, valve motor, cylinder, or other component

E

Fluid heated

Remedy

Relief Valve Heated

See Fluid Heated

Fluid heated

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

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

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

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

________________________________________________________________ 5.304 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

________________________________________________ Troubleshooting Table 5: Flow chart III for troubleshooting incorrect flow No Flow Cause

Low Flow Remedy

Excessive Flow

Cause

Remedy

Cause

Remedy

Pump not receiving fluid

A

Flow control set too low

D

Flow control set too high

D

Pump drive motor not operating

E

Relief or unloading valve set too low

D

RPM of pump drive motor incorrect

H

Pump to drive coupling sheared

C

Flow by-passing thru partially open valve

E of F

Improper size pump used for replacement

H

Pump drive motor turning in wrong direction

G

External leak in system

B

Directional control set in wrong position

F

RPM of pump drive motor incorrect

H

Entire flow passing over relief valve

D

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

E

Damaged pump

C

Pilot filter clogged

A

Improperly assembled pump

E

Pilot filter clogged

A

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

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

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

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

______________________________________________________________ A6474X347 REV 06 5.305

BI016954-06 (EN-US)

Troubleshooting _________________________________________________ Table 6: Flow chart IV for troubleshooting incorrect pressure No Pressure

Low Pressure

Erratic Pressure

Cause

Remedy

Cause

Remedy

No flow

See Table 5

Pressure relief path exists

See Table 5

Pressure reducing valve set too low

Cause

Excessive Pressure

Remedy

Cause

Remedy

Air in fluid

B

Pressure reducing, relief, or unloading valve misadjusted

D

D

Worn relief valve

E

Pressure recuing, relief, or unloading valve worn or damaged

E

Pressure reducing valve damaged

E

Contamination in fluid

A

Damaged pump, motor, or cylinder

E

Accumulator defective or has lost charge

C

Worn pump, motor, or cylinder

E

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

________________________________________________________________ 5.306 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

________________________________________________ Troubleshooting Table 7: Flow chart V for troubleshooting faulty operation No Movement Cause No flow or pressure

Slow Movement

Remedy

Cause

See Table Low flow 5

Erratic Movement Remedy

Excessive Speed or Movement

Remedy

Cause

Cause

Remedy

See Table 5

Erratic pressure

See Table Excessive flow 6

See Table 5

Air in fluid

See Table Feedback 3 transducer malfunctioning

E

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

E

Fluid viscosity too high

A

Mechanical bind

B

Insufficient control pressure for valves

See Table 6

No lubrication of machine ways or linkage

G

Misadjusted or malfunctioning valve amplifier

C

No command signal to valve or amplifier

F

No lubrication of machine ways or linkage

G

Erratic command signal

F

Overriding work load

H

Inoperative or misadjusted valve amplifier

C

Misadjusted or malfunctioning valve amplifier

C

Misadjusted or malfunctioning valve amplifier

C

Inoperative solenoid or proportional valve

E

Sticking valve

D

Malfunctioning feedback transducer

E

Worn or damaged cylinder or motor

E

Worn or damaged cylinder or motor

E

Sticking valve

D

Pilot filter clogged

See Table 5

Worn or damaged cylinder or motor

E

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

______________________________________________________________ A6474X347 REV 06 5.307

BI016954-06 (EN-US)

Troubleshooting _________________________________________________ Table 8: Restarting checklist Has the cause of the failure been remedied?

No

Carry out further investigation.

Yes

Clean or flush the system as required.

Yes Can dirt have entered the system by the unit failure or during replacement?

No Is the unit the correct one?

No

Modify or replace with correct unit.

No

Remedy installation.

No

Remedy installation.

Yes

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

Yes Are all hydraulic connections correct?

Yes Are all electrical connections correct?

Yes Is the unit adjustable?

Yes

No

Adjust to a safe condition.

No Have the cases of pumps and motors been filled?

No

Fill case.

Yes

Bleed or prime as necessary.

No

Remove safety interlocks.

No

Sound alarm or inform personnel.

Yes Will the system require bleeding or priming?

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

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

________________________________________________________________ 5.308 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

________________________________________________ Troubleshooting Water System including Circuits Table 9: Water system troubleshooting including circuits Trouble, symptom or cause

Probable cause

Test, check and/or remedy

recommended water volume  Dynamic water pressure (psi) is  Change setting to the recomnot being supplied to the recommended psi. (gpm) cannot be maintained mended psi.  Water supply hose is not the minimum diameter

 Change hose to the recommended diameter size.

 Incoming supply of water has a problem.

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

damaged or clogged filter, con-  Dirt in the system. taminates in the water system

 Remove the filter and clean it thoroughly; flush the system as necessary.  Change water filter frequently.

plugged water nozzles are re-  Dirt in the system. stricting the flow of water or pressure fluctuates

 Remove the nozzles and clean thoroughly; flush the system as necessary.  Change water filter frequently.

pressure fluctuates and there is  Air in the system. extreme noise in the system  Pressure too high. excessive water blowing from  Excessive pressures on scrubber screen sprays. scrubber exhaust

 Check for leaks.  Adjust the pressure.  Adjust psi setting.

 Pressure setting on jet pump too low.

 Adjust psi setting.

 Damaged screen or mist eliminator.

 Replace.

 Mist eliminator not sealing.

 Replace seal.

 Sump needs cleaned.

 Remove mist eliminator and clean sump.

 Mist eliminator baffles dirty.

 Remove mist eliminator and clean.

water function will not shut  Hydraulic pilot operated water valve stuck closed.

“OFF” with radio remote

 Clean or replace.

 Faulty solenoid.

 Replace.

 Radio remote toggle switch faulty.

 Replace toggle switch.

______________________________________________________________ A6474X347 REV 06 5.309

BI016954-06 (EN-US)

Troubleshooting _________________________________________________ Table 9 (continued): Water system troubleshooting including circuits Trouble, symptom or cause

Probable cause

no water pressure on the  Water filter plugged. pressure gauge  Main water ball valve “OFF”.  No incoming water. water filter stopping up  Contaminated water supply frequently scrubber water will not turn  Faulty solenoid plug connection.

“ON” when scrubber motor is running  Faulty solenoid.

Test, check and/or remedy  Replace or clean.  Close valve.  Fix water supply issue.  Clean or filter the incoming water supply to the miner.  Check the connection.  Replace.

 No hydraulic pilot pressure to water  Check for pinched hose and valve. check the hydraulic pilot valve. scrubber water will not shut  Hydraulic pilot operated water valve  Clean or replaced valve. stuck closed.

“OFF” after scrubber motor stops  Replace.  Faulty solenoid jet pump not removing water  Incorrect pressure reducing valve setting. from sump

 Adjust psi.



Low water volume to scrubber circuit.  Check water volume gpm.



Pressure reducing valve internal strainer dirty.



Remove strainer and clean.



Jet pump nozzle plugged with dirt.



Backflush pump, remove nozzle and clean.



Excessive pressure setting on scrubber screen sprays.



Adjust psi.



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



Remove restriction or tighten hose connection.



Incorrect hose size from jet pump to manifold.



Check for correct hose size.



Manifold plugged.



Clean.



Adjust psi.

scrubber screen dirty  Incorrect pressure reducing valve setting.



Low water volume to scrubber circuit. 

Check water volume gpm.



Pressure reducing valve internal strainer dirty.



Remove strainer and clean.



Spray nozzles clogged or incorrect nozzle size.



Clean nozzles and check nozzle part size.

________________________________________________________________ 5.310 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

________________________________________________ Troubleshooting Electrical System Table 10: Electrical system troubleshooting Trouble, symptom or cause Probable cause motor contact chatter  Low voltage

Test, check and/or remedy  Check supply voltage, especially during starting. Check coil voltage rating. Increase voltage or change coil rating as required.

 Poor contact in control circuit.

 Replace the contact or use holding-circuit interlock.

(3-wire control)

 Broken shading coil.

 Replace magnet and armature assemblies.

welding of motor contactor tips  Abnormal in rush current.

 Use the next larger size contactor or check for grounds, shorts or excessive motor current.

 Rapid jogging.

 Install larger device rated for jogging service.

 Insufficient contact pressure.

 Replace contacts and springs, check for contacts for abnormal wear or damage.

 Incorrect vacuum contactor gap.  Use the over-travel gauge mounted on the front of the unit.

When the gap on the bottle goes below 0.010 inches, the unit should be replaced.  Low voltage preventing magnet from sealing.

 Check supply voltage to coil, especially for momentary voltage dip during starting.

 Foreign matter preventing contacts from closing.

 Clean contacts with Freon.

Contacts used at low current and voltage levels should be cleaned with Freon.

 Vibration in starter mounting.

 Insulate starter from shock and vibration.

 Short circuit.

 Remove fault and check to be sure fuse or breaker size is correct.

 For vacuum contactor: after a short circuit examine vacuum bottles, conductor bars, and cables for physical damage.

Check over-travel on vacuum bottle. ______________________________________________________________ A6474X347

REV 06

5.311

BI016954-06 (EN-US)

Troubleshooting _________________________________________________ Table 10 (continued): Electrical system troubleshooting Trouble, symptom or cause

Probable cause

chart contact life or  Filing or dressing. overheating of motor contactor

Test, check and/or remedy  Do not file silver contacts.

Rough spots or discoloration will not harm contacts or impair their efficiency.

 Interrupting excessively high currents.

 Install larger unit. Check for grounds, shorts or excessive motor currents.

 Excessive jogging.

 Install larger unit rated for jogging service.

 Weak contact pressure.

 Replace contacts and springs.

Check contacts for abnormal wear or damage.

 Foreign matter on contact surface.

 Clean contacts with Freon.

Take steps to reduce entry of foreign matter into enclosure.

 Short circuit or ground fault.

 Remove fault and check to be sure fuse or breaker size is correct.

 Loose connections in power circuit.

 Clean and tighten.

 Sustained overload.

 Check for excessive motor load current or install larger unit.

failure to pick-up and seal  Low voltage.

 Check system voltage and voltage dips during starting.

 Wrong coil or wrong connection.

 Check coil marking and wiring.

 Mechanical obstruction.

 With power off, check for free movement of armature and contacts.

 Coil open or overheated.

 Replace.

failure to drop out  Sticky substance on pole faces.

 Clean pole faces with Toluol and seal with a drop of DC200 silicone fluid.

 Voltage not removed.

 Check coil circuit or length of leads from supply voltage to coil. May be excessive.

 Worn or rusted parts causing binding.

 Replace unit.

 Contacts welded.

 See welding under contacts section.

open circuit  Mechanical damage.

 Handle and store coils carefully.

________________________________________________________________ 5.312 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

________________________________________________ Troubleshooting Table 10 (continued): Electrical system troubleshooting Trouble, symptom or cause

Probable cause

both cutter head motors do not  Three phase power not present at contactors. start

Test, check and/or remedy  Check three phase input to contactors.

 Contactor tips damaged.

 Check contactor tips.

 Pump not running.

 Start pump.

 Low hydraulic level.

 Check oil level and level indicator light.

 Failed control relay contacts.

 Check contacts

 Cutter head motor start and stop switches, conveyor start switch, or pump start switch not working properly.

 Check for faulty switches.

 Control relay malfunction.

 Check coil and contacts.

 Overload relay.

 Check overload relays.

 Failed left cutter head motor contactor.

 Check contactor coil. Verify that contacts are free to move.

left cutter head motor starts but  Auxillary contacts not closing. right cutter head motor does not

 Check contactor auxillary contacts and wiring.

 Time delay malfunction.

 Check coil and timed closed contacts and wiring.

 Load current relay problem.

 Verify that normally closed load current relays are NOT open.and check wiring.

 Failed contactor.

 Check contactor coil and contact tips and wiring.

 Overload relay problem.

 Check overload relays and wiring.

both cutter head motors start but  Problem with auxillary contacts.  Check right cutter head motor contactor auxillary contacts and stop when pump start and cutter associated wiring. head start switches are released  Overcurrent relays.

 Check overcurrent relays.

______________________________________________________________ A6474X347 REV 06 5.313

BI016954-06 (EN-US)

Troubleshooting _________________________________________________ Table 10 (continued): Electrical system troubleshooting Trouble, symptom or cause

Probable cause

Test, check and/or remedy

conveyor starts forward operation  Problem in holding circuit. but stops when conveyor start switch is released

 Check normally open conveyor forward auxiliary contact and associated wiring.

conveyor will not start in forward  Pump not running. or reverse. Contactor IS NOT pulling in contacts  Failed control relay contacts.

 Start pump.  Check contacts.

 Conveyor start and stop switch-  Check for faulty switches. es or conveyor forward/reverse not working properly  Overload relay tripped/faulty/

 Check overload relays.

 Over current relay tripped/faulty.  Check over current relay.  Conveyor forward/reverse contactor failure.

 Check contactor coils. Verify that contacts are free to move.

conveyor will not start in forward  Three phase power is not present at contactors. or reverse. Contactor IS pulling in contacts  Contactor tips are damaged.

 Check three phase power input to the contactors.

conveyor operates in forward only  Reverse switch.

 Check that the Reverse switch is completing the circuit.

 Conveyor Forward auxiliary contacts.

conveyor operates in reverse only  Forward switch.  Conveyor Reverse auxiliary contacts.

 Check contactor tips.

 Verify that the conveyor forward auxiliary normally closed contacts have not failed to open.  Check that the Forward switch is completing the circuit.  Verify that the conveyor reverse auxiliary normally closed contacts have not failed to open.

________________________________________________________________ 5.314 25M3 (CM240) Continuous Miner

BI016954-06 (EN-US)

________________________________________________ Troubleshooting Bearings Table 11: Bearing troubleshooting Trouble, symptom or cause

Probable cause

overheating bearing  Wrong type of grease or oil.

Test, check and/or remedy  Consult the lubrication chart for the proper lubricant.

 Low oil level; loss of lubricant through seal; excessive grease.

 Oil level should normally be at the center of lowest ball or roller in bearing; check seals for signs of leaking.

 Insufficient clearance in bearing.

 Replacement bearing should be identical to original equipment to ensure proper internal clearance.

 Housing bore out of round; hous Check and scrape housing bore to ing warped; excessive distortion of relieve pinching of bearing; be housing; undersized housing bore. sure pedestal surface is flat and shims cover entire area of pillow block base when applicable.  Shaft out of line.

 Correct alignment and be sure shafts are coupled in a straight line.

noisy bearing  Insufficient clearance in bearing.

 Replacement bearing should be identical to original equipment to ensure proper internal clearance.

 Foreign matter acting as abrasive.

 Clean bearing housing and replace worn seals.

 Housing bore out of round; hous Check and scrape housing bore to ing warped; excessive distortion of relieve pinching of bearing; be housing; undersized housing bore. sure pedestal surface is flat and shims cover entire area of pillow block base when applicable.  Shaft and other parts of bearing assembly distorted.

 Replace bearing, shaft and other parts as needed.

vibrating bearing  Enlarged housing bore causing spinning of outer ring in housing.

 Re-bore housing and press steel bushing in bore, then machine bore to correct size.

 Foreign matter acting as abrasive.

 Clean bearing housing and replace worn seals.

 Unbalanced loading

 Check balance of rotating parts and rebalance as needed.

 Replace with OEM bearing; do not unsatisfactory performance  Chip in bearing housing; insufficient clearance in bearing; Ball or hammer on any part of bearing; roller dented from extreme loading. clean housing and use fresh lube.

______________________________________________________________ A6474X347 REV 06 5.315

BI016954-06 (EN-US)

________________________________________________ Troubleshooting

______________________________________________________________ A6474X347 REV 06 5.316