DOWNLOAD PDF : Cat CM235 Continuous Miner Operation and Maintenance Manual A6474X375 by www.heydownloads.com

Operationand Maintenance Manual

CM235ContinuousMiner

A6474X375(Introduction - Operation)

ThismanualisintendedtoprovideGENERALproductinformation. Theillustrations,descriptionsandprocedurescontainedinthispublicationapplyonlytoTHISmachine.Caterpillarreservestherightto revisemodelsanddesignswithoutpriornotice.

Thismachinewasmanufacturedundertheguidelines,proceduresand requirementsoftheappropriategovernmentregulatoryagencies.

Atthecompletionofthemanufacturingprocess,thisunitwasissued theappropriateapprovalnumbersandnameplatesindicatingitmetthe technicalrequirementsoftheseregulatoryagencies.Anychangeto thedesignorstructureofthisunit,withouttheconsentofCaterpillar andtheseregulatoryagencies,oranyrepairorreplacementofparts contrarytotheinstructions,mayinvalidatetheseapprovalsandrender thisunitunsafetooperate.

Strictcompliancewithalllaws,regulationsandpracticesregardingthe safeoperationandmaintenanceofundergroundminingequipment andstrictadherencetotheinstructionsinthismanualisnecessaryfor thepersonalsafetyofthoseworkingonoraroundthisunit.

Whilethismanualattemptstoanticipatethemostimportantoperations andmaintenanceneedsforthisunit,unforeseencircumstancesmay arisethathavenotbeenaddressedinthismanual.Ifanyconcernsor questionsarise,pleasecontactyourservicerepresentative immediately

Thisworkcontainsinformationprotectedundertradesecretandother intellectualpropertylaws,andisprotectedundertheU.S.Copyright Actof1976,asamended.Thisworkisprovidedunderlicenseandthe licenseisnon-transferable.Distributionandaccessislimitedonlyto authorizedpersonnel.Disclosure,reproduction,distributionorunauthorizedusemaybeaviolationoffederalandstatelawsandmaysubjecttheunauthorizedusertocriminalliability.

SafetyPrecautions

Thefollowingsafetyprecautionsshouldbeobservedwheneveroperatingor performinganymaintenance,repair,oradjustmentprocedureonthismachine. Additionalprecautionsmayappearineachsectionofthisbook.Allprecautions listed,aswellasallFederal,State,andMinesafetyregulationsmustbefollowedatalltimes.

Federallawrequiresthattemporaryroofsupportsbeinplacebeforeapproachingthe machinetoresetacircuitbreaker.Undernocircumstancesshouldpersonnelbeunder unsupportedroof.Failuretofollowtheseregulationsmayresultinseriousinjuryor death.

Donotattempttooperatethecontinuousmineruntilyouhavebeensufficientlytrained onthemachineandhavereadandunderstandthismanualandarefamiliarwithallcontrolsandindicators.Operatingthismachinewithoutthepropertrainingandknowledge mayresultinseriousinjuryordeathtotheoperatororotherpersonnel.

Followallapplicablelawsandregulationsregardingtheuseoftemporaryroofsupports beforeapproachingthemachinetoconnecttheumbilicalcord.Undernocircumstances shouldpersonnelbeunderunsupportedroof.Failuretofollowtheseregulationsmay resultinseriousinjuryordeath.

OnlyusetheEmergencyStopBypassfunctiontotramtheminerawayfromtherib,releasingtheaccidentallypushedMachineStopbutton.NeverusetheEmergencyStop BypasswhenaMachineStopswitchhasbeenactivatedintentionally.Failuretocomply withthiswarningmayleadtosevereinjuryordeathofpersonnel.

Donotattempttooperatethiscontinuousmineruntilyouhavebeensufficientlytrained onthismachineandhavereadandunderstoodthismanualandarefamiliarwithallcontrolsandindicators.Operatingthismachinewithoutthepropertrainingandknowledge mayresultinseriousinjuryordeathtotheoperatororotherpersonnel.

Theradioremotecontrolofminersintroducescertainpotentialsafetyhazards whichthemineroperatormustwatchforandbeawareof.Whiletheoperatoris nowfreetopositionhimselfforconvenientvisibilityofminingoperationsatthe face,hecaneasilyexposehimselftothedangerofbeingnearmobileheavy equipment.

Mostsignificantly,theoperator’sgreatestdangerisfromhisContinuousMiner, especiallywhenheismaneuveringitduringminingoperations.Themineris capableofslewingwhenturning,especiallywhenthecrawlersaresplit.The dischargeconveyorcanalsoswing.Ineachofthesecases,themineroperator isindangerofbeinghit,orworseyet,runoverbyhisownmachine.Equally dangerousisthepossibilityoftheoperatorbeingpinnedagainsttheribbyhis ownminer.

Sometypicalsituationsdangeroustothemineroperatorareillustratedonthe followingpages.Thedangerarea,orredzone(Fig.1)isindicatedbyalternatingredandwhitediagonalstripes.

Thisinformationisforgeneralreferenceonly.Allminingmethodsare dictatedbythemineregulationsandventilationandroofcontrolprocedures.

Fig.1:Redzonedesignation

RedZones(DangerAreas)

RedZones

Trammingtheminer (Fig.2)fromoneplacetoanother,especiallymaneuveringaroundintersections.Thisillustratesthattheoperatorshouldnotplacehimselfbetweenhisminerandtherib.

Beginningthefirstsump (Fig.2)inanewcut.Theminerisagainsttheleftrib andthedischargeconveyorisswungtowardthecenteroftheentryreadyfor thehaulagecar.Theoperatormuststayclearofthedischargeconveyorand therearoftheminer.

Trammingtheminerredzone Beginning1stsumpredzone

Fig.2:Redzones

Sumpinginthelefthandside ofthecut(Fig.3).Astheminerpenetratesthe face,newunsupportedroofisbeingexposed,andtheoperatornowhasanadditionalconstrainttohismovements.Hemustalsostayclearofthehaulage vehicleattherearoftheminerasitapproachestheminerandwhileitisloading.

Repositioningtheminerfortherighthandcut (Fig.3).Becausethemineris backingoutandturninginclosequarters,theoperatormuststaybehindthe minertobesafe.

Sumpingintherighthandcut (Fig.3).Again,theoperatormuststayaway fromthefacewherethenewly-exposedroofisunsupported,aswellasstaying clearofthehaulagevehiclewhileitapproachesandloads.

Sumpingonthelefthand sideredzone

Repositioningminerforright handcutredzone

Sumpingintherighthand cutredzone

Fig.3:Redzones

RedZones

Crosscutredzones (Fig.4). Beginningandcompletingcrosscutsrequiresalot ofmaneuveringoftheminerandloadingthehaulagevehiclewhileatawkward positions.Crosscutsalsoresultinnewly-exposedunsupportedroof.Respectingareddangerzoneisimportanttooperatorsafetyintheseconditions.

Whentheminerbeginningarighthandcrosscutitisnearlyagainsttheopposite (lefthand)rib,whilethedischargeconveyorisswungtoitsmaximum45o right positionforloadingthehaulagevehicle.Hence,theentirerearofthemineris treatedasaredzone.Therearetwootherdangerareas.Ontherighthand side,theminerformsapinchpointattheribwhichmustbeavoided.Also,on thelefthandsideoftheminer,astheminerprogressesintotherib,asharpangledfenderwillbeformedwhichwillbesusceptibletosloughingandfalling off.Hence,thatribmustbeconsideredaredzone.

Theredzonesurroundstheminerasthedischargeconveyorisfreetoswing eitherwayandmoreunsupportedroofisexposedduringthefurtherdevelopmentoftherighthandcrosscut.

Beginningarighthand crosscutredzone

Righthandcrosscut development

Fig.4:Crosscutredzones

Pillaringredzones (Fig.5) Remotecontroloffersasignificantsafetyadvantageinpartialorcompleteremovalofthepillarsinretreatminingbecauseit placestheoperatorfurtherawayfrompotentialcollapsingroof.

Muchoftheareaaroundtheminermustbeconsideredaredzone,mostlybecauseofextensiveunsupportedroofandtheneedfortemporarysupportsunderweakenedroof.Withremotecontrol,theoperatorcanpositionhimself safelyawayfromtheminerwhilestillretainingagoodviewoftheminingcycle.

Aredzonearoundtheminerisnolongerapplicablewhenworkingintheoppositerighthandpillar,astheoperatorisnowexcludedfromtheentireworking areabecauseoffailingroofconsiderations, evenwiththeexistenceoftemporary roofsupports

Whenmakinganadditionalendcutintothepillar,creatingafenderofcoalbetweenthetwocuts,additionaltemporaryroofsupportsareinstalled.

Becauseofroofpressures,thefenderwilltendtosloughitsribsintheprocess ofeventuallycrushing.Hence,theoperatormuststayawayfromthisfenderas wellasavoidingtheentryandcrosscutareasasshown.

Fig.5:Pillaringredzones

Introduction

Fig.6:GeneralArrangement

TheCM235isdesignedforhardercuttingapplications.Thecutterheadispoweredbytwo275HP(onehourrating)cuttingheadmotorsmountedinthecutter headassembly.Themotorstietogetheratacommondriveshaft,allowingfor thecombinedpowerofbothmotorsatthecutterhead.Additionally,thereare two60HPconveyor/gatheringheadmotors,two110HPACtractionmotors controlledbyVariableFrequencyDrives(VFDs),anda50HPpumpmotor.

Cutterheadassembly

Cuttermotorlocation

Gatheringheadassembly

Gatherheadmotorlocation

Hydraulicpumpandmotorlocation

Tractionmotorlocation

Tractioncontroller

Gatheringheadcylinder

Conveyorswingcylinder

Conveyorassembly

Introduction

MachineandComponent Weights

TheCM235ContinuousMinercanbeshippedeitherasacompletemachineor incomponentsections,dependingoncustomerpreferenceortransportation weightrestrictions.Themachineshouldonlybeunloadedbyexperiencedpersonnel.AlwaysrefertothePre-OperationalChecksandStartUpprocedure beforeattemptingtounloadanassembledmachine.Ifshippedincomponents, itisrecommendedthatarepresentativeassistinthereassembly.

Whenliftingthemachine,alsoverifymachineorcomponentweightsanduse appropriateliftingmechanisms.Notethattheweightslistedbelowmayvary dependingonoptionsandcustomdesign.

Table1:ComponentWeights

Completemachine 140,000lbs(63,503kg)

Tractorframeassembly

Gatheringheadassembly 23,000lbs(10,433kg)

Conveyorassembly 17,000lbs(7,711kg)

Cutterheadsupportframewithdrum drivesanddrums 35,000lbs(15,846kg)

Fig.7:Assemblyliftingpointsandtransportdimensions

Frametransportdimensionsandliftingeyelocations

Liftingeyelocation

Liftingeyelocation (bothsides)

Fig.7,continued:Assemblyliftingpointsandtransportdimensions

Conveyortransportdimensionsandliftingeyelocations

Liftingeye

Liftingeye(bothsides)

Liftingeye

Liftingeye(bothsides)

Liftingeye

Fig.7,continued:Assemblyliftingpointsandtransportdimensions

Cutterheadtransportdimensionsandliftingeyelocations

Liftingpoints

Fig.7,continued:Assemblyliftingpointsandtransportdimensions

Gatheringheadtransportdimensionsandliftingeyelocations

Liftingpoint

Liftingpoint(bothsides)

Lifting point

Observanceofthesestorageandtransportinstructionsandtipswillincrease theservicelifeandavailabilityofthemachine.Youwillalsobeabletocarryout thetransportworkquickerandmoresafely.Carefulattentiontothepointsin thischapterwillhelpyoutosimplifyyourday-to-daywork.

Componentscoatedwithtemporarycorrosioninhibitorareprotectedforapproximatelysixmonths.

Storetheequipmentindoorsorcoverwithatarpaulintoprotectagainstdirect exposuretosunlight.

Protecttheequipmentandallsparepartsstoredoutdoorsagainstmoistureand dirt,e.g.usingtarpaulins.

Protectthehydraulicplugconnectorsandtheconnectorsoftheelectricalcables withthecapsandplugssupplied.

Duringshort-termstorage(approximately4weeks)ofequipmentoutdoors,but attemperaturesabovefreezing,electricalcomponentsneednotberemoved. Suchcomponentsmustbeparticularlyprotectedagainstexcessivetemperatures,dirt,andmoisture.

Iftheequipmentistobestoredmorethansixmonths,thefollowinglubrication andcorrosioninhibitingproceduresmustbefollowed:

1. Ifthecylinderrodsareexposed,therodsmustbecoatedwithacorrosion inhibitingfluid.

2. Completelyfillthehydraulicoiltankwithoil.

3. Fillallgearcasestothemaximumfilllevel.Thegearcasesmustberotatedmonthlytoensurethattheinteriorofthegearcaseremainslubricated.

4. Lubricateallgreasepoints(seetheMaintenancesectioninChapter5of thismanual).

5. Completelydrainthewatersystemandrefillwitha50/50antifreeze/water solution.Pumptheantifreezemixthroughthesystemuntiltheantifreeze mixcomesoutthewatersprays.ENSURETHATTHESYSTEMISCOMPLETELYPURGEDANDNOWATERORAIRPOCKETSEXIST.

6. Theequipmentmustbestoredinawellventilated,dryroom.Donotstore outdoors.

TractionDrives

RandomSampleInspection

Thetractiondrivesshouldbestoredat -10°Cto50°C(14°Fto122°F).

Majorproblemswithcondensationcanoccurifadriveisstoredinacoldenvironmentandisthentakenintoadeepminewherethetemperatureismuch higher.Eventhoughthehumiditymaybeatanacceptablelevel,condensation willoccuronthecolddrive.Slightexposuretoacondensingenvironmentisnot harmfulprovidedthedriveiscompletelydrybeforeelectricalpowerisapplied.

Afterastorageperiodofapproximatelytwoyears,arandomsampleinspection mustbeperformedtodeterminewhetherthemeasurestakenandthemethod ofstoragehaspreventeddamage.Uponrequest,theinspectioncanbecarried outbyaservicerepresentative.

NaturalAging

HydraulicComponents

MiscellaneousComponents

Evenwithproperstorage,sealsandhosesaresubjecttonaturalageing.Do notusethesepartsiftheyhavebeenstoredformorethantwoyears.

Long-termstorageofsparecomponents

Ifacomponentistobestoredmorethansixmonths,thehydrauliccomponent mustbecompletelyfilledwithacorrosioninhibitingfluid.Fillthehollowareas ofhydrauliccomponents(e.g.thepistonchambers)inhorizontalposition(ports facingupwards)untiltheystarttooverflowthensealtheportswithplasticor steelplugs.

Storetheelectricalequipment,electroniccomponents,sparepartsofrubberor plastic – suchassealsandhoses – andhydraulicfluidsonlyinclosedroomsat temperaturesof15°Cto25°C(60°Fto77°F).

Motors

FanAssembly

PlasticDeformation

Refertothemotormanufacturer’sstorageprocedureguideinyourpartsmanual.

Rotatetheimpeller1-1/4turnoncepermonthtopreventdimplingofthemotor bearingsrollers.

Inordertopreventplasticdeformationofthesealelements,cylindersmustbe storedinanuprightposition.Somecylindersmustberemovedsothatthey canbestoredupright.

CircuitBreakers

Powerissuppliedtothemachineviaatrailingcable.Oncethetrailingcableis connectedandenergized,powerisisolatedfromthemachinebythemaincircuitbreaker,thecuttercircuitbreaker,andthetramcircuitbreaker.

Assoonasthemaincircuitbreakerisclosed,powerissuppliedtothepump motor,leftandrightconveyor/gatheringheadcircuits,andthelightingandcontrolcircuits.

Fig.8:CircuitBreaker

1. Maincircuitbreaker 2.Auxiliarycircuitbreaker

BreakerOperation

1.Maincircuit

2.Aux.circuit

Isolatestheentiremachine frompowersuppliedviathe trailingcable.

Isolatesthegatheringhead, fanandpumpmotorcircuits.

Pushtothe left toturn ON (closethebreaker).

Pushtothe right toturn OFF (openthebreaker).

Pushtothe right toturn ON (closethebreaker).

Pushtothe left toturn OFF (openthebreaker).

ControlSwitches

Therearecontrolswitcheslocatedonthefrontofthecontrollercasethatwill functionafterthemaincircuitbreakerison(closed).Thecontinuousmineris normallyoperatedbyradioremote.Manualoperationviacontrolsonthecontrollercaseisnotpermittedforproductionoperation.Manualoperationisfortroubleshootingandmaintenanceundersupportedroofonly.Notallswitchesdepictedbelowareactive.Thefollowingaretheactiveswitchesonthismachine:

Fig.9:Controlswitches

PanicBar/PumpStop

Radio/E-TramSwitch

MachineLighting

MCB4

MCB5

MCB6

MCB13

PumpHourMeter

CutterHourMeter

ConveyorHourMeter

ControlSwitchOperation Switch

PanicBar/MachineStop Removespowerfromthecontrolcircuit, shuttingdownthemachine.

PUSH thebartostopallmotors.

Radio/E-Tram Determinesmodeofoperation. MANUAL putsthemachineundermanual control.

RADIO putsthemachineunderradiocontrol.

MachineLighting Controlsthelights.

MCB4 15Abeakerforthe120VAC+sideofthe controlpowercircuit.

MCB5 15Abreakerforthe120VAC- sideof thecontrolpowercircuit.

MCB6 10Abreakerforthe120VAC+sideof thearealightcircuit.

MANUAL turnsontheheadlightsandarea lights.

OFF turnsoffalllights.

RADIO turnsonarealights.Headlightscan becontrolledbytheradioremote.

PUSH intoset/reset.

PULL toopen.

PUSH intoset/reset.

PULL toopen.

PUSH intoset/reset.

PULL toopen.

MCB7 10Abreakerforthe120VAC- sideof thearealightcircuit. PUSH intoset/reset. PULL toopen.

MCB8 20Abreakerforthe12VAC+sideofthe headlightcircuit. PUSH intoset/reset. PULL toopen.

MCB9 20Abreakerforthe12VAC- sideofthe headlightcircuit. PUSH intoset/reset. PULL toopen.

MCB10 Spare5Abreaker. N/A

MCB11 Spare5Abreaker. N/A

MCB12 5Abreakeronthe110VDC+sideofthe solenoidcircuit. PUSH intoset/reset.

PULL toopen.

MCB13 5Abreakeronthe0VDC- sideofthe solenoidcircuit. PUSH intoset/reset. PULL toopen.

ControlSwitchOperation,continued

PumpHourMeter

CutterHourMeter

ConveyorHourMeter

LeftSideMachineStop

Displayshoursofrunningtimeforthe pumpmotor. N/A

Displayshoursofrunningtimeforthe cutterheadmotors. N/A

Displayshoursofrunningtimeforthe conveyormotors. N/A

Thereisamachinestopbuttonlocatedontheleftrearcornerofthemachine. Likethemachinestopbuttononthecontrolcase,pressingtheleftsidemachinestopbuttonwillshutdownthepump,therebyshuttingdownthemachine.

RemoteOperation

RadioRemote

PendantControl

Thecontinuousminerisnormallyradioremotecontrolledduringproductionoperations.Remoteoperationisallowedwhenthemachineisenergizedandthe minerswitchisintheremoteposition.SeetheRemoteOperationsectionof thismanualforfurtherinformationontheradioremotecontrolofthemachine.

Limitedmachinefunctionscanbeoperatedfromapendantcontrolconnectedto themachinebyanumbilicalcable.Thiscontrolisusedintheeventthatthe operatorlosesradiolinkwiththeminerandtheminerneedstobemoved.

Thependantcontrollercanturnthepumpmotoronandoff,cantramthemachine,andcanraiseandlowerthecuttinghead.

Inordertousethependant,itmustbeconnectedtothemachineviaapigtail. Afterpluggingintheumbilicalcord,theminerswitchmustbeplacedintheETramposition.

Thependantcontrolleranditsumbilicalcordshouldbestoredinaprotected locationontheworkingsection,awayfromtheminer,topreventcontrollerdamage.

Pre-OperationalChecks

Thefollowingchecksshouldbecompletedbeforethemachineisputintoserviceforthefirsttime.Correctionsoradjustmentsshouldbemadebyaqualifiedmaintenanceperson.

1. VerifythatallcircuitbreakersareintheirOFFpositions.

2. Checkallhydraulicandlubricantfluidlevels.

3. Verifythatthecoolingwaterisconnected.Operatingthemachinewithout coolingwaterwillseriouslyreducethelifeofthemotors.

4. Checkandoperateallcontrolhandlesandremoteswitchestoensureall machinefunctionsareoperatingcorrectly.Returnallhandles/switchesto theneutralposition.

5. Check,andadjustasnecessary,thetensionoftheconveyorandcrawler chains.

DailyChecks

Thefollowingchecksshouldbecompletedatthebeginningofeveryshift.Repairsandadjustmentsshouldbemadeimmediatelybyaqualifiedmaintenance person.

1. Visuallyinspectallcylinders,gearboxes,tanks,andhydrauliccomponents forleaksanddamage.

2. Visuallyinspectallelectricmotorsandelectricalcomponentsforsignsof damage.

3. Checkthefulllengthofthetrailingcablefordamage.Ensurethatthetrailingcableisproperlysuspendedacrossintersectionsandthatthetrailing cableclampatthemachineissecure.

4. Cleananyforeignmaterialfromtheconveyorandgatheringpan.

5. Checkthatallcoversandguardsareinplaceandaresecure.

6. Performdailymaintenance.

7. Checktheconveyorandcrawlerchaintensions.

8. Becertainthatallothermachinesandpersonnelareclearoftheareaand startthemachine.Checkforcorrectoperationofallstopandemergency stopbuttons(bothonthemachineandontheradioremote).

9. Afterstartingthemachine,allowthehydraulicsystemtowarmupforfiveto tenminutesandthenverifythatthehydraulicsystempressureiscorrect (seethehydraulicschematicinthepartsbookforyourmachine).

EmergencyShutdown Controls

EmergencyStop(Machine Stop)Bypass(optional)

Thearecontrolslocatedonthemachine,theradioremote,andthetrampendantthatgivetheoperatortheabilitytoquicklyshutdowntheminer.Allpersonnelshouldbeawareofthelocationofshutdowncontrolsandhowtousethem.

Thefollowingcontrolscanbeusedtoshutdownthemachine:

Control Location Action Result

MainCircuit Breaker MainDisconnectBox

MachineStop ControlCase

Pushtothe right to turn OFF (openthe breaker).

Isolatestheentiremachinefrompowersuppliedviathetrailingcable.

MachineLeft Side TramPendant Pushtoactivate. Shutsdownallmotors onthemachine.

E- STOP RadioRemote Pushtoactivate. Shutsdownallmotors onthemachine.

PumpOff RadioRemote Pushtoggleswitch uptoactivate. Shutsdownallmotors onthemachine.

MachineStop TramPendant Pushtoactivate. Shutsdownallmotors onthemachine.

Atypicalcontinuousminerisfittedwithamushroomstyleemergencystopbuttonontheleftsideofthemachine.Thebuttonisusedtoshutdownthemachineintheeventofanemergency.Itispossibleforthebuttontobestuckin the“ON”positioniftheleftsideofthemachinebecomesjammedagainstthe rib.Inthisevent,thereisanoptionalEmergencyStopBypassfunctionavailablethatallowsthepumpmotortobestartedandthemachinetobetrammed awayfromthewall.Theoverridefeatureisonlyactiveinthirtysecondintervals.

WARNING ! EmergencyStop(Machine Stop)BypassProcedure

ToactivatetheEmergencyStopBypassfunction:

1. Pressandholdthe“SHIFT”and“BYPASS”keys(Fig.10)togetherfora continuousfiveseconds.

2. Whilethekeysareheldtogether,thetextdisplayontheminerwillshowa countdowntimer(Fig.11),indicatingbypassmodeisactive.Thetimer countsthefiveseconddelayperiod.

Fig.11:Bypassenabledelayperiodtimer

Fivesecondtimer

Fig.10:Bypasskey

Presskeydown

Presskeyup

3. Oncethefiveseconddelayhaspassed,thesystementersbypassmode. The“SHIFT”and“BYPASS”keyscanthenbereleased.Thetextdisplay willnowshowatimerthatwillcountdownthethirtysecondactiveperiod (Fig.12).Oncethethirtysecondshasexpired,thebypasswillagainbe disabledandtheproceduremustberepeated.

Thirtysecondtimer

Fig.12:Bypassactivecountdowntimer

Introduction

Thefollowingproceduresarerecommendedforstartingupthecontinuous miner.Theseproceduresareforstartingthemachineduringnormaloperations andassumethattheoperatorhasbeenfullytrainedandthatmachineiscorrectlyconnectedtothetrailingcableandthatallpre-operationalchecks,includingdailymaintenance,havebeenperformed.

Start-Up(RadioRemote)

Tostartthecontinuousminerusingtheradioremote:

1. Turnthemaincircuitbreakertothe“ON”position.

2. Select“RADIO”onthe“RADIO/E-TRAM”switchontheoperator’scase.

3. Pressandholdthe“ON”keyfor1second.Theconsoledisplayshould read“HOLD”.Releasethekeyandthedisplayshouldread“ON”.

4. Press“SHIFT”andwait1/4second.

5. Whilepressing“SHIFT”,press“PUMPON”.Holdbothkeysinuntilthe pumpstarts.

6. Releasethe“PUMPON”key.

The“PUMPON”keymustbereleasedbefore“SHIFT”.If“SHIFT”isreleasedfirst,thepumpmotorwillshutoff.

7. Releasethe“SHIFT”key.

Start-Up(TramPendant)

Tostartthecontinuousminerusingthetrampendant:

1. Pressandholdthe“PUMPSTART/ENABLE”button.

2. Pressthe“PUMPON”button.Holdbothbuttonsuntilthepumpstarts (approximatelyonesecond).

3. Releasebothbuttons.

ShutdownProcedure (RadioRemote)

Thefollowingproceduresarerecommendedforshuttingthemachinedownduringnormaloperations:

1. Backthemineraboutonefootfromthefaceprovidingsufficientclearance.

2. Turnoffthecuttermotorsbypressingthe“CUTTEROFF”key.Thecutter motorsshouldshutdownimmediately.

3. Emptytheconveyorandshutitoffbypressingthe“CONVOFF”key.The conveyormotorsshouldshutdownimmediately.

4. Lowerthecutterheadtothefloor.

5. Lowertheconveyorandgatheringhead.

6. Parkthemachineinitsdesignatedparkingarea,outoftrafficandonflat, solidground.Ifitisnotpossibletoparkthemachineonflatground,parkat arightangletotheslope.

7. Pressandholdthe“PUMPOFF”key.Thepumpmotorshouldshutdown immediately.

8. Releasethe“PUMPOFF”key.

9. PositionallleversandcontrolstoNeutralorOff.

10. Turnoffthewatersprays.

11. Turnofftheradioremote.

12. Shutoffthemainpowersupply.

13. Shutofftheminewatersupply.

SumpTramming (TrammingForwardWhile Cutting)

Table5:Tramminglimitations

TrammingislimitedbythecontrolsystemasshowninTable5.

TrammingOperation

Bothremotecontrolleversforwardorreverse

CuttersnotRunning

Oneleverforward,onereverse(splittracktramming)

Oneleverengaged(forwardorreverse),onleverhome (singletracktramming)

SpeedLimitation

Tramspeedselected(1,2or3)

Bothmotorslimitedto1stspeed

Speedofengagedmotorlimitedto1stor2ndspeed

CutterRunningandCutterAmps<cutterinFaceParameter

TrammingOperation

Bothremotecontrolleversforward

Bothremotecontrolleversreverse

Oneleverforward,oneleverreverse(splittracktramming)

Oneleverforward,oneleverhome(singletracktramming)

Oneleverreverse,oneleverhome(singletracktramming)

SpeedLimitation

FWDCLEANUPspeedregardlessofspeedselected

Tramspeedselected(1,2or3)

SpeedofmotorgoingforwardlimitedtoFWDCLEANUP speedregardlessofspeedselected

SpeedofmotorgoingreverselimitedtoREVSLEWspeed regardlessofspeedselected

FWDCLEANUPspeedregardlessofspeedselected

REVSLEWspeedregardlessofspeedselected

CuttersRunningandCutterAmps>CutterinFaceParameter

TrammingOperation

Bothremotecontrolleversforward

Bothremotecontrolleversreverse

Oneleverforward,oneleverreverse(splittracktramming)

Oneleverforward,oneleverhome(singletracktramming)

Oneleverreverse,oneleverhome(singletracktramming)

SpeedLimitation

Speedlimitedbycontrolsystem

Tramspeedselected(1,2or3)

Speedofmotorgoingforwardlimitedbycontrolsystem

SpeedofmotorgoingreverselimitedtoREVSLEWspeed regardlessofspeedselected

Speedislimitedbycontrolsystem

REVSLEWspeedregardlessofspeedselected

SumpTramming

ThecontrollersettingscanbeadjustedthroughthegraphicsdisplayACtraction parameterspage,“SUMPSETUPMENU”(Fig.40)whichisaccessedwitha password.Thisscreenallowstheoperatortotunethemachineforindividual minconditions.AdescriptionoftheparametersaregiveninTable6.

Fig.40:“SUMPSETUPMENU”,ACtractionparameterspage

Table6:ACtractionadjustableparameters

SumpSettings

Determinesmaximumforwardspeed availablewhensystemhasdetermined

Determinestherateofchangeinforward sumpdirectionfromminimumtomaximumspeedswhensystemhasdeterminedthatthemachineiscuttinginthe face

SumpTramming

Table6,continued:ACtractionadjustableparameters

SumpSettings, continued

MINSUMP CUTTER CURRENT(A)

Determinesmaximumthresholdforcutter currentthatdeterminesifthemachineis increasingordecreasingspeedoutput

Determinesminimumthresholdforcutter currentthatdeterminesifthemachineis increasingordecreasingspeedoutput

Determinesthethresholdforcuttercurrentatwhichthemachinewillhaltuntil thecurrentleveldropsbelowtheStop currentvalue

SHEARUP STOP CURRENT(A)

SHEARDOWN STOP CURRENT(A)

CUTTERIN COAL CURRENT(A)

FWDCLEANUP SPEED(%)

HIGHSPEED PREVENT(YES/ NO)

REVERSEANTI SLEWSPEED (%)

Setsthethresholdforcuttercurrentthat determineswhentostopshearupcontrol.Whenthecurrentfallsbelowthis, shearupwillrestart

Setsthethresholdforcuttercurrentthat determineswhentostopsheardown control.Whenthecurrentfallsbelowthis, sheardownwillrestart

Determinesthepointatwhichthemachinewillengageautomaticsumping/ tractioncontrol.Abovethispoint,algorithmwillactivate

Determinestheforwardspeedthatwillbe availablewhenthecuttersarerunning beforethecutterinfacecurrentthreshold hasbeenreached

WhensettoYES,inhibitsthemaximum reversespeedto2ndspeedwhencutters arerunning

Determinesthespeedinthereversedirectionwhentramminginsingletrackor pirouettewhenthesystemhasdeterminedthatthemachineiscuttinginthe face

Table6,continued:ACtractionadjustableparameters

VFDSetup CURRENTLIMIT (A)ACONLY

ACtractiondrivecurrentlimitasapercentageoffullload.Determinesthe valueatwhichthetractiondrivesprotect againstoverload

TractionSetup

RECTIFIERDC BUSREF(V)AC ONLY

ACtractionrectifierDCbusbrakinglimit. BrakingwillactivatewhentheDCbus exceedsthisvalueduringregeneration. RectifierIGBTwilldumpenergyintobus resistorstokeepthebusvoltagebelow thislevel

MachineSetup

LHTRAMTRIM (%)DCONLY

RHTRAMTRIM (%)DCONLY

LefttramreferenceadjustmentforDC tractiondrives.Duetoinherentmismatch ofdrivecomponents,firingangleis trimmedwiththisvaluetoassurethatthe machinetramsstraightinallspeeds

RighttramreferenceadjustmentforDC tractiondrives.Duetoinherentmismatch ofdrivecomponents,firingangleis trimmedwiththisvaluetoassurethatthe machinetramsstraightinallspeeds

Digitaloutputcurrenttoshearsolenoid whencutterheadrunning.Ignoredwhen inproportionalmodeorautoshearactive

Digitaloutputtopansolenoidatalltimes. Ignoredinproportionalmode

Usingtheseparameter,themachinewillautomaticallycontrolthemachinecut sequencetoprovideoptimaltraction/motorcontrol.

Tosetthetractionparameters:

1. Enterthesumpconfigurationmenuintheengineeringmenuandrecordall existingparametervalues.

2. Startthecutterheadandobserveandrecordtherunningcurrentinfreeair forthecuttermotors.

3. Setthe“CUTTERINFACECURRENT”approximately30ampsabovethe freeaircurrentobservation(step2).

4.Operatetheminerinthefaceand,usingthegraphicsscreenforcuttingoperations,observethepeakcurrentreachedduringsumpingoperation.Set thisvalueasthe“SUMPTRAMMAXCUTTERCURRENT”value.

5. Setthe“SUMPTRAMMINCUTTERCURRENT”approximately30amps belowthemaxvalue(step4).

SumpTramming

6. Atthistime,settheleftandrighthandmaxsumpspeedsat20%andset theleftandrighthadminsumpspeedsat5%belowmax.

7. Startraisingthemaxsumptramcuttercurrentinsmallincrementsuntilthe cuttercurrentlevelsoutorpeaksinsumpingoperations.Thisvaluenow becomesthe“SUMPTRAMMAXCUTTERCURRENT”.

8. Setthe“SUMPTRAMMINCUTTERCURRENT”value30ampsbelowthe valueobtainedinstep7.

9. Startraisingthesumpspeeds(leftandrighthand)untilthecrawlersappear tostartbreakingtraction.Thisisthemaxsumpspeed.

10. Settheminsumpspeed(leftandrighthand)5%belowthemaxsump speed(step9).

Theminermaystartwithalurchingmotionwhensumpingatthistime.Ifthis occurs,startraisingthe“SUMPDELTA”valueinsmallincrementsuntilthisactionsubsides.

Cleanupspeedallowsfastertramwhenapproachingthefacewithcuttersrunningandpullingonlyfreeaircurrent.

Oncethe“inface”currentismet,thealgorithmforthesumpconfigurationis activated.

Theseparametervaluesshouldbetheoptimumvaluesforthismachineinyour cuttingconditions.Thefollowingexampleillustratestheparametersettingprocedure.

IMPORTANT

Thisexampleisforillustrationonly.Parametersmustbedeterminedforeachindividual application.

Parametersettings:

Leftandrightmaxsumpspeed:15%

Leftandrightminsumpspeed:10%

SumpDelta:4

MaxCutterCurrent:140amps

MinCutterCurrent:110amps

Forwardcleanup%:20%

ForwardandReversespeeds:20,40,and72% CutterinCoal:80amps

Introduction

Hydraulicpowerforallhydraulicallyactuatedfunctionsoriginateswiththepump assembly.Thisincludespowerfortheconveyorswingandraise/lowercylinders,theconveyorchaintake-upcylinders,thestabilizershoecylinders,the cuttingheadraise/lowercylinders,andthehydraulicallyactuateddustsuppressionsystem.

A50HPpumpmotordrivesatwo-stagegearpumpthatdelivershydraulicoilto thehydraulicsystem.The72gallon(273L)hydraulicoiltankisanintegralpart ofthemainframe.Onlyanti-wearhydraulicoilmeetingSpecification100-1 shouldbeusedinthehydraulicsystem.

Thepurposeofaloadholding(loadlocking)valveistopreventtheaccidental loweringofahydrauliccylinder,whethersuddenlyorbygradualbleedoff.Both theconveyorraise/lowercylindersandthecutterheadraise/lowercylinders incorporateloadholdingvalves.

Thereisapilotoperatedcheckvalveintheloadholdingvalveofeachconveyor raise/lowercylinderandapilotloadholdingvalveattachedtoeachcutterhead raised/lowercylinder.Eachofthesevalvespreventsitsrespectivecylinder fromloweringitsloadintheabsenceofaspecificpilotpressure.(Thispressureisinducedonlywhenthelowercontrolofthatparticularfunctionisengaged.)Theloadholdingvalvesfrotheconveyorandcutterheadincorporatea relieffunctionwhichby-passesthepilotoperationwheneverthepressuresettingisexceeded.

Thesheardown(anti-chatter)/maintenancevalveprovidesbackpressure againstthecutterhead(shear)cylindersinthecutterheadlower(sheardown) cycle.Thisbackpressuremustbeovercomebeforethecutterheadwilllower, preventingcutterheadbounce(chatter).

Themachineoperatorshouldbefamiliarwiththeoperating(system)pressure ofthemachineduringnormaloperations.Iftheoperatingpressureisoutsideof thenormalrange,itshouldbereportedimmediately.

Themachineisequippedwithapowerfillfunctionthatassistsinaddinghydraulicoiltothemachine’shydraulicoiltank.Thepowerfilloperatesfromthe conveyorlowercircuit.Theconveyorlowerlineteesofftoa2-position,4-way valvethatisnormallyclosed.Withtheconveyorinthedownposition,the valveismanuallyopened.Whentheconveyorlowerfunctionisactivated,oil entersthecircuitandrunsthepowerfillfunction.Oilpassesthroughthevalve toajetpump,whichcreatesaventuri(vacuum)effect,pullingoilfromtheclean oilreservoirthrougha10micronfilter,acheckvalve,aYstrainerandthento tank.

HydraulicSystem

Tooperatethepowerfillfunction:

1. Startthepumpmotorandfullylowertheconveyor.

2. Wipethesuctionhosecleanandplaceitinacleancontainerofhydraulic fluid.

3. Openthe2-position,4-wayvalve.

4. Engagetheconveyordownfunction.

5. Afterfillingthetank,releasetheconveyordownfunction.

6. Closethe2-position,4-wayvalve.

7. Cleanandplugthesuctionhosetopreventcontaminationandsecurethe hoseonthemachine.

8. Stopthepumpmotor.

Therearethreehydraulicfiltersonthemachine:

1. Pressurefilter,bypassing

2. Pilotfilter,non-bypassing

3. Powerfillfilter

Introduction

Motors

Themaininputpowersupplyforthismachineisthree-phase995VACpower whichdirectlysuppliesthemotorcircuits.Acontroltransformerstepsthevoltagedownto120VACforthecontrolcircuitand12VACforthelightingcircuit andthermistormodule.

Thismachineispoweredbyseven995VACelectricmotors:

1. One50hppumpmotor

2. Two275hpcuttermotors

3. Two60hpgatheringhead/conveyormotors

4. Two110hpACtractionmotors

Introduction

Theminerisequippedwithawatersystemusedfordustcontrolandtocoolthe electricalmachinecomponents.Theminewaterisnormallyconnectedonthe rightrearofthemachine.

Watersupplyrequirementsare:

Flow:30gpmforcooling

Pressure:250psi(dynamic)minimum 500psimaximum

Thewatersupplyisconnectedtoaballvalve,whichmustbemanuallyopened beforethecooling/dustsuppressionsystemcanbeactivated.Fromtheball valve,waterflowsthroughanon-bypassingwaterfilterandaflowmeter.

Aftertheballvalveismanuallyopened,thedust-coolingcircuitisoperatedby remotesolenoidcontrol.Whenthedust-coolingsolenoidisenergized,thenormallyclosedwatervalveisopened.Waterpassesthroughthesolenoidwater valvetoapressuremanifoldandisdistributedtotheleftandrightdustcooling circuits.

Thefollowingmaintenanceitemsshouldbeobservedtoproperlymaintainthe dust/coolingsystem:

1. Insurethatthewatersupplymeetstherequirementslistedabove.Insufficientwaterflowand/orpressurewillaffectcoolingcapabilitiesanddust sprayoperation.

2. Onlyusewaterthatiscleanandasfreeaspossibleofcorrosiveelements.

3. Donotoperatetheminerwithoutthewatersupplybeingconnectedand activated.Operatingtheelectricmotorswithoutpropercoolingwillseriouslyreducemotorlife.

4. Monitorthewaterfilterandremoveandcleanasneededtoeliminateclogging.Thisisaby-passingfilter;ifthefilterisclogged,thewaterwillpass unfilteredtothedust/coolingsystem.

5. Inspectthewaterspraynozzlesonaregularbasis.Watershouldflowfrom allnozzleswhenthespraysareoperating.Cleanasnecessary.

1. DustSprays

2. CutterMotor,LH

3. CutterMotor,RH

4. GatheringHeadMotor,LH

5. GatheringHeadMotor,RH

6. PumpMotor

7. TramMotor,LH

8. TramMotor,RH

9. ControlCase

10. ReliefValves

11. PumpControlManifold

12. FireSprayValves

13. PressureManifold

14. FlowMeter

15. Filter,Non-bypassing

16. PressureGauges

17. BallValve

18. FlowControlValve

19. SumpPump

A6474X376 February2012

Operationand Maintenance Manual

CM235ContinuousMiner

A6474X376(Introduction - Maintenance)

ThismanualisintendedtoprovideGENERALproductinformation.The illustrations,descriptionsandprocedurescontainedinthispublication applyonlytoTHISmachine.Caterpillarreservestherighttorevise modelsanddesignswithoutpriornotice.

Thismachinewasmanufacturedundertheguidelines,proceduresand requirementsoftheappropriategovernmentregulatoryagencies.

Atthecompletionofthemanufacturingprocess,thisunitwasissuedthe appropriateapprovalnumbersandnameplatesindicatingitmetthe technicalrequirementsoftheseregulatoryagencies.Anychangetothe designorstructureofthisunit,withouttheconsentofCaterpillarand theseregulatoryagencies,oranyrepairorreplacementofpartscontrarytotheinstructions,mayinvalidatetheseapprovalsandrenderthis unitunsafetooperate.

Strictcompliancewithalllaws,regulationsandpracticesregardingthe safeoperationandmaintenanceofundergroundminingequipmentand strictadherencetotheinstructionsinthismanualisnecessaryforthe personalsafetyofthoseworkingonoraroundthisunit.

SafetyPrecautions

WARNING !

CAUTION !

IMPORTANT

WARNING !

NOTICE !

IMPORTANT

Thefollowingsafetyprecautionsshouldbeobservedwheneveroperatingor performinganymaintenance,repair,oradjustmentprocedureonthismachine. Additionalprecautionsmayappearineachsectionofthisbook.Allprecautions listedapplicabletothismachine,aswellasallapplicableregulatoryagency rulesandregulationsmustbefollowedatalltimes.

Ifthehydraulicoverflowisblockedduringpowerfilloperations,thehydraulictankwill becomepressurizedduringthepowerfillprocedureanddamagetotheairreservoirs mayresult.

Shimsmustbeinsertedcompletelyintotheidlerslidechannel.Ashimthatisnotcorrectlyseatedontheidlerslidechannel’sinsidesurfaceprovidesunevensupportthat cancauseidlerslant.Aslantedidlercancauseunevenwearandstressonthetram trackandcancauseimproperoperationofordamagetothetramsystem.

Checkthattheshimsarecorrectlyseatedontheidlerslidechannel’sinsidesurfaceby lookingatthechannel’sinsidesurfacefromtheoppositesideoftheminerthroughthe spacebetweenthegatheringheadandtheidlerassembly.

Useextremecautionwheninspectingforleakswiththemachinerunning.Unexpected machinemovement,orcontactwithmovingparts,couldresultininjury.

Escapingfluidsunderpressurecanpenetrateskinandcauseseriousinjury.Donot attempttolocatehydraulicleaksbyfeelinghosesandfittingswithbarehands.Pinhole leakscanpenetratetheskin.

Ifthegearcaseisscheduledforoildrainandrefill,obtaintheoilsamplepriortotheoil change.

Alwayscollectoilsamplesusingasiphonpump.Donotremovethedrainplugandcollectoilbyallowingittorunoutintothebottle.

Ifthegearcaseisscheduledforoildrainandrefill,obtaintheoilsamplepriortotheoil change.

Alwayscollectoilsamplesusingasiphonpump.Donotremovethedrainplugandcollectoilbyallowingittodrainintothebottle.

Formotorbearingsthatrequirehightemperaturelithiumcomplexgrease(Spec.10015),aspecial“button”stylelubricationfittingisavailabletopreventtheaccidentaluse ofmulti-purposelithiumcomplexgreaseattheselocations.

Incorrectgreaseorovergreasingoftheelectricmotormaycauseseriousdamagetothe motor.Followthegreasingprocedureoutlinedabove. NOTICE !

IMPORTANT

Formotorbearingsthatrequirehightemperaturelithiumcomplexgrease,aspecial “button”stylelubricationfittingisavailabletopreventtheaccidentaluseofmultipurposelithiumcomplexgreaseattheselocations.

Incorrectgreaseorovergreasingoftheelectricmotormaycauseseriousdamagetothe motor.Followthegreasingprocedureoutlinedinpreviousinstructions.

WARNING !

Ifthehydraulicoverflowisblockedduringpowerfilloperations,thehydraulictankwill becomepressurizedduringthepowerfillprocedureanddamagetotheairreservoirs mayresult.

WARNING !

Thefollowingstepsreleasestheshims,whichwillfallfree.Watchoutforfallingshims whenlooseningthecapscrews.

IMPORTANT

Thisexampleisforillustrationonly.Parametersmustbedeterminedforeachindividual application.

GeneralMaintenanceInstructions

Maintenanceatregularintervalsincreasestheoperationalsafetyandprolongs theservicelifeofthemachine.Thismanualcontainsrecommendationsonmachineandcomponentinspections,machinelubrication,lubricant(oil)change procedures,filtermaintenance,andadjustmentprocedurestoproperlymaintain themachine.

Generaltoolsarerequiredformaintenance.Ifaprocedurerequiresaspecialty toolormaterial,itwillbeidentifiedintheprocedure.

Themaintenanceintervalsandproceduresgiveninthismanualarebasedon typicalmachinesandtypicalmineconditions.Mineconditionsandmachine configurationmayrequiretherecommendedintervalsormaintenanceprocedurebemodifiedfromthosegiven.

Theillustrationsusedinthismanualareforatypicalmachineandmayvary fromyourmachine.Ifrepairworkisrequired,alwaysrefertothespecificdrawinginthepartsbooksuppliedwithyourmachine.

MaintenanceNotes

Beforeperformingmaintenanceonthismachine,observethefollowing:

1. Inordertoavoidindividualcomponentsnotbeingservicedorbeinginadequatelyserviced,ageneralmaintenanceplanshouldbedeveloped.

2. Useonlysuitableandapprovedtoolsformaintenancework.

3. Useonlyoriginalsparepartswhenreplacingcomponents.

4. Allelectricalworkmustbesupervisedandinspectedbyacertifiedelectrician.

5. Anyoneperformingmaintenanceonthisequipmentmustbetrainedonmachineoperation.

6. Shutdownthemachineonlevelground.

7. Turn circuitbreakertothe"OFF"positionanddisconnectthetrailingcable. FollowallMine,State,andFederallockout/tagoutprocedures.

8. Onlyworkontheminerinanareawheretheroofisproperlysupported.

9. Blockanyandallelevatedassembliesbeforeworkingunderthem.Make surethattheblockingcansupporttheweightoftheassemblywithoutslippingorfailing.

10. Relieveallhydraulicpressuresandpositiontheleversandcontrols,ifapplicable,inNeutralorOff.

11. Afterensuringthatallpersonnelareclearofthemachine,testallcontrolsto ensurethattheunitwillnotmove.

12. Testtheairformethane(ifapplicable)beforeandduringanymaintenance orrepairwork.

13. Donotperformmaintenanceonacircuitwhilethereisaloadrestingonthe hydrauliccylinder.Boomsmustbesecurelyblockedwiththeboominthe raisedpositionifmaintenanceistobeperformed.

14. Donotperformmaintenanceinacongestedarea.Thiscouldendangerthe maintenancepersonorothersinthevicinity.

15. Wheneverapotentialproblemisuncoveredduringaperiodicmaintenance check,itisimperativethatitbecorrectedimmediatelybyaqualifiedmaintenancetechnician.

16. Cleanlinesscannotbeoveremphasizedastheessentialingredientofa goodmaintenanceprogram.Machinesshouldbekeptasfreeaspossible ofdirtanddebriswhichcouldimpedeperformanceorinfiltratesystemsand causeprematurewearorfailure.

SpecialFasteners

Introduction

LockingWireFasteners

Varioustypesofspecialtyfasteners,self-lockingboltsandnuts,lockwiring, SuperBolts,etc.,maybeinuseonthemachine.Itisimportantthatthesefastenersbeusedinthecorrectmannertoprovidethelockingqualitiesrequired.

Whenusingasinglelockingwire,insertthewirethroughthefastenerfromthe insidetotheoutsideoftheboltcircle,advancinginaclockwisedirection(Fig. 1).

Whenusingwiredpairs,insertthewireinthelefthandfastener(asviewedfrom thecenteroftheboltcircle)fromtheinsidetotheoutsideoftheboltcircle.Inserttherightendofthewirethroughtherighthandfastener(Fig.1).

Fig.1:Lockwirefasteners

Self-LockingScrews

1. Self-lockingscrewsaregenerallyusedwheremeasuredtorqueisrequired.

2. Useahandwrench,notapowerwrench,totightentogetanaccuratereading.

3. Performanceisreducedwitheachuse.Limitreusetotwice.

4. Ifassemblyrequiresshimming,establishtheshimmingrequirementsusing standardfasteners.Aftershimmingrequirementsareestablished,replace standardfastenerwithself-lockingandtorqueasrequired.

1. Locknutswithnylonorfiberinsertsshouldnotbereused.

2. Locknutswithaspringsteellockringintheheadcanbereused.

3. Handthreadthenuttoengagethethreadsbeforeusingapowerwrench.

4. Boltorstudthreadsshouldextendbeyondthenut.

LockNuts

Introduction

Thefollowingchartslisttherecommendedtorquevaluesforcommonfasteners usedontheContinuousMiner.Usethesetorquevaluesunlessthedrawingor instructionalmaterialstatesotherwise.

Donotusethesetablesforanyboltgradesexceptthosespecifically listed.

Useacalibratedtorquewrenchforaccuracy.

ImperialBolts

Table1:Grade8bolttorquespecifications (calculatedat75%proofload)

TorqueValues

Table2:Metricbolttorquespecifications(calculatedat75%proofload)

NominalSize and ThreadPitch

M5X0.80 (54) (41) (78) (59) (91) (68)

M6X1.00 (92) (69) (133) (99) (156) (116)

M7X1.00 (156) (116) (222) (167) (260) (195)

M8X1.25 (2250 (169) (333) (242) (377) (284)

Introduction

LubricantandFluid Capacities

Thissectionoutlinesthefrequencyatwhichmaintenancetasksshouldbecarriedout.Dependingonoperatingconditions,morefrequentintervalsmaybe required.

Thefollowinglubricantspecificationsandfluidcapacitiesshouldbeobserved whenaddingorchangingalubricantorgreasingacomponent.

Table3:Lubricantsandfluidcapacities

Spec,sheets,listingboththephysicalcharacteristicsandvendorsand lubricantsthatareknowntomeeteachspecification,aregivenattheend ofthissection.

Notes:

1.Allmotorlubehosesaretobefilledwithhightemperatureelectricmotorgrease(Spec.100-14)beforeassemblingthemtotheelectricmotortoensurethattherearenoairgapsbetweenthegreasenippleandthe pointwherethegreaseentersthemotor.

Note1:Whentheoilsampleandoilchangeintervalareidentical,asampleoftheoldoilistobetakenandsent foranalysispriortochangingtheoil(seetheOilsamplingprocedureinthischapter).Alwaysinspectbreathers whentakinghydraulicoilsamples.

Fig.2:Lubricationandmaintenancechart

3 - Conveyorswingcylinderrearpin

4 - Conveyorswingcylinderfrontpin

22,41,44 - Maincutterheadgearcase

23,48,53,54,55 - Hydraulicoiltank

37 - Machinestopswitch 47,52 - Tramgearcase

23,48, 53,54,55

Fig.2:Lubricationandmaintenancechart,continued

9 - Crawleridlerroller

12 - Stabilizershoecylinderlowerpin

13 - Conveyorraisecylinderupperpin

15 - Conveyorswingpivots

16 - Gatheringheadcylinderupperpin

18,38,45 - CLAheadpotassembly

19,39,46 - CLAheadinputcase

20 - Tramgearcase

21,40,43 - Inputcutterheadgearcase

25,26,27 - Hydraulicfilters

30 - Crawlerchain

37 - Pumpstopswitch

49 - Cuttermotor

50 - Gatheringheadmotor

51 - Pumpmotor

9 - Crawleridlerroller

12 - Stabilizershoecylinderlowerpin

15 - Conveyorswingpivots

16 - Gatheringheadcylinderupperpin

18,38,45 - CLAheadpotassembly

19,39,46 - CLAheadinputcase

20 - Tramgearcase

21,40,43 - Inputcutterheadgearcase

49 - Cuttermotor

50 - Gatheringheadmotor

CutterHeadCylinder Pins(upperandlower)

Specificlubricationandmaintenanceprocedures

Everyshift

Thepurposeofthissectionistodescribethefollowingmaintenanceprocedures,tobeperformedeveryshift:

1. Cutterheadliftcylinderpins(upperandlower,leftandright)lubrication

2. Conveyorswingcylinderpins(frontandrear)lubrication

3. Cutterheadpivotpinlubrication

4. Cutterheadbitinspection

5. Scrubbercleanout

Lubricatetherightandleftcylinderpins(upperandlower)throughthegrease fittingslocatedoneachcylinder(Fig.3).Pumpapproximately3cu.in.(50cu. cm.)intoeachfitting.

Lowercutterhead cylinderpingrease fitting

Uppercutterhead cylinderpin

Fig.3:Cutterheadcylinderpins(typicalbothsides)

ConveyorSwingCylinder Pin(frontandrear)

CutterHeadPivotPin (leftandright)

Lubricatethefrontandrearconveyorswingcylinderpinsthroughthegrease fittingslocatedoneachendofthecylinder(Fig.4).Pumpapproximately3cu. in.(50cu.cm.)intoeachfitting.

Fig.4:Conveyorswingcylinderpinlubrication

Conveyorswingcylinderpin,rear Conveyorswingcylinderpin,front

Lubricateleftandrightcutterheadpivotpinsthroughthegreasefittingslocated ontheleftandrightfrontlubricationblocks(Fig.5).Pumpapproximately3cu. in.(50cu.cm)ofgreaseintoeachfitting.

Fig.5:Cutterheadpivotpins(typicalbothsides)

Cutterhead pivotpinlubrication

CutterHeadBits

ScrubberCleanout

Inspectthecutterheadbitstoensurethattheywillrotateintheirholdersand fordamagedormissingbits(Fig.6).Replacebitsimmediatelyifanyaremissingordamaged.

Fig.6:Cutterheadbits

Cleanoutthescrubbereveryshift.

1. Openthescrubberscreenaccesscover(Fig.7).

2. Removethescrubberscreenandwash.

3. Removethedemistorcellandwash.

4. Usingthewashdownhose,sprayoutthescrubber.Sprayforwardandout thefrontofthescrubber.

5. Washoutthedemistorsump.

Fig.7:Scrubberscreenaccesscover

Scrubberscreen accesscover

Bitholder Bit

ConveyorRoller Lubrication

Daily

Thepurposeofthissectionistodescribethefollowingmaintenanceprocedures,tobeperformeddaily:

1. Conveyorrollerlubrication

2. Gatheringheadpivotpin(rightandleft)lubrication

3. Crawleridlerroller(rightandleft)lubrication

4. Conveyorraisepivotpin(rightandleft)lubrication

5. Stabilizershoecylinderpin(upperandlower,leftandright)lubrication

6. Conveyorraisecylinderin(upperandlower,leftandright)lubrication

7. Conveyorswingpivotpin(topandbottom)lubrication

8. Gatheringheadcylinderpin(upperandlower,leftandright)lubrication

9. CLAheadpot(rightandleft)andtransfergearcases(rightandleft),oil levelcheck

10. Tramgearcases(rightandleft),oillevelcheck

11. Inputcutterheadandreachcuttergearcases,oillevelcheck

12. Hydraulicoillevelcheck

13. Finalcuttergearcase,oillevelcheck

Lubricatetheconveyorrollerthroughthegreasefittingslocatedontheshaft (Fig.8).Pumpapproximately3cu.in.(50cu.cm.)intoeachfitting.

Fig.8:Conveyorrollerlubrication

Greasefittings(2)

GatheringHeadPivotPin (rightandleft)

CrawlerIdlerRoller (rightandleft)

ConveyorRaise CylinderPin(leftandright)

Lubricatetheleftandrightupperandlowergatheringheadcylinderpins throughthegreasefittingslocatedontheleftandrightfrontlubricationblocks (Fig.9).Pumpapproximately3cu.in.(50cu.cm.)ofgreaseintoeachfitting.

Lubricatetheleftandrightcrawleridlerrollers(Fig.9)throughthegreasefittingslocatedontheoutsidefaceofthecrawleridlerroller.

Lubricatetheupperconveyorraisecylinderpinsthroughthegreasefittingslocatedontherightsideoftheconveyor(Fig.10).Pumpapproximately3cu.in (50cu.cm)ofgreaseintoeachfitting.

Fig.9:Gatheringheadpivotpin,conveyorraisepivot,andcrawleridler roller(typicalbothsides)

Gatheringhead pivotpinlubrication

Upperconveyor raisecylinderpin greasefittings(2)

Crawleridler roller

Fig.10:Conveyorraisecylinderpinlubrication

ConveyorSwingPivot Pins

Lubricatetheconveyorswingpivotpinsthroughthefour(4)greasefittingslocatedeachsideoftheconveyor(Fig.11).Pumpapproximately3cu.in(50cu. cm)ofgreaseintoeachfitting

Fig.11:Conveyorswingpivotpins(typicaltopandbottom)

Conveyorswing pivotpinlubrication fittings(2)(typical bothsides)

GatheringHeadRaise CylinderPins

Conveyorswing pivotpinlubrication fittings(2)(typical bothsides)

Lubricatetheuppergatheringheadraisecylinderpins(Fig.12)throughthe greasefittingslocatedoneachendofthecylinder.Pumpapproximately3cu. in(50cu.cm)ofgreaseintoeachfitting.

Fig.12:Gatheringheadraisecylinderpins(typicalbothsides)

Gatheringheadraise cylinderpin(upper)

Gatheringheadraise cylinderpin(lower)

StabilizerShoePin (rightandleft)

ConveyorChainTake-up Pin(rightandleft)

Lubricatethelowerstabilizershoecylinderpins(rightandleft)throughthe greasefittingslocatedontherodendofeachcylinder(Fig.13).Pumpapproximately3cu.in(50cu.cm)ofgreaseintoeachfitting.

Fig.13:Lowerstabilizershoecylinderpin(typicalbothsides)

Stabilizercylinderpivot(right)

Stabilizercylinderpin(right)

Stabilizercylinderpin(left)

Stabilizercylinderpivot(left)

Stabilizershoepivot

Lubricatetheconveyorchaintake-uppin(Fig.14)throughthegreasefitting locatedonthepin.Pumpapproximately3cu.in(50cu.cm)ofgreaseintoeach fitting.

Fig.14:Conveyorchaintake-uppin(rightandleft)

Conveyorchain take-uppin

CLAHeadPotAssembly (rightandleft)

CLAHeadTransferCase (rightandleft)

TramGearCase(rightand left)

Leveltheminerandplacethegatheringheadongradebeforecheckingoraddinglubricant.Checktheoillevelinthepotassembly(Fig.15).Ifoilisneeded, addoilthroughthefillholeuntiloilcomesoutofthebreather.

Leveltheminerandplacethegatheringheadongradebeforecheckingoraddinglubricant.Checktheoillevelinthehydraulictransfercase(Fig.15).Ifoilis needed,addoilthroughthefillholeuntiloilcomesoutofthebreather.

Fig.15:CLAheadpotassemblyandtransfercaselubrication

Withtheminerinalevelposition,checkthe oillevel inbothtramgearcases by lookingatthesightglasslocatedonthesideofeachgearcase(Fig.16).Oil shouldbevisibleineachsightglass.Ifoillevelislow,addoilthroughthefill plughole.

Fig.16:Tramgearcaseoillevel(typicalbothsides)

Oilfill,

Potfillplug

InputCutterGearCase ReachCutterGearCase

FinalCutterGearCase

Withthegatheringheadloweredtogroundlevelandthecutterheadboomlevel withground,checktheoillevelinbothinputandreachcuttergearcases throughthesightglasseslocatedoneachsideofthecutterheadassembly (Fig.17).Ifoillevelislow,addoilthroughthefillplugslocatedoneachsideof thegatheringhead.

Withthecutterheadboomlevelwithground,checktheoillevelinbothofthe maincutterheadgearcasesbyremovingthecheckpluglocatedonthefrontof eachgearcase(Fig.18).Oilshouldflowfromcheckplugholewhenplug(s)is removed.Ifoillevelislow,addoilthroughthefillplugholelocatedontopof eachgearcase.

Fig.17:Inputandreachcutterheadgearcaseoillevels

Fig.18:Finalcutterheadgearcaseoillevels

Inputfillplug (oneperside)

Reachfillplug (oneperside)

Oilfillplug (oneperside)

Oilcheckplug (oneperside)

Inputsightglass (typicalbothsides)

Reachsightglass (typicalbothsides)

HydraulicOilLevel Checkthehydraulicoillevelusingthereadoutonthemainpageofthegraphicsdisplayontheoperator’scaseontherighthandsideofthemachine (Fig. 19).

Iftheoillevelislow,addoilasfollows: Hydraulicoilpowerfillprocedure

1. Openthediversionvalve.

2. Checkthatthehydraulictankoverflowisobstructionfree(Fig.19).

Ifthehydraulicoverflowisblockedduringpowerfilloperations,thehydraulictankwill becomepressurizedduringthepowerfillprocedureanddamagetotheairreservoirs mayresult.

3. Activatethe“CONVEYORDOWN”functionontheremotecontroltobegin powerfill.

4. Addoiluntiloilflowfromtheoverflow.

5. VerifythattheoillevelisOKonthemainpageofthegraphicsdisplay.

6. Closesthediversionvalve.

Hydraulicoillevel

Hydraulicoil fillhose

Hydraulicoil overflow

Fig.19:Hydraulicoillevel

Thepurposeofthissectionistodescribethefollowingmaintenanceprocedures,tobeperformedweekly:

1. Pressurefilters(bypassingandnon-bypassing),checkandchangeasrequired

2. Returnfilter,checkandchangeasrequired

3. Crawlerchain,inspect

4. Conveyorchain,inspect

5. Inspect/checktightness/conditionofallfasteners(nuts,bolts,screws,etc.)

6. Inspectelectricalcables,conduits,andglands

7. Inspecthydraulicandwaterhosesandconnections

8. Inspectlighting

9. Inspectreflectorsandwarningtags

10. Inspect/checkthefunctionofeachmachinestopswitch

11. Scrubbercleaning

Changethepressurefilterelement(Fig.20).Iftheelementisextremelydirty,a morefrequentchangeintervalmayberequired.

Changethepilotpressurefilterelement(Fig.20).Iftheelementisextremely dirty,amorefrequentchangeintervalmayberequired.

Changethereturnfilterelement(Fig.20).Iftheelementisextremelydirty,a morefrequentchangeintervalmayberequired.

Fig.20:Hydraulicfilterlocation

CrawlerChainTension

Checkthecrawlerchainsforpropertension.

Tocheckforpropertension:

1. Raisethecompletecrawlerassemblyoffofthegroundandsecurelyblock underthemachine.Themachinemustbesecurelysupportedoffthe ground.

2. Chainsagshouldbe2-1/2inches(64mm)to3-1/2inches(89mm)atthe centerofthecrawler(Fig.21).

ConveyorChainTension

Checktheconveyorchaintensionwiththemachinerunning.Theconveyor chainshouldriseabout51mm(2inches)orlessabovethegatheringheadfoot shaftsprocketasthechainemergesfromundertheconveyorpan(Fig.22).If adjustmentisnecessary,seetheConveyorchaintensionadjustmentprocedure inthischapter.

Fig.22:Conveyorchaintensionmeasurement

Fig.21:Crawlertracktensionmeasurement

Bottomoftractor wearshoe 21/2” - 31/2”gap (64 - 89mm) Topof tramtrack

Introduction

CrawlerChainAdjustment

Itiscriticaltomaintainpropercrawlerchaintension.Loosechainscandamage thesprocketandtightchainscancauseexcessivewearonthetramtrackassembly,includingmotorsanddrives.Bothconditionsreducecrawlerchainlife. Thecrawlerchaintensionisadjustedusingthefrontidlertake-upjacks. Greaseisaddedtotightenorbledofftoloosenthetrack.

ToolList

Procedure

Standardtoolset

Greasegun

Toadjustthecrawlerchaintension:

1. Lowertheconveyortailsectionuntilitislevelwiththefloor.

2. Raisethegatheringheadandcutterheadandblockbothassembliesfollowingstandardblockingprocedures.

3. Lowerthegatheringheadandcutterheadontotheblockingsothatthe frontendoftheminerliftsoffthefloor.

4. Extendthestabilizercompletelysothattherearendoftheminerliftsoffthe floor.

5. Securelyblockunderthemachine.Themachinemustbesecurelysupportedoffthegroundwiththetramtrackfreetoturn.

6. Raisethestabilizer,gatheringhead,andcutterheadassembliessothatthe weightoftheminerrestsontheblocking.

7. Disconnectthetrailingcabletode-energizetheminer.FollowallFederal andminelockout/tagoutregulations.

8. Doublecheckthetractorframesupportblockingnowthattheweightofthe tractorframeiscompletelyuponit.

9. Evaluatethetramtrackforpropertension(Fig.21).Thetramtrackisatthe propertensionwhenithangsapproximately64to89mm(2-1/2to3-1/2 inches)fromthebottomwearshoeswhenthetractorframeisblockedoff thefloor.Usingthisevaluation,determinewhetherstep11,12,or13providestheappropriatesub-proceduretocorrectimpropertracktension.

10. Locatethefrontidlertake-upjackgreasefittingandattachthegreasegun tothefitting.

11. Ifthetramtracktensionistootight,readjusttheidlerpositionusingthe followingsteps:

a. Pumpgreaseintothetake-upjacktoextendthecylinderandremove pusherplatepressureontheidlershims.

b. Removeoneormoreidleradjustmentshimsfromtheidlerslidechannel.

c. Openthepressurereleasevalveforthefrontidlertake-upjackand allowthejacktocontract.Thepusherplatewillslidebackwardsuntilit isstoppedbytheremainingidlershims.

d. Pumpgreaseintotheidlertake-upjacktoextendthecylinder,move theidlerassemblyforwardandtightenthetramtrackuntilitisatthe correcttension.Thetramtrackisatthepropertensionwhenithangs 64to89mm(2-1/2to3-1/2inches)fromthebottomwearshoeswhen thetractorframeisblockedoffthefloor.

12. Ifthetramtrackistooloose,readjusttheidlerpositionusingthefollowing steps:

a. Pumpgreaseintotheidlertake-upjacktoextendthecylinder,move theidlerassemblyforwardandtightenthetramtrackuntilitisatthe correctlocation.Thetramtrackisatthepropertensionwhenithangs 64to89mm(2-1/2to3-1/2inches)fromthebottomwearshoeswhen thetractorframeisblockedoffthefloor.

b. Insertshims(Fig.23)intotheidlerslidechanneluntilthespacebetweenthetractorframeandthepusherplateisfilled.

c. Openthepressurereleasevalveforthefrontidlertake-upjackand allowthecylindertocontract.Theidleradjustmentshimswillkeepthe idlerstationaryandthetracktensioned.

d. Evaluatetheresultingtracktensionandrepeatthesestepsuntilthe trackreachespropertension.

13. Ifthetramtracktensionisstilltooloosewhentheentire5”shimsetisinsertedintotheidlerslidechannel,re-adjusttheidlerpositionafterremoving atramtracklinkusingthefollowingsteps:

a. Pumpgreaseintothetake-upjacktoextendthecylinderandremove thepusherplatepressureontheidlershims.

b. Removealloftheidleradjustmentshimsfromtheidlerslidechannel.

c. Openthepressurereleasevalveforthefrontidlertake-upjackandallowthecylindertocontract.

d. Thetramtracktensionshouldnowbereducedandseparationofthe tramtrackwillbeeasier.

e. Locateatramtracklinknearthetramidler.

f. RemovethefourConeloknutsandflatheadscrewsthatsecurethe crawlerpins(Fig.23).

g. Usingthehammerandpunch,removethecrawlerpinstodisconnect thelinkfromthetrack.Removethedisconnectedlink.

h. Connectthetwoendsofthetramtrackandsecurethetwoendlinks togetherwiththecrawlertrackpin

i. Securethecrawlertrackpinbetweenthetwolinkswiththe3/8-16X11/4flatheadsocketheadscrewsand3/8-16Coneloknuts.

j. Pumpgreaseintotheidlertake-upjacktoextendthecylinder,movethe idlerassemblyforwardandtightenthetramtrackuntilitisatthecorrect tension.Thetramtrackisatthepropertensionwhenithangsapproximately64to89mm(2-1/2to3-1/2inches)fromthebottomwearshoes whenthetractorframeisblockedoffthefloor.

k. Insertshimsintotheidlerslidechanneluntilthespacebetweenthe tractorframeandthepusherplateisfilled.

l. Openthepressurereleasevalveforthefrontidlertake-upjackandallowthecylindertocontract.Theidleradjustmentshimswillkeepthe idlerstationaryandthetracktensioned.

m. Theidleradjustmentshimswillkeeptheidlerstationaryandthetrack tensioned.

n. Evaluatetheresultingtracktensionandrepeatuntilthetrackreaches propertension.

14. Whenthetramtrackhasbeenadjustedtothepropertension,removethe greasegunfromtheidlertake-upjackgreasefitting.

15. Openpressurereleasetotakepressureoffoftake-upcylinder.

16. Closethefrontrubrailcoverandsecurethefrontrubrailtothetractor framewithhexheadcapscrewsandlockwashers.

17. Connectthetrailingcabletoenergizetheminer.

18. Raisethetractorframeofftheblockingbyloweringthestabilizerandgatheringheadandcutterheadassemblies.

19. Carefullyremovethesupportblockingfromunderthetractorframe.

20. Lowerthetractorframeontothefloorbyraisingthestabilizerandgathering headandcutterheadassemblies.

21. Carefullyremovetheblockingfromunderneaththeraisedstabilizer,gatheringhead,andcutterheadassemblies.

Fig.23:Tramtrackadjustment

Take-upcylinder

Shims

Idlerassembly

Pad

Lockpin

Trackretentionpin

ConveyorChainTension

Tocheckthechaintension:

1. Makesuretheconveyorchainareaiscleanandfreeofanyloosematerial.

2. Positiontherearconveyorsectioninastraightlinewiththecuttingheadto maximumpossibleheight.

3. Positionyourselftothesideofthegatheringpan,underprotectedroof,and starttheconveyor.

a. Thereshouldbeasmoothtransitionorflowofthechainasitcomes throughandoverthefootshaftsprocket.Ifthearchofthechainistrailingabovethesprocket,thechainneedstobetensioned.

b. If,whentheconveyorisrapidlystartedandstopped,thechaintendsto foldbackonitself,thechainneedstensioned.

c. If,whentheconveyorisswungtotheextremelefttoright,thereistoo muchexcesschain,thechainmayneedtobeadjustedinthatposition. Ifadjustedinthisposition,swingtheconveyorbackstraightandrecheckadjustmenttoverifythatthechainhasnotbeenover-tensioned.

5. Withcorrecttension,thereshouldbenodeflectionoftheflighttipsnearthe tailroller.

Conveyorchaintensionadjustment

Theconveyorchainistensionedwithahydraulictake-upcylinder.Ifthechain tensionisnotbeingmaintained,then:

1. Theconveyorchaintake-upvalvemayneedtobeadjusted.Ifthevalve adjustmentiscorrect,then

2. Thecylindermaybefullyextendedand,therefore,unabletotakeupany morechainslack.Removealinkfromthechainorreplacechainasnecessary.

Fasteners

ElectricalCables,Conduits, andGlands

HosesandFittings

Theminerissubjectedtocontinualshockloadingandvibrationandcloseattentiontoallmountingboltsandscrewsisrequired.Loosefastenerswillcause prematurewearandfailureofbearings,couplings,etc.Inspectthefollowing fastenersandtightenasrequired:

1. Cutterheadgearcasebolts

2. Cutterheadmotorsbolts

3. Centerdrumsbolts

4. Enddrumsbolts

5. Tramcasesbolts

6. Trammotorsbolts

7. GatheringheadCLAsbolts

8. Gatheringheadpotsbolts

9. Gatheringheadmotorsbolts

Visuallyinspectallelectricalcablesandglandsforsignsofwearordamage.

Visuallyinspecthydraulicandwaterhosesandfittingsforsignsofwear,damage,orleakage.Thisinspectionshouldbeperformedwiththemachinerunning.Observethefollowingprecautions/procedureswhilecheckingforleaksor makingrepairs:

1. Relievepressurebeforedisconnectinghoses.

2. Checkforleakswithapieceofcardboard.Donotusehands.

3. Donotexceedtheworkingpressureofhydraulichoses.

Useextremecautionwheninspectingforleakswiththemachinerunning.Unexpected machinemovement,orcontactwithmovingparts,couldresultininjury.

Escapingfluidsunderpressurecanpenetrateskinandcauseseriousinjury.Donot attempttolocatehydraulicleaksbyfeelinghosesandfittingswithbarehands.Pinhole leakscanpenetratetheskin.

Lighting

ReflectorsandWarning

MachineStopSwitches

Turnonthelightsandvisuallyinspectforbulbsthatneedtobereplaced.

Visuallyinspecttheconditionandreadabilityofallwarningtags,labels,and reflectorsforsignsofwearordamage.Replaceanyreflectorortagthatis missingordamaged.

Checkthemachinestopswitcheslocatedoneachsideofthemachinefor properoperation.Startthemachineandstriketheswitch;themachinepump motorwillshutdown,inturnshuttingdownallothermotors.Repeatforthe otherswitch.

ScrubberCleaning

Cleanthescrubber(Fig.24)asfollows:

1. Lowerthegatheringheadandcutterheadassembliesuntiltheytouchthe floor.

2. Lowertheconveyorassemblyuntilitislevelwiththefloor.

3. Disconnectthetrailingcabletode-energizetheminer.

4. Insertahoseinthescrubberairintakeatthefrontoftheminer.Thoroughly flushthescrubberinletduct.

5. Removeanyaccumulateddebrisfrominsidetheduct.Insertthehoseinto theductandthoroughlyflushitwithwater.

Fig.24:Scrubbercleaning

Scrubberintake

Monthly

Thepurposeofthissectionistodescribethefollowingmaintenanceprocedures,tobeperformedmonthly:

1. CLAheadpotandtransfergearcases,changetheoil

2. Inputandreachcutterheadgearcases,changetheoil

3. InspecttheCLAs

4. Sampletheoilintheinputandreachcutterheadgearcases,theCLA headpotandtransfergearcases,thetramgearcases,andthemainhydraulicoiltank

ChangetheoilinbothCLAheadpotassemblies(Fig.25).

1. Leveltheminer,raisethegatheringheadpan,andsecureinplace.

2. Cleandirtanddebrisfromaroundthedrainpluglocatedunderthegear case.

3. Removethedrainplugandallowoiltocompletelydrainfromthegear case.

4. Cleanandreinstalldrainplug.

5. Cleandirtanddebrisfromaroundthecheckplugandremovetheplug.

6. Cleandirtanddebrisfromaroundthefillplugandremovetheplug.

7. Slowlyaddoilthroughthefillpluguntiloilbeginstoflowfromthecheck plughole.Allowsufficienttimefortheoiltoravelthroughthegearcase whenfilling.

8. Cleanandreinstallthecheckandfillplugs.

ChangetheoilinbothCLAheadinputcases(Fig.25).

1. Leveltheminer,raisethegatheringheadpan,andsecureinplace.

2. Cleandirtanddebrisfromaroundthedrainpluglocatedunderthegear case.

3. Removethedrainplugandallowoiltocompletelydrainfromthegear case.

4. Cleanandreinstalldrainplug.

5. Cleandirtanddebrisfromaroundthecheckplugandremovetheplug.

6. Cleandirtanddebrisfromaroundthefillplugandremovetheplug.

7. Slowlyaddoilthroughthefillpluguntiloilbeginstoflowfromthecheck plughole.Allowsufficienttimefortheoiltoravelthroughthegearcase whenfilling.

8. Cleanandreinstallthecheckandfillplugs.

Ifthegearcaseisscheduledforoildrainandrefill,obtaintheoilsamplepriortotheoil change. NOTICE !

IMPORTANT

Alwayscollectoilsamplesusingasiphonpump.Donotremovethedrainplugandcollectoilbyallowingittorunoutintothebottle.

Ifthegearcaseisscheduledforoildrainandrefill,obtaintheoilsamplepriortotheoil change.

Fig.25:CLApotassemblyandinputcase

Potcheck plug

Oilfill, Inputcase

Inputcase Checkplug

Potfillplug

InputCutterHead GearCase

ReachCutterHead GearCase

Changetheoilinbothinputandreachcutterheadgearcases(Fig.26).

1. Positionthecutterheadhorizontally(flatbackinaverticalposition).Clean dirtanddebrisfromaroundthedrainpluglocatedunderthegearcase.

2. Removethedrainplugandallowoiltocompletelydrainfromthegearcase.

3. Cleanandreinstallthedrainplug.

4. Cleandirtanddebrisfromaroundthecheckplugandremovetheplug.

5. Cleandirtanddebrisfromaroundthefillplugandremovetheplug.

6. Slowlyaddoilthroughthefillpluguntiloilbeginstoflowfromthecheck plughole.Allowsufficienttimefortheoiltotravelthroughoutthegearcase whenfilling.

7. Cleanandreinstallthecheckandfillplugs. Fig.26:Inputandreachcutterheadgearcase

Inputfillplug (oneperside)

Reachfillplug (oneperside)

Inputsightglass (typicalbothsides)

Reachsightglass (typicalbothsides)

Changetheoilinbothfinalcutterheadgearcases(Fig.27).

1. Lowerthecutterheadcompletelytotheground.Cleandirtanddebrisfrom aroundthedrainplug,locatedunderthegearcase.

2. Removethedrainplugandallowoiltocompletelydrainfromthegearcase.

3. Cleanandreinstallthedrainplug.

4. Cleandirtanddebrisfromaroundthecheckplugandremovetheplug.

5. Cleandirtanddebrisfromaroundthefillplugandremovetheplug.

6. Slowlyaddoilthroughthefillpluguntiloilbeginstoflowfromthecheck plughole.Allowsufficienttimefrotheoiltotravelthroughoutthegearcase whenfilling.

7. Cleanandreinstallthecheckandfillplugs. Fig.27:Finalcutterheadgearcase

Oilfillplug (oneperside)

Oilcheckplug (oneperside)

CLAs

InspecttheCLAs(Fig.28)fordamage.IfaCLAneedsreplaced,seeCLAremovalandinstallationprocedureintheMechanicalsectionofthismanual.

Fig.28:CLAs

Oilsamplingplan

Thisplancontainsspecificinstructionstobefollowedinordertocorrectlycollect gearcaselubricantsamples,andpreparationofthesamplesforlaboratory analysis.Adherencetotheseinstructionswillinsurethatalloilsampleanalysis reportsgiveanaccuratepictureoftheoilsconditionaswellasweartrendsof gears,bearings,etc.Accuratereportingandanalysisofoilsampleswillprove extremelybeneficialprovidingatooltoallowplanningofscheduleddown-time andpreventionofcostlyequipmentbreakdown.

Preparationpriortosamplecollection

Foreachmachinetobesampled,youwillneedasupplyofsamplecollection bottlesandidentificationlabels(Fig.29)sufficienttosampleeachidentifiedgear case(everysixtyshifts).

Onesamplebottleandcollectionhoseisrequiredforeachgearcasetobe sampled.Labeleachcontainerwiththeidentifyingnameofthegearcase (crawlergearcase,leftorcutterheadgearcase,rightfront,etc.).

Collectionofoilsamples

Ifthegearcaseisscheduledforoildrainandrefill,obtaintheoilsamplepriorto theoilchange.

Eachoilsampleshouldbetakenwhiletheoilisatnormaloperatingtemperature.Ifthemachinehasnotbeenoperatingjustpriortosampling,runthemachineuntiloiltemperaturereachesapproximatenormaloperatingtemperature. Shutdownthemachineandallow2 - 3minutesfortheoiltodrainbackandstabilizeit’slevel.

Alwaysusethecollectionhoseprovidedwitheachbottle.Alwaysdiscardhose immediatelyfollowingcollectionoftheoilanddonotuseitforthenextsample. Todosowillcontaminatethenextsamplewithoilfromtheprevioussample.

Aftertakingsample,checkandrefillgearcasebacktoproperfilllevel.

Followingcollectionofalloilsamples,recordthespecificbrandandproduct nameofthelubricantthathasbeeninstalledineachgearcase.

Recommendedgearcasestobesampled:

1. Inputcutterheadgearcase(leftandright)

2. Maincutterheadgearcase(leftandright)

3. Inputgatheringheadgearcase(leftandright)

4. Maingatheringheadgearcase(leftandright)

5. Mainhydraulicoiltank

Oillevel

Placeendofsiphontubeapproximatelyhalfwayintosump

Typicalsiphon pumpandbottle

Note: Holdsamplepumpandbottle belowoillevel

Fig.29:Oilsamplingprocedure

Oilfillplug

IMPORTANT

Everythreemonths

Thepurposeofthissectionistodescribethefollowingmaintenanceprocedures,tobeperformedeverythreemonths:

1. Lubricatethecuttermotors

2. Lubricatethegatheringheadmotors

3. Lubricatethepumpmotor

4. Lubricatethescrubbermotorbearings

CutterMotorBearings

Lubricatetheleftandrightcutterheadmotorbearingswithhightemperature lithiumcomplexgreasethroughthetwogreasefittingslocatedoneachsideof thecutterhead(Fig.30)usingthefollowingprocedure:

1. Openthecover(Fig.30)toaccessthemotor.

2. Inspectthegreasefittingsontheexitsideofthefrontandrearmotorbearing.

Iftheexitsidemotorbearingportsareequippedwithspringloadedrelief fittings,then

a. Lubricatebothmotorbearingsuntilnewgreaseappearsoutoftherelief portsontheexitsideofthebearing.

b. Operatethemotorforfive(5)minutesandtheninspectforgrease leaksinthebearingarea.

Iftheexitsidemotorbearingportsareequippedwithplugs,then:

a. Removetheplugandlubricatebothmotorbearingsuntilnewgrease appearsoutofthereliefportsontheexitsideofthebearing.

b. Operatethemotorforfive(5)minutesandtheninspectforgrease leaksinthebearingarea.

3. Replacetheplugsintheports.

Incorrectgreaseorovergreasingoftheelectricmotormaycauseseriousdamagetothe motor.Followthegreasingprocedureoutlinedabove.

Fig.30:Cuttermotorbearinglubrication(typicaleachside)

Exitplug

Entryplug

GatheringHeadMotor Bearings

Lubricatetheleftandrightgatheringheadmotorbearingswithhightemperature lithiumcomplexgreasethroughthetwogreasefittingslocatedoneachmotor (Fig.29).

Tolubricatethemotors:

1. Openthecover(Fig.31)toaccessthemotor.

2. Inspectthegreasefittingsontheexitsideofthefrontandrearmotorbearing.

Iftheexitsidemotorbearingportsareequippedwithspringloadedrelief fittings,then

a. Lubricatebothmotorbearingsuntilnewgreaseappearsoutoftherelief portsontheexitsideofthebearing.

b. Operatethemotorforfive(5)minutesandtheninspectforgreaseleaks inthebearingarea.

Iftheexitsidemotorbearingportsareequippedwithplugs,then:

a. Removetheplugandlubricatebothmotorbearingsuntilnewgrease appearsoutofthereliefportsontheexitsideofthebearing.

b. Operatethemotorforfive(5)minutesandtheninspectforgreaseleaks inthebearingarea.

3. Replacetheplugsintheports.

Fig.31:Gatheringheadmotorbearinglubrication(typicaleachside)

Bearinggrease fittingslocated behindcover

PumpMotorBearings

Lubricatethepumpmotor(Fig.32)withhightemperaturelithiumcomplex grease(Spec.100-14)throughthetwo(2)greasefittingslocatedtherightside ofthemachineusingthefollowingprocedure:

1. Openthecover(Fig.32)toaccessthemotor.

2. Inspectthegreasefittingsontheexitsideofthefrontandrearmotorbearing.

Iftheexitsidemotorbearingportsareequippedwithspringloadedrelief fittings,then

a. Lubricatebothmotorbearingsuntilnewgreaseappearsoutoftherelief portsontheexitsideofthebearing.

b. Operatethemotorforfive(5)minutesandtheninspectforgreaseleaks inthebearingarea.

Iftheexitsidemotorbearingportsareequippedwithplugs,then:

a. Removetheplugandlubricatebothmotorbearingsuntilnewgrease appearsoutofthereliefportsontheexitsideofthebearing.

b. Operatethemotorforfive(5)minutesandtheninspectforgreaseleaks inthebearingarea.

3. Replacetheplugsintheports.

Pumpmotor location

Operator’s case (swingopen toexpose pumpmotor)

Rubrail (Swingopentoallowoperator’s casetoswingout)

Fig.32:Pumpmotorbearings

IMPORTANT

Formotorbearingsthatrequirehightemperaturelithiumcomplexgrease,aspecial “button”stylelubricationfittingisavailabletopreventtheaccidentaluseofmultipurposelithiumcomplexgreaseattheselocations.

ScrubberMotorBearings

IMPORTANT

Lubricatethescrubbermotorbearings(Fig.33)withhightemperaturelithium complexgreasethroughthegreasefittingslocatedonthescrubbersideofthe machine.Tolubricatethemotors:

1. Removethecovertoaccessthemotor.

2. Removegreaseplug(s)onexitsideofbearing(s).

3. Lubricatebearingusing“button”fittinguntilnewgreaseappearsoutof openportonexitsideofbearing(s).

4. Operatemotor(s)forfive(5)minutes.

5. Replacegreaseplug(s)inallport(s).

Incorrectgreaseorovergreasingoftheelectricmotormaycauseseriousdamagetothe motor.Followthegreasingprocedureoutlinedinpreviousinstructions.

Fig.33:Scrubbermotorbearings

Scrubbermotor

Everysixmonths

Thepurposeofthissectionistodescribethefollowingmaintenanceprocedures,tobeperformedeverysixmonths:

1. Changetheoilinthetramgearcases

2. Changethehydraulicoil

3. Changethewaterfilter

4. Inspectandclean/changeallbreathers Changetheoilinbothtramgearcases(Fig.34).

1. Removethedrainplugandallowoiltocompletelydrainfromthegearcase.

2. Cleanandreinstallthedrainplug.

3. Replacethebreather,locatedinthefilltube.

4. Removethefillpluglocatedontopofthegearcaseoronthefilltube.

5. Addoilthroughthefillplugholeuntiloilisvisibleinthesightglass.When filling,allowsufficienttimefortheoiltotravelthroughoutthegearcase.

6. Cleanandreinstallthefillplug. Fig.34:Tramgearcase

TramGearCase

HydraulicOil

Changetheoilinthehydraulicoiltank(Fig.35).

1. Cleanalldirtanddebrisfromaroundthefillcapandthedrainplug.

2. Removethedrainplugandallowtheoiltanktocompletelydrain.

3. Cleanandreinstallthedrainplug.

4. Inspectandcleanoiloverflow,makingsuretherearenoobstructionsto overflow.

Ifthehydraulicoverflowisblockedduringpowerfilloperations,thehydraulictankwill becomepressurizedduringthepowerfillprocedureanddamagetotheairreservoirs mayresult.

5. Fillthetankwithoilusingthepowerfillpumpuntiltheoillevelreachesthe fulllevelasindicatedonthedipstick.Thehydraulictankcapacityis73gal (273L),hydraulicsystemcapacityis82gal(310L).Toactivatethepower fill:

a. Openthediversionvalve.

b. Engagetheconveyordownfunction.

6. Afterfilling,startthemachineandengageallcylindersforthefulllengthof travel(fullextendandretract)inordertopurgethehydraulicsystemofair.

7. Checktheoillevelonthegraphicsdisplayontheoperator’scaseonthe righthandsideofthemachine.Addadditionaloilasrequireduntiloillevel is“OK”.

Hydraulicoillevel

Hydraulicoil fillhose

Hydraulicoil overflow

Fig.35:Hydraulicoilchange

WaterFilter(Strainer) Changethewatercircuitfilter(Fig.36).

Fig.36:Waterfilter

GearCaseBreathers

Changethebreathersontheinputandmaincuttergearcases,theCLAhead potandtransfergearcases,andthetramgearcases(Fig.37).

Fig.37:Gearcasebreatherlocations

Breather

CLAinputcase breatherplug

CLApot breather

Waterfilter

Breather

Tailshimadjustment

Astheconveyorwearsthetailsectionmaysagrelativetotheconveyorfront section.Theconveyorhasbeendesignedtoallowcorrectionofthesagbyaddingshims.

1. Lowerthecutterheadandgatheringheadassembliesuntiltheytouchthe floor.

2. Positiontheconveyortailsectiondirectlybehindtheminerandraiseittoits highestposition.

3. Insertblockingunderthetailsectionandlowerthetailontotheblocking. Theconveyorshouldbeatananglewiththerearendofthetailsection slightlyhigherthanthefront.

4. Insertblockingbetweenthetopofthetractorframeandthebottomofthe conveyor,leavingabout51mm(2inches)ofspacebetweentheblocking andtheconveyorbottom.

5. Disconnectthetrailingcabletode-energizetheminer.FollowallFederal andminelockout/tagoutregulations.

6. Loosenthesocketheadcapscrewsthatsecuretheshimsbetweentheshim retainerandtheconveyorlowerpivotplate(Fig.38).

7. Connectthetrailingcabletoenergizetheminer.

Fig.38:Shimremoval

Sockethead capscrews

Shimretainer

Lower pivotplate

Shims

Thefollowingstepsreleasestheshims,whichwillfallfree.Watchoutforfallingshims whenlooseningthecapscrews.

8. Slowlylowertheconveyorslightlysothatthefrontsectionrestsonthe framesupportblocking.Theslottedshimswillnowfallfree.

9. Disconnectthetrailingcabletode-energizetheminer.FollowallFederal andminelockout/tagoutregulations.

10. Replacetheremovedshims(Fig.38)andaddthenumberofshimsrequiredtoleveltheconveyorfrontandtailsections.

11. Tightenthesocketheadcapscrews.

12. Connectthetrailingcabletoenergizetheminer.

13. Raisetheconveyortailfromtheblocking.

14. Removebothsetsofblockingandlowertheconveyortailuntilitislevel withthefloor.

15. Checkthegapandalignmentatthejunctureoftheconveyorfrontandtail sectionsforalignment(Fig.39).Ifthesectionsarenothorizontallyaligned, thenaddorsubtractshimsasrequired.

16. Re-inserttheblockingbetweenthetopofthetractorframeandthebottom oftheconveyorfollowingminestandardblockingprocedures.

17. Securelyretightenthesocketheadcapscrews.

Fig.39:Tailshimadjustment

Correctgapandalignment

Conveyortailsection Conveyorfrontsection

Addshims

Conveyortailsection

Removeshims

Conveyortailsection Conveyorfrontsection

Conveyorfrontsection

Introduction Thefollowinglubricantsspecificationsarereferencedthroughoutthismanual. Anylubricantusedmustmeetthesestandardslisted.Foryourconvenience,a listofmanufacturersandlubricantsthathavebeenidentifiedasmeetingthese standardsisgivenforeachspecification.

Failuretouselubricantsthatmeetthestandardlistedmayreducecomponentlifeandmayvoidanyassociatedwarranty.

Table7:Spec.100-1:Anti-wearhydraulicoilspecification

RustPreventionTest(ASTMD-665,A&B Pass Pass FoamTest(ASTMD-892-46T) Pass Pass

FourBallWearTest(ASTMD-2266)(40KG, 1800RPM,130°F,onehour)

Sludge&MetalCorrosion(ASTMD-943) (conductedatconclusionof1000houroxidation test)

Insolublesludgeinoilandwaterlayersplut thatadheringtothecatalystcoilsorthetest tub.

(ASTMD-810-59)

PumpWearTest(ASTMD-2882)(TotalRing andVaneWeightLoss)

Table9:Spec.100-3: Extremepressuremotorbearinggreaseandhandgreasespecification

NLG1GradeNumber2

WorkerPenetration(ASTMD-217) 265-295

DroppingPoint(ASTMD-566) BombOxidation(ASTMD-942)

Min.350°F(177°C) Notmorethan10PSIDROP

RustInhibitors Required Yes

WheelBearingTest(ASTMD-1263) (6Hours@235°F)

Notmorethan5%loss

WaterWashout(ASTMD-1264) Lossnotmorethan5%@100°F Lossnotmorethan15%@175°F

GreaseMobility

Notlessthan0.1gramflowper Second@0°F

TimkenOKLoad(ASTMD-2509) Notlessthan50lbs. (50lbs.)

FourBallEPTest(ASTMD-2569) Loadwearindexnotlessthan30.0 Weldpointnotlessthan200kg.Min. 31 200

FourBallWearTest(ASTMD-2266) (20KG.,1800RPM,130°F,OneHour) Notmorethan0.60mm.SCARdiameter 0.44

Table10:Spec.100-3:Extremepressuremotorbearingandhandgreaseapprovedsuppliers

Supplier Brandname

1 AmocoOilCompany AmolithGrease2EP RykonPremiumGrease2EP

2 GulfOil GulfcrownGreaseEP#2

3 MobilOilCorporation MobiluxEP-2

4 ChevronU.S.A. ChevronDura-LithGreaseEP-2NLGI2

5 SunOilCompany SunPrestige742EP

6 Unocal76 MultiplexEP2

7 ShellOilCompany AlvaniaEP-2

8 Century - Fuchs HullithEP2MultipurposeGrease,or Replex2,or Uniwrl2,or UniwrlEMB,or HullithGP2,or HullithEP2

9 TexacoLubricantsCompany TexacoMultifakEP2

10 Exxon LidokEP2

11 Pennzoil PennlithEP712Grease

12 LubricatingEngineers 3752AlmagardVari-PurposeLubricant

13 ConocoInc. EPConolithGreaseNo.2,or SuperStaGreaseNo.2

14 Hydrotex LC-65Hyplex

15 Phillips PhilubeEPGrease

16 AtlanticRichfieldCompany LitholineHEP-2Grease

Table11:Spec.100-14:Syntheticlithiumcomplexgreaseforelectricmotorbearings

NLG1Grade 2

Thickener

BaseOilType Syntheticpolyalphaolefin baseoils(POA)

WorkedPenetration(60strokes) (ASTMD-217)

DroppingPoint(ASTMD-2265)

- 295

WaterWashoutResistanceWeight Loss@175°F(79°C)(ASTMD-1264) 10%orless

GreaseMobility(USSteelTestLT-37) 18grams/min@0°F(-18°C)min 20grams/min

FourBallWear(ASTMD-2266) 0.70mmMaxscardiameter 0.50mm

FourBallEPWeldLoad(ASTMD2596) 530lb(240kg)min 550lb(250kg)

TimkenOKLoad(ASTMD-2509) 55lb(25kg)min 65lb(30kg)

RustCorrosionProtection(ASTMD1743) Pass Pass

BaseOilViscosity@104°F(40°C) 95 - 120 100

Table12:Spec.100-14:Syntheticlithiumcomplexgreaseforelectricmotorbearings approvedsuppliers

Supplier

1 MobilOilCorp. MobilitySHC100 2 Conoco-Phillips Triton100 3 Shell AlbidaEMS2

LubricantSpecifications___________________________________________

Table13:Spec.100-15:Highdemulsibilityextremepressuregearoilsspecification

ViscosityIndex(ASTMD-2270)

FlashPoint(ASTMD-92)

PourPoint(ASTMD-97)

TimkenTest(ASTMD-2782) Min.65lbs. 70lbs.

FKOURBallEPTest(ASTMD-2783)

Weldloadkg.Min.260loadwearindex notlessthan51.0

OxidationStability(ASTMD-2893) ViscosityIncrease@100°C Notmorethan6%

FZGScuffingTest(ASTMD-5182)

FailureLoadStage

Viscosity(ASTMD-445)

Notlessthan12thstage. >12

DEMULSIBILITY(ASTMD-1401)Min.30@ 180°FmlOil,Water,Emulsion 0ml.EmulsionMax. 42ml.Oil 38ml.Water 0ml.Emulsion

CopperCorrosion(ASTMD-130) 1or1b 1b

FoamTest(ASTMD-892) Pass Pass

RustTest(ASTMD-665) Pass Pass

Table14:Spec.100-15:Highdemulsibilityextremepressuregearoilsapprovedsuppliers

A6474X377 February2012

Operationand Maintenance Manual

CM235ContinuousMiner

A6474X377(Mechanical - Traction)

ThismanualisintendedtoprovideGENERALproductinformation.The illustrations,descriptionsandprocedurescontainedinthispublication applyonlytoTHISmachine.Caterpillarreservestherighttorevise modelsanddesignswithoutpriornotice.

Thismachinewasmanufacturedundertheguidelines,proceduresand requirementsoftheappropriategovernmentregulatoryagencies.

Atthecompletionofthemanufacturingprocess,thisunitwasissuedthe appropriateapprovalnumbersandnameplatesindicatingitmetthe technicalrequirementsoftheseregulatoryagencies.Anychangetothe designorstructureofthisunit,withouttheconsentofCaterpillarand theseregulatoryagencies,oranyrepairorreplacementofpartscontrarytotheinstructions,mayinvalidatetheseapprovalsandrenderthis unitunsafetooperate.

Strictcompliancewithalllaws,regulationsandpracticesregardingthe safeoperationandmaintenanceofundergroundminingequipmentand strictadherencetotheinstructionsinthismanualisnecessaryforthe personalsafetyofthoseworkingonoraroundthisunit.

Safetyinstructions

SafetyPrecautions

Thefollowingsafetyprecautionsshouldbeobservedwheneveroperatingor performinganymaintenance,repair,oradjustmentprocedureonthismachine. Additionalprecautionsmayappearineachsectionofthisbook.Allprecautions listedapplicabletothismachine,aswellasallapplicableregulatoryagency rulesandregulationsmustbefollowedatalltimes.

WARNING ! Youcouldbeseriouslyinjuredorkilledbyfallingloads.Observethesafeworkingload limitsofallblockingdevices.

WARNING ! FollowallFederalandminelockout/tagoutregulationsandprocedures.Failuretodoso couldresultinmachinedamageorseriousinjuryordeathtopersonnel.

WARNING ! Donotreconnectthetrailingcabletotheminerwhilethepowercableisdisconnected fromthemotor.Seriousinjuryordeathmayoccur.

WARNING ! Theflatedgeofthecoverlocatedadjacenttothelubricationfittingisthetopofthe cover.Orientthecoversothatthelubricantlevelcheckplugisonthemotorsideofthe coverandthedrainplugisonthebottom.

WARNING ! Thetramcase(withsprocketandreachgears)isextremelyheavy.Bepreparedtosupportthetramcasebeforeremovingitfromthetractorframe.

WARNING ! Ensurethattheelectricalcablesandcoolingwaterhosesforthetrammotorarefree fromthetramcasesbeforeattemptingtoremovethetramcasefromthetractorframe.

WARNING ! Theguidewireswillbeusedtopullthetramtracklinksontothetramcasesprocketafter thetramcaseisinstalled.

WARNING ! Beforeattemptingtoslidethetramcaseintothetractorframe,ensurethatthetrammotorelectricalandwaterconnectionsareoutoftheway.Failuretodosomayresultin damagetotheelectricalandwaterconnections.

WARNING ! Standclearoftheminerwhenusingthemotortopullthetramtrackthroughthetram case.

WARNING ! Doublecheckthatthelinksofthetramtrackarecorrectlyseatedontothetramdrive sprocket.Improperengagementofthetramtracklinksontothesprocketcancauseseriousmechanicaldamage.

IMPORTANT

There-installationprocedureforthetramcaseincludesre-installationoftheprimary andsecondaryplanetarygearsandthetrammotor,andreconnectionofthetramtrack.

WARNING ! Ensurethattheendofthetramtrackisoutofthetramcaseexitopeningbeforeattemptingtoremovethetramcasefromthetractorframe.

WARNING ! Thesprocketisextremelyheavy.Bepreparedtosupportitsweightbeforeremovingit fromthetramcase.

IMPORTANT

Whenthebearingsleeveisinsertedintoposition,theo-ringformsasealbetweenthe sleeveandthepiecethatholdsit.

WARNING !

Standclearoftheminerwhenusingthemotortopullthetramtrackthroughthetram case.

WARNING ! Doublecheckthatthelinksofthetramtrackarecorrectlyseatedontothetramdrive sprocket.Improperengagementofthetramtracklinksontothesprocketcancauseseriousmechanicaldamage.

WARNING ! Standclearoftheblockedtractorframeduringcontractionofthestabilizercylinder.

WARNING ! Verifythattheconveyortailsectionisadequatelysecuredbeforecrawlingunderthe blocksupports.

WARNING ! Eachstabilizercylinderisextremelyheavy.Bepreparedtosupporttheweightfromits tractorframemounting.Bepreparedtosupporttheweightofthecylinderwhenitbecomesfreefromthemounting.

Thefollowingprocedureisfortheremovalandinstallationofthetrammotor.

BasicToolSet Blocking

Whenremovingorinstallingatrammotor,observethefollowingsafetyprecautions:

WARNING ! Youcouldbeseriouslyinjuredorkilledbyfallingloads.Observethesafeworkingload limitsofallblockingdevices.

WARNING ! FollowallFederalandminelockout/tagoutregulationsandprocedures.Failuretodoso couldresultinmachinedamageorseriousinjuryordeathtopersonnel.

WARNING ! Donotreconnectthetrailingcabletotheminerwhilethepowercableisdisconnected fromthemotor.Seriousinjuryordeathmayoccur.

Toremovethetrammotor:

1. Lowertheconveyortailsectionuntilitislevelwiththefloor.

2. Lowerthegatheringheadandcutterheadassembliesuntiltheytouchthe floor.

3. Disconnectthetrailingcabletode-energizetheminer.FollowallFederal andmineregulationsforlockout/tagout.

4. Removetherubrailpinsthatsecurethetramrubrailtotherubrailsection adjacenttoit.

5. Swingthetramrubrailouttoexposethetramgearcaseandlocatethe tramdrivemotorinsidethegearcase(Fig.1).

6. Removetheseven(7)1/2X11/4”hexheadcapscrewsandhi-collarlock washersthatsecuretheinputshaftaccesscovertothemotorhousing.

7. Removetheinputshaftaccesscoveranditso-ring.

8. Removetheretainingringthatsecurestheshaftpluginposition.

9. Removetheshaftplugwitho-ringthatsecurestheinputshaftinthemotor.

10. Pulltheinputshaftfromthemotorandstoreinasafeplace.

11. Replacetheinputshaftaccesscoveronthemotorhousingandsecurethe coverwiththetwo(2)5/8X13/4”hexheadcapscrewsandhi-collarlock washers.

12. Tag,disconnect,andcapthecoolingwaterhosesfromthecoolingwater fittingslocatedonthetopleftandrightcornersofthetrammotor.

13. Removethecoolingwaterfittingsfromthetopleftandrightcornersofthe trammotorandstoreinasafeplace.

14. Removethetwo(2)1/2X11/4”hexheadcapscrewsanddisclockwashersthatsecurethetrammotorbrackettothetramcase.

15. Removethetwo(2)6X3/8”socketheadsetscrewsthatsecurethetram motorbrackettothetrammotor.

16. Removethetrammotorbracketfromthetrammotor.

17. Carefullyslidethetrammotoroutfromthetramcaseuntilthemotor’selectricalconnectionandjunctionboxcoverareaccessible.

18. Removethethree(3)3/4X2/1/4”socketheadcapscrewsandhi-collarlock washersthatsecurethejunctionboxcovertothemotorhousing.

19. Removethejunctionboxcoveranditso-ringfromthemotorhousing.

20. Removethethree(3)3/4X21/4”socketheadcapscrewsandlockwashers thatsecurethestuffingbox'shalfmoonclamptothejunctionbox.

21. Taganddisconnectthepowercablelugsandthecommunicationconnections.

22. Removetheclampsandslidethestuffingboxoutofthejunctionbox.The powercableandcommunicationcableshouldbecompletelydisconnected fromthemotor.

23. Topreventdamagetothepowercablelugsandglandassembly,coverthe powercableandcommunicationcable,andsecurethemtotheminerina safelocation.

24. Toprotectthemotor’selectricalconnections,replacethemotorjunctionbox coverando-ringandsecureusingthesocketheadcapscrewsandhi-collar lockwashers.

25. Carefullyremovethetrammotorfromthetramcaseandslideontoblocking.

TramMotorInstallation Toinstallthetrammotor:

1. Slidethetrammotor(Fig.1)intothetramcase,leavingthemotor’sjunction boxcoverandstuffingboxaccessibleoutsidethetramcase.

2. Removethethree3/4X21/4”socketheadcapscrewsandhi-collarlock washersthatsecurethejunctionboxcovertothemotorhousing.

3. Removethejunctionboxcoveranditso-ring.

4. Insertthethreelugsofthepowercable(withglandandstuffingboxalready installed)andcommunicationcableintothetrammotor’sjunctionbox.

5. Replacethestuffingbox’shalf-moonclampinitschanneltosecurethe stuffingboxinthejunctionbox.

6. Tightenthethree(3)3/4X21/4”socketheadcapscrewstosecurethe clamptothejunctionbox,andtorqueto210 - 230lb-ft.

7. Connectthemotorsothatitisphasedcorrectly.Tractionmotorhavetobe phasedsuchthatonemotorrotatesclockwiseandtheothercounterclockwise.Atalltimes,theleftandrightmotorconnectionsshouldbemadeas below:

- Left

2 - Right

Note:ThemotorleadsarephasedattheMOTOREND.Theelectrician shouldonlychangethemotorendconnectionstophasethemotorcorrectly.

Anewmotorshouldcomeequippedwithanencoder.Theencoderconnectionsshouldbemadeinsidethetractionenclosureandthetractioncase. SeetheEncoderremovalandinstallationprocedureinthissectionformore information.

8. Replacethemotorjunctionboxcoverando-ring,andsecureitwithsocket headcapscrewsandhi-collarlockwashers.

9. Assemblethebrackettothemotor.

10. Carefullyslidethetrammotorintopositioninthetramcase.Theendofthe motormustbecompletelyflushagainsttheprimaryplanetaryadapterplate.

11. Insertandtightenthetwo(2)1/2X11/4”hexheadcapscrewsanddisc lockwasherstosecurethetrammotorbrackettothetramcase,andtorque to35 - 40lb-ft.

12. Insertthetwocoolingwaterfittingsintothecoolingwaterportslocatedon thetopleftandrightcornersofthetrammotor.

13. Attachthecoolingwaterhosestothetwocoolingwaterfittingslocatedon thetopleftandrightcornersofthetrammotor.

14. Removetheinputshaftaccesscoveranditso-ring.

15. Slidetheinputshaftthroughthetrammotorandintothetramplanetaryprimarygear(theinputshaftendwithoutthethreadedholeshouldbeinserted first).Theshaftmayrequiresomeadjustingsothatitssplinedendfitsinto thegear.

16. Whenthedriveshaftiscorrectlypositionedinthemotor,installtheo-ring ontotheinputshaftplugandtheninserttheplugintothemotor.

17. Inserttheretainingringtosecuretheinputshaftpluginsidethetrammotor.

18. Replacetheinputshaftaccesscoveranditso-ringonthemotorhousing. Securethecoverwithhexheadcapscrewsandhi-collarlockwashers.

19. Swinginthetramrubrailbetweenthetwoadjacentrubrailsandsecureit withtherubrailpins.

Fig.1:Trammotorremovalandinstallation

Tramcase

Trammotor

TramPrimaryPlanetaryGear_______________________________________

Thefollowingprocedureisfortheremovalandinstallationofthetramprimary planetarygearcase.

BasicToolSet Blocking

Safety WARNING ! FollowallFederalandminelockout/tagoutregulationsandprocedures.Failuretodoso couldresultinmachinedamageorseriousinjuryordeathtopersonnel.

Whenremovingorinstallingatramprimaryplanetarygearcase,observethe followingsafetyprecautions:

Toremovetheprimaryplanetarygear:

1. Lowertheconveyortailsectionuntilitislevelwiththefloor.

2. Lowerthegatheringheadandcutterheadassembliesuntiltheytouchthe floor.

3. Disconnectthetrailingcabletode-energizetheminer.FollowallFederal andmineregulationsforlockout/tagout.

4. Removethetworubrailpinsthatsecurethetramrubrailtothetworubrail sectionsadjacenttoitandremovethetramrubrailtoexposethetramgear case.

5. Removethetrammotor(seeTrammotorremovalandinstallationprocedureinthischapter).

6. Removethesixteen(16)3/4X71/2”socketheadcapscrewsthatsecure themotoradapterplatetotheprimarygearring(andalsosecuretheprimaryplanetarycarrierassemblytothetramcase).

7. Removethemotoradapterplatefromthetramcase.

8. Carefullyslidetheprimaryplanetarycarrierassemblyoutoftheprimary gearringandremovetheassemblyfromthetramcase.

9. Carefullyslidetheprimarygearringoutofthetramcase.

TramPrimaryPlanetaryGear_______________________________________

Toinstallthetramprimaryplanetarygear:

1. Insertalignmentdowelsintofourofthesixteencapscrewholesinthetram case.

2. Tofacilitategearringinsertion,markthemountingholesoftheprimary planetarygearringthatcorrespondstotheholesinwhichdowelswere placed.

3. Slidetheprimaryplanetarygearringontothealignmentdowelssothedowelsappearthroughthemarkedholes.

4. Carefullyinserttheprimaryplanetarygearassemblyintothegearring,ensuringthattheextensionofthesungearfacesoutfromthecenterlineof theminerandthattheinternalgearteethoftheprimarycarrierareseated securelyontothetramdrivepiniongear.

5. Placethetwoadapterplatedowelsintotwo(2)1inchholesonthebottom leftandrightcornersoftheadapterplate.

6. Orienttheadapterplatewiththeadapterdowelsalongthebottomedge.

7. Slidetheadapterplateontothefouralignmentdowels.

8. Insertandtightentwelve(12)3/4X71/2”socketheadcapscrewsintothe holesintheadapterplatenotblockedbythealignmentdowels.

9. Removethefouralignmentdowelsandinsertandtightenthefinalfour socketheadcapscrewstosecuretheadapterplateandgearringtothe tramcase.

10. Torquethesixteen(16)3/4X71/2”socketheadcapscrewsto210 - 230lbft.

11. Installthetrammotorinthetramcase(seeTrammotorremovalandinstallationprocedureinthischapter).

12. Replacethetramrubrailbetweenthetwoadjacentrubrailsandsecureit withthetworubrailpins.

13. Refillthetramgearcasewithoil.

Safety

Thefollowingprocedureisfortheremovalandinstallationofthetramsecondaryplanetarygearcase.

BasicToolSet Blocking

Whenremovingorinstallingatramsecondaryplanetarygearcase,observethe followingsafetyprecautions:

WARNING ! FollowallFederalandminelockout/tagoutregulationsandprocedures.Failuretodoso couldresultinmachinedamageorseriousinjuryordeathtopersonnel.

WARNING ! Thesecondaryplanetarygearringisextremelyheavy.Bepreparedtosupportitsweight beforeremovingitfromthesecondaryplanetaryassembly.

TramSecondaryPlanetaryGear ____________________________________

SecondaryPlanetary GearRemoval

Toremovethetramsecondaryplanetarygear:

1. Lowertheconveyortailsectionuntilitislevelwiththefloor.

2. Lowerthegatheringheadandcutterheadassembliesuntiltheytouchthe floor.

3. Disconnectthetrailingcabletode-energizetheminer.

4. Removethetworubrailpinsthatsecurethetramrubrailtothetworubrail sectionsadjacenttoitandremovethetramrubrail.

5. Removetheplugfromthebottomofthetramsecondaryplanetarygear coveranddrainthelubricantfromthegearcase.

6. Replacetheoildrainpluginthegearcover(Fig.2).

7. Removethesixteen(16)3/4X71/2”socketheadcapscrewsthatsecure thesecondaryplanetarygearcovertothetramcaseandcarefullyremove thesecondaryplanetarygearcover.

Fig.2:Tramsecondaryplanetarygearcoveranddrainplug

Drainplug

Sockethead capscrews

Tramsecondary Planetarygear cover

8. Removethesecondaryplanetarygearthrustwasher(Fig.3).

9. Carefullyslidethesecondaryplanetarygearringoffthesecondaryplanetarygearassembly.

10. Inserteighthexheadcapscrewsintothesprocketbearingcarriertosecure ittothetramcase.

11. Carefullypullthesecondarytramdriveshaftfromthegearandsprocket andstoreinasafeplace.

12. Carefullyslidethesecondaryplanetaryassemblyoutofthesprocketbearingcarrier.

Fig.3:Secondaryplanetaryassemblyremoval

Secondary planetary gearassembly Ring gear

Thrust washer

Secondary planetary gearassembly

Secondary tramdrive shaft

Hexhead capscrew

Secondary planetary gearassembly

Sprocket bearing carrier

TramSecondaryPlanetaryGear ____________________________________

SecondaryPlanetary GearInstallation

Toinstallthetramsecondaryplanetarygear:

1. Carefullyinsertthesecondaryplanetarygearassemblyintothesprocket bearingcarrier(Fig.4),ensuringthatthesplinedextensionoftheplanetary carrierseatssecurelyintheinteriorteethofthesprocket.

Fig.4:Planetarycarrierinstallation

Secondary planetary gear assembly

Sprocket bearing carrier

Splined extension

2. Slidethesecondarytramdriveshaftthroughthesecondaryplanetarygear assemblyandintothetramdrivesprocketandreachgearset(thedrive shaftendwithoutthethreadedholeshouldbeinsertedfirst).Theshaftmay requiresomeadjustmentsothattheendfitsintothereachgears.

3. Insertfouralignmentdowelsintotheholesinthesprocketbearingcarrier notblockedbytheeighthexheadcapscrews(Fig.5).

4. Tofacilitategearringinsertion,markthemountingholesofthesecondary planetarygearringthatcorrespondstotheholesinwhichthedowelswere placed.

5. Removetheeighthexheadcapscrewsthatsecurethesprocketbearing carriertothetram.

Fig.5:Gearringinstallation

Gearring

Sprocket teeth Secondary planetary gearassembly

Alignment marks

Hexhead capscrews

Alignment dowels

Sprocket bearing carrier

Thrust washer

6. Applysiliconsealanttotheringgear.

7. Carefullyslidethesecondaryplanetarygearringontothefouralignment dowelssothatthedowelsappearthroughthemarkedholes.Theplanetary gearteethshouldslidesmoothlyandsecurelyintothegearteethshould slidesmoothlyandsecurelyintothegearringteeth.

8. Placethethrustwaterintothesecondaryplanetarycarrierdirectlybehind thesecondarytramdriveshaft.Thesideofthethrustwasherwiththeinscribedcirclesshouldfaceawayfromthedriveshaft.

9. Applysiliconsealanttothecover.

10. Tofacilitategearcoverreplacement,markthemountingholesofthesecondaryplanetarygearcoverthatcorrespondstotheholesinwhichalignment dowelsareplaced.

11. Slidethesecondaryplanetarygearcasecoverontothealignmentdowels sothatthedowelsappearthroughthemarkedholes.

WARNING ! Theflatedgeofthecoverlocatedadjacenttothelubricationfittingisthetopofthe cover.Orientthecoversothatthelubricantlevelcheckplugisonthemotorsideofthe coverandthedrainplugisonthebottom.

12. Insertandtightenthetwelvesocketheadcapscrewsintotheholesinthe gearcasecovernotblockedbythealignmentdowels.

13. Removethefouralignmentdowels.

14. Insertandtightentheremainingfoursocketheadcapscrewstosecurethe cover,thegearring,andthesprocketbearingcarriertothetramcase.

15. Usingatorquewrench,torqueallsixteen(16)3/4X71/2”to210 - 230lb-ft.

16. Usingthelubricationfittingatthetopofthegearcover,fillthesecondary planetarygearcasetotheproperlevelwithlubricant.

17. Examinethesecondaryplanetarygearcaseinvariousplacesforsignsof leakinglubricantthatidentifyimproperinstallationorgearcasedamage.

18. Replacethetramrubrailbetweenthetwoadjacentrubrailsandsecureit withthetworubrailpins.

Thefollowingprocedureisfortheremovalandinstallationofthetramcase.

BasicToolSet Blocking

Whenremovingorinstallingatramcase,observethefollowingsafetyprecautions:

WARNING ! Youcouldbeseriouslyinjuredorkilledbyfallingloads.Observethesafeworkingload limitsofallblockingdevices.

WARNING ! FollowallFederalandminelockout/tagoutregulationsandprocedures.Failuretodoso couldresultinmachinedamageorseriousinjuryordeathtopersonnel.

WARNING ! Thetramcase(withsprocketandreachgears)isextremelyheavy.Bepreparedtosupportthetramcasebeforeremovingitfromthetractorframe.

WARNING ! Ensurethattheelectricalcablesandcoolingwaterhosesforthetrammotorarefree fromthetramcasesbeforeattemptingtoremovethetramcasefromthetractorframe.

WARNING ! Standclearoftheminerwhenusingthemotortopullthetramtrackthroughthetram case.

Toremovethetramcase:

1. Lowertheconveyortailsectionuntilitislevelwiththefloor.

2. Raisethegatheringheadandcutterheadandplaceasmallstackofblockingunderthesetwoassemblies.

3. Lowerthegatheringheadandcutterheadontotheblockingsothatthe frontendoftheminerliftsoffthefloor.

4. Extendthestabilizercompletelysothattherearendoftheminerliftsoffof thefloor.

5. Placeblockinginmultiplelocationsundertheminertramtrack.Whenthe minerislowered,thetramtrackshouldbesecuredbetweentheblocking andthetractorframe.

6. Raisethestabilizerandthegatheringheadandcutterheadassembliesso theweightoftheminerrestsontheblocking.

7. Disconnectthetrailingcabletode-energizetheminer.FollowallFederal andmineregulationsforlockout/tagout.

8. Removethetworubrailpinsthatsecurethetramrubrailtothetworubrail sectionsadjacenttoitandremovethetramrubrailtoexposethetram case.

9. Removethehexheadcapscrewandlockwasherthatsecurethefrontrub railtothetractorframeandopenthefrontrubrailcover.

10. Attachthegreaseguntothefrontidlertake-upcylinderfitting(Fig.6)and pumpgreaseintothetake-upcylindertoextendthecylinderandremove pusherplatepressureontheidlershims.

11. Removealltheidleradjustmentshimsandstoretheshimsinasafeplace.

12. Openthepressurereleasevalveforthefrontidlertake-upjackandallow thecylindertocontract.

location

13. Locateatramtracklinknearthetrackentryopeningatthebottomofthe tramcase(Fig.7)and,usingahammerandpunch,removethetworollpins thatsecurethetramtrackpinbetweenthelinks.Storetherollpinsinasafe place.

14. Usingthehammerandpunch,removethetramtrackpintodisconnectthe linksandseparatethetrack.Storethetrackpininasafeplace.

Fig.7:Tramtrackremoval Idlertake-up cylinder

Fig.6:Idlertake-upcylinder

15. Attachguidewirestotheendofthetramtrackthatpassesthroughthetram case.

16. Connectthetrailingcabletoenergizetheminer.

17. Usethetrammotortoslowlyrotatethesprocketsothattheendofthetram trackthatpassesthroughthecaseispulledupthroughthecaseandrolls offthesprocket.

18. Disconnectthetrailingcabletode-energizetheminer.FollowallFederal andmineregulationsforlockout/tagout.

19. Pullonthetramtrackfromthefrontoftheminer(neartheidler)sothatthe freeendofthetramtrackispulledclearofthetramcaseexitopening.

20. Removethetrammotor(seeTrammotorremovalandinstallationprocedureinthischapter).

21. Removetheboltsandwashersfromthesprocketandmotorsidesofthe tramcase.

22. Placeastackofblockinginfrontofthetramcaseontowhichthecasecan beremoved.

23. Carefullyslidethetramcaseoutfromthetractorframeandontotheblocking.

24. Pullthetramtrackguidewiresoutofthetramcaseexitopeningandsecure thewirestothetractorframe.

Toinstallthetramcase:

1. Blockupthetramcaseadjacenttoitstractorframepositionatalevelthat makesiteasytoslidethecaseintothetractorframe.

2. Threadtheguidewiresthroughthetramcaseexitopening,betweenthe sprocketgears,andoutthetramcaseentryopening.

3. Slidethetramcaseintopositioninthetractorframe.

WARNING ! Theguidewireswillbeusedtopullthetramtracklinksontothetramcasesprocketafter thetramcaseisinstalled.

WARNING ! Beforeattemptingtoslidethetramcaseintothetractorframe,ensurethatthetrammotorelectricalandwaterconnectionsareoutoftheway.Failuretodosomayresultin damagetotheelectricalandwaterconnections.

4. Slidethetramcaseintopositioninthetractorframe.

5. Installtheboltsthatsecurethemotorsideofthetramcasetothetractor frame.

6. Installtheboltsthatsecurethesprocketsideofthetramcasetothetractor frame.

7. Replacethetrammotor(seeTrammotorremovalandinstallationprocedureinthischapter).

8. Whilefeedingthetramtrackfromthefrontoftheminer(neartheidler),pull onthetramtrackguidewiresuntilalinkofthetramtrackengagesthe sprocket.

9. Connectthetrailingcabletoenergizetheminer.

10. Usethetrammotortoslowlyrotatethesprocketandpullthetramtrack throughthecaseuntiltheendappearsoutthebottom.

WARNING ! Doublecheckthatthelinksofthetramtrackarecorrectlyseatedontothetramdrive sprocket.Improperengagementofthetramtracklinksontothesprocketcancauseseriousmechanicaldamage.

11. Disconnectthetrailingcabletode-energizetheminer.FollowallFederal andmineregulationsforlockout/tagout.

12. Removetheguidewiresfromthetramtrack.

13. Connectthetwoendsofthetramtrackandusingthehammerandpunch, insertthetrackpintosecurethetwotracklinkstogether.

14. Usingthehammerandpunch,insertthetworollpinsintothetrackpinto securethepininthelinks.

15. Adjustthetramtracktension.

16. Closethefrontrubrailcoverandreplacethehexheadcapscrewsandlock washersthatsecurethefrontrubrailtothetractorframe.

17. Replacethetramrubrailbetweenthetwoadjacentrubrailsandsecureit withthetworubrailpins.

18. Connectthetrailingcabletoenergizetheminer.

19. Removeblocking.

Introduction

ToolSet

Safety

Thefollowingprocedureisfortheremovalandinstallationofthetramreach gearset.

BasicToolSet Blocking

Whenremovingorinstallingatramreachgearset,observethefollowingsafety precautions:

WARNING ! Youcouldbeseriouslyinjuredorkilledbyfallingloads.Observethesafeworkingload limitsofallblockingdevices.

WARNING ! FollowallFederalandminelockout/tagoutregulationsandprocedures.Failuretodoso couldresultinmachinedamageorseriousinjuryordeathtopersonnel.

There-installationprocedureforthetramcaseincludesre-installationoftheprimary andsecondaryplanetarygearsandthetrammotor,andreconnectionofthetramtrack.

Toremovethetramreachgearset:

1. Lowertheconveyortailsectionuntilitislevelwiththefloor.

2. Raisethegatheringheadandcutterheadassembliesandplaceasmall stackofblockingundereach.

3. Lowerthegatheringheadandcutterheadontotheblockingsothatthe frontendoftheminerliftsoffthefloor.

4. Extendthestabilizercompletelysothattherearendoftheminerliftsoffthe floor.

5. Placeblockinginmultiplelocationsundertheminertramtracktosecurely supportthetractorframeoffthefloor.

6. Raisethestabilizerandthegatheringheadandcutterheadassembliesso theweightoftheminerrestsontheblocking.Whenthetractorframeislowered,thetramtrackshouldbesecuredbetweentheblockingandthetractor frame.

7. Disconnectthetrailingcabletode-energizetheminer.FollowallFederal andmineregulationsforlockout/tagout.

8. Double-checkthetractorframesupportblockingnowthattheweightofthe tractorframeiscompletelyuponit.

9. Removethetworubrailpinsthatsecurethetramrubrailtothetworubrail sectionsadjacenttoitandremovethetramrubrailtoexposethetram case.

10. Removethetramcase(seeTramcaseremovalandinstallationprocedure inthischapter).

11. Removetheplugfromthemotorendofthereachgearcasebottomand drainthelubricantfromthegearcase.

12. Whenthelubricanthasbeencompletelydrained,replacetheplug.

13. Removethefourteen(14)1/2X11/4”hexheadcapscrewsandlockwashers(Fig.8)thatsecurethereachgearcasecovertothegearcaseandremovethecover.

14. Locatethecapbearingcarrierthatsecuresthetramdrivepinioninsidethe reachgearcase.

15. Usingretainingringpliers,removetheretainingringlocatedoutsidethecap bearingcarrieronthetramdrivepinion(Fig.9).

16. Usingthewirecutters,cutandremovethewiresecuringthecapbearing carriercapscrewsinposition.

17. Removethesix(6)5/8X13/4”drilledheadcapscrewsandlockwashers thatsecurethecapbearingcarriertothetramcaseandremovethecap bearingcarrier.

Fig.9:Capbearingcarrierremoval

Drilledhead capscrews Capbearing carrier

Retaining ring

Tramdrive pinion

18. Removethethreesteelshimsandthebearingfoundundertheshims(Fig. 10).

19. Carefullypullthetramdrivepinionoutofthereachgearcasethroughthe capbearingcarrieropening.

20. Cutandremovethewiresecuringtheidlershaftcapscrewsinposition.

21. Removetheten(10)1/2X11/4”drilledhexheadcapscrewsthatsecure theidlershaftcaptothetramcaseandremovetheidlershaftandthree steelshimslocatedunderthecap.

22. Carefullyslidetheidlershaftoutofthereachgearcasethroughtheidler shaftcapopening.

23. Removetheidlerreachgearthroughthetopopeningofthereachgear case(Fig.11).

24. Removethebearingcupandconesetsfromthecenterindentionsofthe idlerreachgear.

Fig.10:Tramdrivepinionremoval

Fig.11:Idlerreachgearandidlershaftremoval

Bearingcarrier opening

Tramdrive pinion

Bearingcup andconeset

Shims

Capbearing carrier

Idlerreachgear

Rearside oftramcase

Bearingcupand coneset Shims

Idlershaftcup

Hexheadcapscrews

Reachgear case

25. Removethesix(6)5/8X13/4”hexheadcapscrewsandlockwashersthat securethesprocketreachgearbearingcaptothereachgearcase(Fig. 12).

26. Removethebearingcapandthethreesteelshimsunderthecap.

27. Removethebearingconeandcupsetfromtheendofthesplinedsleeve.

28. Carefullyslidethesplinedsleeveoutofthesprocketreachgear.

29. Removethesprocketreachgearthroughthetopopeningofthereachgear case.

30. Removethesecondsplinedsleevebearingconeandcupsetfromtherear ofthereachgearcase,locatedbehindthesprocketreachgear.

Sprocketreach Gearbearingcup

Fig.12:Sprocketreachgearremoval

Reachgearcase

Hexheadcapscrews

Splined sleeve

Toinstallthetramreachgearset:

1. Insertoneofthebearingcupandconesets(conesidefacingout)intothe cut-outinsidethereachgearcaseadjacenttothetramcasesprocket(Fig. 13).

Fig.13:Bearingcupandconesetinstallation

Bearingcup Andconeset

2. Insertthesprocketreachgearintothetopofthereachgearcaseandpositionitagainstthebearingcupandconesetadjacenttothetramcase sprocket(Fig.14).

Fig.14:Sprocketreachgearinstallation

Sprocketreach gearset

3. Insertthesplinedsleeveintothereachgearcase(Fig.15),throughthe sprocketreachgearandthroughthebearingcupandconesetuntilitispositionedagainstthetramsprocket.

4. Slidethesecondbearingcupandconeset(cupsidefacingout)ontothe endofthesplinedsleeve.

5. Replacethethreesteelshimsoverthebearingset.

6. Replacethesprocketreachbearingcap.

7. Insertandtightenthesix(6)5/8X13/4”hexheadcapscrewsandlock washerstosecurethesprocketreachgearbearingcaptothereachgear case,andtorqueto120 - 130lb-ft.

Fig.15:Splinedsleeveandbearingcapinstallation

Sprocket reachgear Splinedsleeve

Shims

Bearingcup andconeset

Reachgear case

Sprocketreach gearbearingcap

Hexhead capscrews

8. Inserttwocupandconebearingsetsintothecentralcut-outsoneitherside oftheidlerreachgear(Fig.16).Theconesideofthebearingsetsshould faceoutofthegearonbothsides.

9. Inserttheidlerreachgearthroughthetopopeningofthereachgearcase andpositionitagainstthesprocketreachgear,ensuringthatthegearteeth securelymesh.

10. Inserttheidlershaftthroughthebearingsetsintheidlerreachgearuntilit ispositionedagainstthetractorframe.

11. Replacethethreesteelshimsovertheidlershaft.

12. Replacetheidlershaftcap.

Fig.16:Idlerreachgearandidlershaftinstallation

Rearsideof tramcase

Idlerreach gear

Bearingcup andconeset

Reachgear case

Shims

Idlershaft cup

Hexhead capscrews

13. Insertandtightentheten(10)1/2X11/4”drilledhexheadcapscrewsto securetheidlershaftcap.

14. Insertthetramdrivepinionthroughthecapbearingcarrieropening(located ontheinsideofthetramcasetrammotorbay)intothereachgearcase. Ensurethattheteethofthepinionsecurelymeshwiththeidlerreachhear teeth.

15. Replacethepinionbearing.

16. Replacethethreesteelshimsoverthepinionbearing.

17. Replacethecapbearingcarrieroverthepinionend.

18. Insertandtightenthesix(6)5/8X13/4”drilledhexheadcapscrewsand lockwasherstosecurethecapbearingcarriertothetramcase,andtorque to120 - 130lb-ft.

19. Installtheretainingringonthetramdrivepinion.

20. Doublecheckthatthetramdrivepinion,idlerreachgearandsprocket reachgearteethareproperlymeshedandthegearsrotatesmoothly.

21. Tightentheidlershaftcapcapscrews,andtorqueto35 - 40lb-ft.

22. Lockwiretheidlershaftcapcapscrewstosecuretheirpositions.

23. Lockwirethetramdrivepinioncapbearingcarriercapscrewstosecure theirpositions.

24. Replacethereachgearcasecoverontothetopofthereachgearcase.

25. Insertandtightenfourteen(14)1/2X11/4”hexheadcapscrewsandlock washerstosecurethereachgearcasecovertothegearcase,andtorque to35 - 40lb-ft.

26. Removetheplugfromthesprocketsideofthereachgearcasecover.

27. Fillthereachgearcasetotheproperlevelwithlubricant(Spec.100-14).

28. Replacethefillplug.

29. Replacethetramcaseintothetractorframe(seeTramcaseremovaland installationprocedureinthischapter).

30. Replacethetramrubrailbetweenthetwoadjacentrubrailsandsecureit withthetworubrailpins.

31. Reconnectthetrailingcabletoenergizetheminer.

32. Raisethetractorframebyloweringthestabilizerandthegatheringhead andcutterheadassemblies.

33. Carefullyremovethesupportblockingfromunderthetractorframe.

34. Lowerthetractorframeontothefloorbyraisingthestabilizerandthegatheringheadandcutterheadassemblies.

TramSprocket

Thefollowingprocedureisfortheremovalandinstallationofthetramsprocket.

BasicToolSet Blocking

Whenremovingorinstallingatramsprocket,observethefollowingsafetyprecautions:

WARNING ! Youcouldbeseriouslyinjuredorkilledbyfallingloads.Observethesafeworkingload limitsofallblockingdevices.

WARNING ! FollowallFederalandminelockout/tagoutregulationsandprocedures.Failuretodoso couldresultinmachinedamageorseriousinjuryordeathtopersonnel.

WARNING ! Ensurethattheendofthetramtrackisoutofthetramcaseexitopeningbeforeattemptingtoremovethetramcasefromthetractorframe.

WARNING ! Thesprocketisextremelyheavy.Bepreparedtosupportitsweightbeforeremovingit fromthetramcase.

WARNING ! Standclearoftheminerwhenusingthemotortopullthetramtrackthroughthetram case.

Toremovethetramsprocket: